Dye Bobbin Winding with Variable Crossing Angle
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Solution Overview
Problem
Dye bobbins often exhibit uneven coloration, particularly in inner thread layers, leading to inefficiencies and high dyeing costs due to the need for rewinding or soft winding, which increases energy consumption and dyeing liquor usage.
Innovation Solution
A method that initiates with precision winding at a large crossing angle to ensure even dye distribution and transitions to step precision winding at a smaller angle, maintaining high material density and efficient dyeing while minimizing color disturbances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If precision winding is used throughout the bobbin cycle, then the crossing angle becomes smaller and smaller, improving bobbin stability, but the inner thread layers become too dense allowing even dye distribution
Solution Approach 1:
The patent applies dynamics by making the winding mode variable throughout the bobbin cycle. The system dynamically switches between precision winding and step precision winding modes based on the current winding state, allowing the crossing angle to be large initially for even dye distribution and smaller later for bobbin stability. This dynamic adjustment resolves the contradiction between stable bobbin structure and uniform dye penetration.
Solution Approach 2:
The patent segments the bobbin winding process into distinct phases: an initial phase using precision winding for the inner layers, and a subsequent phase using step precision winding for outer layers. This segmentation allows different winding characteristics to be applied to different parts of the bobbin, ensuring both even dye distribution in inner layers and structural stability in the complete bobbin.
2Manufacturing precision
If soft winding with large crossing angle is used, then even dye distribution is achieved, but the yarn mass per diameter is reduced, increasing dyeing liquor consumption and costs
Solution Approach 1:
The patent applies local quality by creating different winding densities in different regions of the bobbin. The inner thread layers are wound with a larger crossing angle to ensure even dye distribution, while outer layers use a smaller crossing angle to maximize yarn mass within the bobbin diameter. This localized variation in winding quality allows the system to achieve uniform dyeing without the high liquor consumption that would result from uniformly soft winding throughout.
3Ease of manufacture
If the crossing angle is kept constant in random winding, then the winding process is simple, but image winding zones occur that negatively affect run-off behavior and dyeing
Solution Approach 1:
The patent improves upon random winding by making the crossing angle dynamic rather than constant. The step precision winding mode causes the crossing angle to vary systematically during the bobbin cycle, which eliminates the image winding zones that plague constant-angle random winding. This dynamic adjustment maintains the relative simplicity of the winding process while dramatically improving dyeing quality and run-off behavior.
Data Source
Figure 1
Figure 2~4
AI summary
The method involves supporting a winding device (24) of a textile machine in a staining coil casing in the coil frame. The winding device has a unit for rotating the cross-wound bobbin and unit for changing a thread. A precision winding is wound at the beginning of a coil travel of a staining coil and is started with a crossing angle.