Buffer Drum Warping System for Pattern Warp Beam Production
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Solution Overview
Problem
The existing pattern warping machines are inefficient in producing pattern warp beams, requiring a long time and resulting in high personnel costs due to the need for extensive pauses during the warping process.
Innovation Solution
A buffer drum is introduced adjacent to the warping drum, allowing for the transfer of the pattern warp in the axial direction, enabling faster production and reducing the need for complex mechanical arrangements, with a transport surface arrangement bridging the gap between the drums and allowing for relative displacement, facilitating quicker transfer and higher speed rotation of the buffer drum.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the warping drum is used to produce pattern warp and then the pattern warp is wound onto a beam element, then a pattern warp beam is produced, but the process requires extensive pauses and takes a relatively long time
Solution Approach 1:
The system is divided into two independent functional units: a warping drum for producing pattern warp and a buffer drum for storing the completed pattern warp. This segmentation allows the warping drum to continue producing pattern warp while the buffer drum stores it, eliminating the need to stop production to wind onto the beam element. The pattern warp beam production process is thus separated into continuous warping operations and periodic beaming operations.
Solution Approach 2:
The buffer drum is prepared in advance as a storage intermediary. When the pattern warp is completed on the warping drum, it is transferred to the buffer drum which is already positioned and ready to receive it. This preliminary preparation of the buffer drum allows immediate transfer without pausing the warping process, as the receiving device is already in place and operational.
2Productivity
If a buffer drum is introduced to transfer pattern warp axially, then production time is reduced, but the device complexity increases due to additional components
Solution Approach 1:
The buffer drum is extracted as a separate, simplified component with a single primary function: axial storage and release of pattern warp. By removing unnecessary moving parts and focusing on one function, the buffer drum adds minimal complexity while providing significant productivity benefits. The buffer drum is positioned axially adjacent to the warping drum, creating a simple linear transfer path.
Solution Approach 2:
The buffer drum serves as an intermediary element between the warping drum and the beam element. It mediates the transfer of pattern warp by receiving it axially from the warping drum and releasing it for winding onto the beam element. This intermediary role simplifies the overall system architecture by providing a dedicated storage buffer that decouples the warping and beaming operations.
3Ease of operation
If the warping drum rotates to release pattern warp onto beam element, then beaming can occur, but the warping drum is unavailable for new jobs during this time
Solution Approach 1:
The system separates the warping function (performed by the warping drum) from the beaming function (performed by the buffer drum and beam element). The warping drum remains dedicated to producing pattern warp and does not need to rotate or change function during beaming operations. This segmentation ensures the warping drum is continuously available for new jobs while beaming occurs independently using the buffer drum as an intermediary storage device.
Solution Approach 2:
The buffer drum enables continuous useful action by maintaining pattern warp availability. While the warping drum produces pattern warp continuously, the buffer drum accumulates it and makes it available for continuous beaming operations. This ensures that both warping and beaming can proceed without interruption, maximizing the productivity and continuous operation capability of the entire system.
Data Source
AI summary
The machine for warping yarn, comprises a warp cylinder (6), a thread guide (5) movable around the circumference of the warp cylinder, a conveyer (7) at the circumference of the warp cylinder with an axially parallel guiding direction (8), a buffer cylinder (9) adjacent to the warp cylinder in axial direction, and a transferring device (12) for the warp yarn in the axial direction toward the buffer cylinder. The transferring device has a transportation arrangement, which bridges a channel between the warp cylinder and the buffer cylinder. The buffer cylinder has a chassis. The machine for warping yarn, comprises a warp cylinder (6), a thread guide (5) movable around the circumference of the warp cylinder, a conveyer (7) at the circumference of the warp cylinder with an axially parallel guiding direction (8), a buffer cylinder (9) adjacent to the warp cylinder in axial direction, and a transferring device (12) for the warp yarn in the axial direction toward the buffer cylinder. The transferring device has a transportation arrangement, which bridges a channel between the warp cylinder and the buffer cylinder having a chassis. The transportation arrangement and the buffer cylinder and/or the warp cylinder are movable relatively to each other, where the buffer cylinder and the warp cylinder are axially movable to one another. The buffer cylinder is shiftable from a transfer position into a removable position. The transportation arrangement is arranged in a delivery process axially overlapping to the conveyer and has a sliding surface and a conveyer. The buffer cylinder has a buffer conveyer with axial feeding direction and has a smaller effective diameter as the warp cylinder. The buffer conveyer and the conveyer system are connected with a common control, which tunes the speed of movement of the buffer conveyer and conveyer system. An independent claim is included for a procedure for producing a sample warp beam.