Lap Winder Drive Control for Cotton Wool Bubble Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing winding machines face challenges in producing high-quality lap rolls with low hairiness and uniformity due to bubble formation caused by air entrainment, which reduces productivity and makes the winding process partially unusable.
Innovation Solution
Each winding roller has a separate drive motor allowing dynamic speed adjustment based on the winding diameter to control tension between rollers, reducing bubble formation and enabling higher operating speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the winding speed is reduced to mitigate bubble formation, then the winding quality is improved, but the productivity decreases
Solution Approach 1:
The patent applies dynamics by making the winding roller speeds adjustable during the winding process. Instead of fixed speeds, the system dynamically changes the rotational speeds of the winding rollers based on the winding diameter and layer position. This allows the machine to operate at higher speeds while maintaining quality by adapting the speed parameters in real-time, thus resolving the contradiction between productivity and winding quality.
2Productivity
If the number of wadding layers is increased to improve productivity, then the output increases, but the likelihood of bubble formation increases
Solution Approach 1:
The system dynamically adjusts the speed differential between winding rollers based on the current winding diameter and layer configuration. As more layers are added, the control system modifies the rotational speeds to maintain optimal tension and prevent bubble formation, enabling high productivity without compromising quality.
Solution Approach 2:
The patent implements feedback control by monitoring the winding process parameters and adjusting the roller speeds accordingly. The control system receives information about the winding state and modifies the operational parameters to prevent bubble formation, allowing multiple layers to be wound efficiently while maintaining high quality standards.
3Device complexity
If the winding rollers are operated at fixed speed ratio, then the device complexity is reduced, but the ability to prevent bubble formation is limited
Solution Approach 1:
The patent transitions from a fixed speed ratio drive system to a dynamic speed control system. Each winding roller can be independently controlled to rotate at variable speeds, allowing the system to adapt to different winding conditions and prevent bubble formation without significantly increasing mechanical complexity.
Solution Approach 2:
The patent replaces the traditional mechanical gear-based speed ratio system with an electronically controlled drive system. This substitution allows for flexible and precise speed adjustment of the winding rollers without the complexity of multiple gearboxes, achieving better bubble prevention while keeping the mechanical structure relatively simple.
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 effectively reduces warping and transverse creases, allowing for the production of high-quality lap rolls with improved productivity by dynamically adjusting the speed difference between winding rollers and monitoring the actual diameter to maintain target specifications.
Implementation Method 1
the speed difference between the winding rollers is dynamically adjustable depending on the winding diameter. This makes it possible to generate tension between the winding rollers during winding production
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a lap winder for winding strips of cotton wool to lap rolls, said lap winder comprising lap rollers (2, 3) for carrying one lap roll (1) each, pressure rollers (5, 6, 7) for calendering a strip of cotton wool (4) supplied thereto, which pressure rollers are mounted upstream of the lap rollers (2, 3), and at least one drawing system (8) having drawing roller pairs which system is mounted upstream of the pressure rollers (5, 6, 7). The invention is characterized in that each lap roller (2, 3) has a separate drive, and at least one drive can be controlled or regulated by a control unit.