Magnetic Coupling Guide Rollers for Yarn Tension Control
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Solution Overview
Problem
Existing take-up winders cause yarn damage and quality deterioration due to large bending angles and insufficient drive force for guide rollers, leading to tension variations and increased air resistance, especially at high winding speeds, and require heavy and complex structures for manual operation.
Innovation Solution
The take-up winder features actively driven guide rollers detachably connected to roller drivers, allowing for independent movement and reduced load on yarns, with magnet couplings for contactless power transmission, enabling easy threading and maintenance operations without applying load to the yarns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If guide rollers are driven rollers rotated in accordance with the running of the yarn, then yarn damage is restrained, but tension variation occurs and yarn quality is lowered
Solution Approach 1:
The patent replaces the mechanical drive system (motor-driven guide rollers) with a magnetic coupling system. The magnetic coupling transfers rotational motion from the drive roller to the guide roller without mechanical contact, eliminating tension variation while maintaining the benefits of active driving.
2Object-affected harmful factors
If guide rollers are driven rollers, then yarn damage is reduced, but air resistance increases and surface abrasion worsens at high winding speeds
Solution Approach 1:
The patent replaces direct mechanical contact between the drive source and guide roller with magnetic coupling. This eliminates friction and surface abrasion while maintaining effective power transmission, allowing high-speed operation without wear.
3Object-affected harmful factors
If guide rollers are actively driven by motors, then yarn damage is restrained, but the structure becomes heavy and complex for manual operation
Solution Approach 1:
The patent divides the guide roller assembly into separable components: the guide roller itself and the magnetic coupling mechanism. This segmentation allows the guide roller to be easily detached and repositioned for manual operations while the drive mechanism remains stationary.
Solution Approach 2:
The magnetic coupling acts as an intermediary between the motor-driven roller and the guide roller. It transmits rotational motion without requiring the guide roller to be permanently attached to the heavy motor assembly, enabling easy manual repositioning.
4Ease of operation
If guide rollers are movable for easy threading and maintenance, then ease of operation improves, but the drive force transmission becomes insufficient
Solution Approach 1:
The magnetic coupling serves as an intermediary that maintains drive force transmission even when the guide roller is detached from its normal position. The magnetic field can transmit torque through the air gap, ensuring sufficient drive force is maintained during threading and maintenance operations.
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
Significantly reduces yarn damage and tension variations, facilitates easy manual movement of guide rollers, and maintains high winding speeds without surface abrasion, improving yarn quality and operational efficiency.
Implementation Method 1
the guide rollers and the roller drivers are connected with one another by magnet couplings in a contactless manner so that power transmission is possible between the guide rollers and the roller drivers
Data Source
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AI summary
A take-up winder in which guide rollers are actively driven while the guide rollers are easily movable at the time of operations such as yarn threading is provided. The take-up winder includes a guide rollers 13 guiding yarns Y spun out from a spinning device to bobbins, respectively, and motors 24 driving the respective guide rollers 13. The guide rollers 13 are connected with the motors 24 by magnet couplings 30, respectively, and are movable independently of the motors 24.