Grooved Drum Ceramic Coating for Textile Wear Resistance

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Solution Overview

Problem

Existing grooved drums for textile machines experience excessive wear at crossing and reversal points due to contact with abrasive yarns, leading to rapid groove degradation and cuts, despite previous attempts to address wear through ceramic materials, embedded wear-resistant parts, and disc-shaped inserts.

Innovation Solution

A method for producing a grooved drum with a ceramic coating applied only at the crossing and reversal points using a cylindrical auxiliary device, employing thermal spraying or electrochemical methods, ensuring localized wear protection and smooth transitions between coated and uncoated areas.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the entire grooved drum surface is coated with ceramic material, then wear resistance is improved, but the complexity of the coating application process increases and damage from creel contact is not prevented

Engineering Contradiction:

Improvewear resistanceVSAvoidcoating application complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies ceramic coating only at specific locations (crossing points and reversal points) where wear occurs, rather than coating the entire drum surface. This localized approach reduces coating material usage and simplifies the coating application process while maintaining wear resistance at critical areas.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The coating process is segmented into discrete application zones corresponding to crossing points and reversal points. The auxiliary device divides the coating application into separate localized areas, allowing independent coating of each wear-prone region without requiring complete surface coverage.

Inventive Principle:

Principle #1Segmentation

2Reliability

If ceramic coating is applied to the entire grooved drum surface, then wear protection is improved, but transitions between coated and uncoated areas cause thread damage

Engineering Contradiction:

Improvewear protectionVSAvoidthread damage at transitions

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

By limiting ceramic coating to only crossing points and reversal points, the patent eliminates the creation of transition zones between coated and uncoated areas on the drum surface. This prevents thread damage that would otherwise occur at the boundaries of extensive coating areas.

Inventive Principle:

Principle #3Local quality

3Reliability

If wear-resistant material parts are embedded in the grooved drum, then wear resistance is improved, but the manufacturing complexity and cost increase

Engineering Contradiction:

Improvewear resistanceVSAvoidmanufacturing simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the mechanical embedding of wear-resistant material parts with a surface coating application process. Instead of embedding ceramic material parts into the drum structure, the invention applies ceramic coating to the surface at specific locations, significantly simplifying the manufacturing process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the approach from embedding solid material parts to applying a ceramic coating layer. This parameter change in the manufacturing method reduces complexity while achieving the same wear protection function through a different physical implementation.

Inventive Principle:

Principle #35Parameter changes

4Reliability

If the grooved drum is made entirely from ceramic material, then wear resistance is improved, but the device complexity and manufacturing difficulty increase

Engineering Contradiction:

Improvewear resistanceVSAvoidstructural complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent creates a composite structure by combining the metallic grooved drum base material with localized ceramic coating at wear-prone areas. This composite approach maintains the structural advantages of metal while adding wear resistance where needed, avoiding the complexity of manufacturing an entirely ceramic drum.

Inventive Principle:

Principle #40Composite materials

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

The ceramic coating provides enhanced wear resistance and prevents damage to the thread at transitions, maintaining the grooved drum's functionality and reducing wear-related issues effectively.

Implementation Method 1

the ceramic coating is applied at the crossing points and at the reversal points by a thermal spraying process or an electrochemical method

Methodology Applied

Scientific EffectThermal spraying: Plasma Spray

Implementation Method 2

the ceramic coating is applied at the crossing points and at the reversal points by a thermal spraying process or an electrochemical method

Methodology Applied

Scientific EffectElectrochemical deposition: Electrodeposition

Data Source

PatentEP3284709B1Method for producing a grooved roller for a textile machine which produces crosswound bobbins

Publication Date: 2020.11.18 SAURER SPINNING SOLUTIONS GMBH & CO KG

Figure 1~2
Figure 3~4

AI summary

The present invention relates to a grooved drum (1) for a textile machine producing cross-wound bobbins, the grooves (5) having grooves for laying a thread on a cross-wound bobbin, wherein the grooves (5) have crossing points (2) and reversal points (3). According to the invention, the grooved drum (1) has a ceramic coating (4) only at the crossing points (2) and the reversal points (3). The invention also relates to a method for manufacturing the grooved drum (1) and a textile machine with the grooved drum (1).