Elastic Winding Roller for Cotton Roll Deformation Control
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Solution Overview
Problem
Conventional winding machines deform cotton rolls due to high compressive forces, leading to increased hairiness and reduced productivity in the combing process, while alternative methods like tape winding are expensive and complex to maintain.
Innovation Solution
The winding machine features elastic rollers with a rigid core and an elastic ring or surface, which absorbs deformation work, reducing temperature and fiber adhesion, and allows adjustable hardness to adapt to different fiber qualities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high winding force is applied to compress cotton wadding, then winding density and productivity are improved, but cotton roll deformation and hairiness increase
Solution Approach 1:
The patent changes the physical state of the winding roller from rigid to elastic by coating it with an elastic material. This parameter change allows the roller to deform elastically under high winding forces, absorbing the energy that would otherwise cause permanent deformation of the cotton roll, while still maintaining high winding speed and productivity
Solution Approach 2:
The winding roller is constructed as a composite structure with a rigid core and an elastic outer layer. This composite design combines the structural strength of rigid materials with the shock-absorbing properties of elastic materials, enabling the roller to withstand high forces without transmitting excessive deformation to the cotton roll
2Manufacturing precision
If high winding force is applied, then winding density is improved, but temperature increase causes fiber adhesion and hairiness
Solution Approach 1:
The elastic coating on the winding roller acts as a cushioning layer that absorbs deformation energy before it can be transmitted to the cotton wadding. This beforehand cushioning prevents the conversion of mechanical work into heat that would otherwise raise the temperature and cause fiber adhesion
Solution Approach 2:
By changing the mechanical properties of the winding roller surface to be elastic rather than rigid, the system alters how energy is dissipated during winding. The elastic material allows reversible deformation that does not generate excessive heat, maintaining lower temperatures and preventing fiber adhesion issues
3Manufacturing precision
If winding force is reduced to prevent deformation, then cotton roll quality is improved, but air bubbles form between fiber layers
Solution Approach 1:
The elastic coating changes the force transmission characteristics, allowing the application of higher forces without the harmful effects of rigid roller deformation. This enables sufficient compression to eliminate air bubbles while the elastic nature of the coating prevents permanent deformation and excessive heat generation
4Manufacturing precision
If winding speed is reduced to prevent air bubbles, then fiber layer bonding is improved, but productivity decreases
Solution Approach 1:
The elastic coating modifies the interaction between roller and cotton wadding, allowing high-speed winding while maintaining adequate fiber layer bonding. The elastic deformation absorbs shock and distributes forces more effectively, preventing air bubble formation even at high speeds, thus maintaining both quality and productivity
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 solution minimizes deformation and hairiness, maintaining high-quality winding while reducing maintenance costs and complexity, allowing for higher productivity and easier adaptation to various fibers.
Implementation Method 1
The at least one winding roller has an elastic outer casing or circumference, in particular in the form of an elastic ring (12a, 12b) which is arranged on a carrier (14a, 14b) or a core (11a, 11b)
Data Source
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AI summary
The invention relates to a winding machine that doubles and stretches several fiber strips together to form a wadding, wherein the resulting wadding is wound onto a winding sleeve by means of two winding rollers or at least one winding roller and a belt to form wadding coils for presentation to a combing machine. The invention is characterized in that the at least one winding roller has an elastic outer shell or circumference.