Winding Cable Yarn Tension Control for Load Capacity
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Solution Overview
Problem
Existing methods for producing endless winding cables result in a maximum load that is lower than the sum of the strengths of individual yarn turns due to uneven pre-stress distribution, leading to premature failure of some yarn turns and reduced overall cable strength.
Innovation Solution
A device and method that control yarn tension during winding by using a yarn brake system, allowing for adjustable pre-tension in each yarn turn, ensuring that inward layers have lower tension than outward layers to prevent premature failure, thereby increasing the overall cable's break load.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If yarn is wound with uniform tension around thimbles, then the winding process is simple and fast, but the maximum load of the cable is lower than the sum of strengths of individual yarn turns due to premature failure of some yarn turns
Solution Approach 1:
The patent applies different tension levels to different locations of the yarn path. Specifically, the yarn tension is varied along the winding path around the thimbles, with some sections experiencing higher tension and others experiencing lower tension. This local differentiation ensures that no single section is over-stressed, preventing premature failure and allowing the cable to achieve a maximum load equal to or greater than the sum of individual yarn turn strengths.
Solution Approach 2:
The patent changes the tension parameter during the winding process. By dynamically adjusting the yarn tension according to the specific winding location and layer, the system optimizes the stress distribution throughout the cable structure. This parameter variation enables the cable to fully utilize the strength potential of all yarn turns without premature failure.
2Strength
If yarn tension is increased during winding to improve cable strength, then break load increases, but some yarn turns become overloaded and fail prematurely
Solution Approach 1:
The patent implements location-specific tension control where different sections of the yarn path receive different tension levels. Critical sections that would be prone to overloading receive reduced tension, while less critical sections can tolerate higher tension. This localized quality differentiation maintains reliability across all yarn turns while still achieving high overall break load.
Solution Approach 2:
The patent applies preliminary counter-measures by reducing tension in specific high-risk sections before the winding process completes. By anticipating which yarn turns would fail under uniform high tension, the system pre-applies lower tension to those specific locations, preventing premature failure and ensuring all yarn turns contribute to the final cable strength.
3Strength
If multiple layers of yarn turns are wound to increase cable strength, then the cable becomes stronger, but tension distribution becomes uneven causing inward layers to fail first
Solution Approach 1:
The patent applies different tension levels to different layers of yarn turns. Specifically, inward layers receive different tension treatment compared to outward layers. This local differentiation compensates for the compressive stresses that inward layers experience, ensuring uniform stress distribution across all layers and preventing the premature failure of inward layers.
Solution Approach 2:
The patent implements dynamic tension adjustment during the multi-layer winding process. The tension control system adapts tension levels based on the current layer being wound and the specific position within that layer. This dynamic adjustment ensures that as each new layer is added, the tension distribution remains optimized to prevent failure in any layer, maintaining stability throughout the multi-layer construction.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The controlled tension distribution in the device and method result in a cable with a higher maximum load capacity, as more yarn turns remain intact under load, enhancing the cable's strength and reliability.
Implementation Method 1
The yarn feeder comprises at least one yarn brake for controlling a tension of the at least one yarn during winding
Data Source
AI summary
A device 100 produces an endless winding cable 101 by winding a yarn 106 around two thimbles 102, 104. The device 100 comprises an elongated guide 110, a carriage 112, a yarn feeder 114, a first thimble holder 116, and a second thimble holder 118. The first thimble holder 116 and the second thimble holder 118 each hold one of the two thimbles 102, 104. The carriage 112 is movable relative to the elongated guide 110. The yarn feeder 114 is connected to the carriage 112, and comprises at least one spool holder 120 for holding a spool 122 with the at least one yarn 106, and an output guide 124 for guiding the at least one yarn 106 to the cable during winding. The yarn feeder 114 comprises at least one yarn brake 126 for controlling a tension of the at least one yarn 106 during winding.