Fancy Yarn Diameter Control via Sensor Feedback
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Solution Overview
Problem
Existing methods for producing fancy yarns on rotor spinning machines struggle to achieve precise and abrupt changes in yarn thickness, leading to deviations from predetermined configurations, resulting in reduced quality or reject yarns due to inadequate coordination of influencing variables.
Innovation Solution
A method that involves guiding the formed yarn through a sensor mechanism to continuously measure diameter or mass, evaluating these measurements to compare with predetermined configurations, and adjusting spinning parameters such as draw-in roller speed and fiber feed to achieve correspondence with the desired configuration, using control algorithms and empirically determined spinning adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical gearings and continuous shafts are used to vary draw-in roller speed for effect formation, then the drive system can be implemented, but the large mass of moved parts makes it impossible to achieve precise and abrupt changes in yarn thickness
Solution Approach 1:
The patent replaces the mechanical gearing and continuous shaft system with an electronic control system using stepping motors. Each draw-in roller is directly connected to its own stepping motor, eliminating the need for complex mechanical transmissions. This allows precise and abrupt speed changes of the draw-in rollers to be achieved electronically, thereby achieving precise yarn thickness control without the inertia problems of heavy mechanical components.
Solution Approach 2:
The patent makes the draw-in roller speeds dynamically adjustable through electronic control of stepping motors. Instead of fixed mechanical gear ratios, the system can rapidly change the rotational speed of individual draw-in rollers based on real-time requirements for effect formation, enabling precise and abrupt transitions in yarn thickness.
2Manufacturing precision
If program control is used to predetermine rotational speed courses for effect formation, then the fancy yarn configuration can be predetermined, but deviations from desired configuration are not recognized leading to reduced quality
Solution Approach 1:
The patent introduces a feedback mechanism where a sensor continuously measures the actual diameter of the produced yarn and sends this information back to the control system. The control system compares the measured diameter with the target diameter and automatically adjusts the draw-in roller speeds to compensate for deviations. This closed-loop control ensures that the actual yarn configuration matches the predetermined configuration, maintaining high quality consistency.
3Adaptability or versatility
If multiple influencing variables such as low pressure and yarn rotation are involved in fancy yarn configuration, then the spinning process is more complex, but inadequate coordination of these variables leads to deviations from predetermined configuration
Solution Approach 1:
The feedback system measures the actual yarn diameter and provides real-time information to the control unit, which coordinates all spinning parameters including draw-in roller speeds, rotor speed, and other influencing variables. This ensures that despite the complexity of multiple interacting parameters, they are all properly coordinated to achieve the predetermined yarn configuration.
Solution Approach 2:
The system dynamically adjusts multiple spinning parameters simultaneously based on feedback from diameter measurements. The control unit modifies draw-in roller speeds, rotor speeds, and other parameters in a coordinated manner to maintain the desired yarn configuration despite variations in material properties or processing conditions.
Data Source
AI summary
A method which improves the correspondence between the produced fancy yarn and the predetermined configuration of said fancy yarn. The fancy yarn is guided through a sensor device in a spinning device after it is formed and the diameter of the fancy yarn is continuously measured by the sensor device. The fancy configuration of the produced yarn is determined on the basis of the measured values of the diameter and is compared with the predetermined fancy configuration. The comparison is carried out until sufficient correspondence between the predetermined fancy configuration and the fancy configuration of the optimized, produced yarn is achieved.