Cross-wound Bobbin Winding with Variable Pitch Angle Control
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Solution Overview
Problem
Existing methods for producing cross-wound bobbins often result in random winding with image zones, leading to poor run-off behavior and inconsistent density, as the turns ratio changes constantly during winding, without effective prevention or control.
Innovation Solution
A device with a variably drivable thread guide and a controller that adjusts the pitch angle based on the known bobbin diameter, maintaining a constant turns ratio and optimizing thread tension, ensuring the bobbin is wound with a consistent pitch angle and density, thereby preventing image zones and improving run-off properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the pitch angle is increased continuously or in small steps during the bobbin cycle to achieve high density in the inner area and low density in the outer area, then the density distribution is improved, but the turns ratio changes constantly causing image winding zones and poor run-off behavior
Solution Approach 1:
The patent applies dynamics by making the pitch angle variable during the winding process. The pitch angle is continuously adjusted based on the current bobbin diameter to maintain a constant turns ratio. This dynamic adjustment prevents image winding zones while achieving consistent density distribution throughout the bobbin, resolving the contradiction between density control and run-off behavior.
Solution Approach 2:
The patent implements feedback control by continuously monitoring the bobbin diameter and using this information to adjust the pitch angle in real-time. The controller receives diameter measurements and automatically modifies the thread guide speed to maintain the desired turns ratio, ensuring both consistent density and proper run-off characteristics without manual intervention.
2Measurement precision
If a separate sensor is installed at each spooling position to measure the spool diameter, then the diameter measurement accuracy is improved, but the device complexity increases
Solution Approach 1:
The patent applies universality by using a single diameter measurement device that serves multiple spooling positions. The measurement device is positioned to measure the diameter of bobbins at different locations along the winding machine, eliminating the need for separate sensors at each position while maintaining measurement accuracy and reducing overall system complexity.
3Manufacturing precision
If the thread guide speed is varied to change the pitch angle, then the pitch angle control is improved, but the thread tension becomes inconsistent
Solution Approach 1:
The patent applies parameter changes by coordinating the adjustment of multiple parameters simultaneously. When the thread guide speed is varied to change the pitch angle, the winding speed is also adjusted in a controlled manner to maintain consistent thread tension. This coordinated parameter adjustment ensures both precise pitch angle control and stable thread tension throughout the winding process.
Data Source
Figure 1~3
Figure 2
AI summary
In a method for producing cross-wound bobbins (6) on a winding head (5) of a textile machine, the angle of twist (x) of the coiled thread (2) is changed during the coiling operation. The angle of twist is calculated as a function of the bobbin diameter (d) with reference to the length of the thread (2) which has already been coiled. An apparatus for producing cross-wound bobbins (6) on a plurality of winding heads (5) contains a drive (15) for rotating the cross-wound bobbins. A variably driveable thread guide (9) for laying a thread (2) to be coiled in the axial direction of the cross-wound bobbin (6) at a variable angle of twist is provided on each winding head (5). A common sensor (19) is provided for measuring the bobbin diameter (d) on a plurality of winding heads (5), which sensor can be advanced to the winding heads successively.