High-Precision Bobbin Thread Placement With Winding-Angle Control
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Solution Overview
Problem
Existing methods for precision and step-precision windings in bobbin winding struggle with maintaining exact frequency ratios to prevent mirror formation and spool vibrations, requiring high metrological accuracy and effort in speed control.
Innovation Solution
A method that uses the winding angle as a continuous parameter to control the traversing thread guide, calculating the traversing thread guide control angle based on the winding angle and K values, ensuring precise thread deposition by controlling the axial thread deposit target position, reducing reliance on speed measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If precision winding with fixed crossing ratio is used to prevent mirror formation, then bobbin surface quality is improved, but device complexity and control effort increase due to high metrological accuracy requirements
Solution Approach 1:
The patent changes the control parameter from speed-based (frequency ratio) to angle-based (winding angle φ). Instead of maintaining a fixed frequency ratio K between bobbin rotation and traversing device, the system uses the winding angle as the independent variable to control thread placement. This transformation simplifies the control system by eliminating the need for high-precision speed synchronization while achieving the same mirror prevention effect through angle-based positioning.
Solution Approach 2:
The patent replaces the mechanical speed synchronization system with a computational angle-based control system. Rather than using complex mechanical gear systems or precision frequency controllers to maintain the crossing ratio, the invention uses digital calculation of the winding angle and its relationship to traversing position, substituting mechanical precision requirements with computational geometry.
2Measurement precision
If high metrological accuracy is maintained for speed control to prevent spool vibrations, then thread placement precision is improved, but measurement effort and system complexity increase
Solution Approach 1:
The patent eliminates speed measurement by changing to angle-based parameters. The winding angle φ is measured from the start of winding and used directly to control traversing position, removing the need for continuous speed measurement and frequency ratio calculation. This parameter transformation reduces measurement effort while maintaining placement precision.
3Stability of the object's composition
If the crossing ratio is kept constant throughout winding, then mirror formation is avoided, but the system cannot adapt to changing bobbin diameter and speed requirements
Solution Approach 1:
The patent creates a dynamic control system where the traversing position is continuously adjusted based on the current winding angle and bobbin diameter. The relationship between winding angle and traversing position changes adaptively as the bobbin grows, allowing the system to maintain optimal thread spacing without requiring a fixed crossing ratio. This dynamic adaptation prevents mirror formation while accommodating varying winding conditions.
Data Source
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AI summary
A method for highly precise thread placement of a thread (1) during the winding of a bobbin (2) comprising the following steps: a) Continuously acquiring a winding angle ϕspool or a precursor value from which the winding angle ϕspool can be calculated, wherein the winding angle ϕspool describes a coordinate (3) of the thread (1) in a circumferential direction (4) on the bobbin (2); b) Calculating a changeover thread guide control angle ϕchanger,control as a function of the winding angle ϕspool and/or the precursor value, wherein the changeover thread guide control angle ϕchanger,control is calculated from the winding angle ϕspool and/or the precursor value taking into account at least one K-value; c) Using the changeover thread guide control angle ϕchanger,control to calculate an axial thread placement target position Ztarget on the bobbin (2);d) Controlling a changing thread guide (5) according to the axial thread placement target position Ztarget for high-precision thread placement at the coordinate described by the winding angle ϕcoil on the axial thread placement target position Ztarget.;