Drying Cylinder Speed Control for Thread Stress Reduction
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Solution Overview
Problem
The existing methods for drying threads to remove moisture after sizing cause stress on the threads, leading to deterioration in quality due to uneven tension and elastic behavior changes during the drying process.
Innovation Solution
A device with controlled rotary drives for drying cylinders that adapt their rotational speed and torque based on real-time moisture, tension, and elongation parameters of the threads, ensuring consistent thread tension or elongation across each cylinder to minimize stress and prevent slippage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the sheet of threads is dried using conventional drying cylinders with fixed rotational speeds, then the moisture is removed effectively, but the threads are subjected to high stress and tension variations leading to quality deterioration
Solution Approach 1:
The patent applies dynamics by making the rotational speeds of the drying cylinders adjustable and controllable during the drying process. The cylinders can change their rotational speeds dynamically based on real-time thread conditions, allowing the system to adapt to thread stretching or shrinking behavior. This dynamic control reduces stress on threads while maintaining effective moisture removal.
Solution Approach 2:
The patent changes the parameter of rotational speed from fixed to variable. By controlling the rotational speeds of different drying cylinders independently and adjusting them based on thread behavior (stretching or shrinking), the system optimizes the drying process to minimize thread stress while maintaining drying effectiveness.
2Productivity
If the rotational speeds of drying cylinders are increased to improve drying efficiency, then the drying speed increases, but the stress on threads increases leading to quality deterioration
Solution Approach 1:
The system dynamically adjusts the rotational speeds of drying cylinders based on real-time thread conditions. When threads stretch during drying, the rotational speeds are increased to maintain drying efficiency. When threads shrink, the speeds are reduced to prevent excessive stress. This dynamic adjustment maintains high productivity while protecting thread quality.
Solution Approach 2:
The patent implements feedback control by monitoring thread behavior (stretching or shrinking) during the drying process and using this information to adjust the rotational speeds of the drying cylinders. This feedback mechanism ensures that drying efficiency is maintained while preventing excessive stress on the threads.
3Reliability
If the drying cylinders are driven at different speeds to account for thread stretching, then thread stress is reduced, but the device complexity increases due to multiple controlled rotary drives
Solution Approach 1:
The patent segments the drying system into multiple independently controllable drying cylinders, each with its own rotary drive. This segmentation allows each cylinder to be controlled individually based on local thread conditions, reducing overall system complexity by breaking down the control into manageable units rather than requiring complex centralized control.
Solution Approach 2:
The patent changes the operational parameters (rotational speeds) of the drying cylinders to match thread behavior. By adjusting speeds based on whether threads stretch or shrink, the system maintains thread quality without requiring overly complex control mechanisms.
4Device complexity
If conventional drying methods are used with fixed cylinder speeds, then the device complexity remains low, but slippage occurs between threads and drying cylinder surfaces leading to uneven drying
Solution Approach 1:
The patent applies dynamics by making the drying cylinders' rotational speeds adjustable during operation. This dynamic control prevents slippage between the threads and cylinder surfaces by matching the cylinder speed to the thread speed, ensuring uniform drying without requiring complex additional mechanical components.
Solution Approach 2:
The patent changes the rotational speed parameter of the drying cylinders to prevent slippage. By adjusting speeds based on thread behavior (stretching or shrinking), the system maintains optimal contact between threads and cylinders, ensuring uniform drying while keeping the device relatively simple.
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
This approach reduces thread stress, maintains quality by ensuring even drying, and prevents slippage, resulting in softer, more elastic, and resistant threads suitable for further processing, while also reducing dust formation and environmental impact.
Implementation Method 1
slippage between the group of threads and the surface of the drying cylinder can be prevented
Implementation Method 2
the moisture introduced in a previous process step, for example when a size is applied, can evaporate
Implementation Method 3
A drying cylinder has a peripheral surface that is heated. When the bundle of threads rests on this surface, it is heated
Data Source
Figure 1~3
AI summary
A device (1) for drying a yarn bundle (2) is described, comprising an inlet, an outlet, and at least two drying cylinders between the inlet and the outlet, wherein a yarn bundle path between the inlet and the outlet encircles the drying cylinders on part of their circumference. The aim is to minimize the stress on the yarns during drying. For this purpose, each drying cylinder is provided with its own rotary drive, and a control device is provided that individually controls the rotary drives.