Modulated Thread-Guide Device for Uniform Bobbin Density
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Solution Overview
Problem
High-speed automatic bobbin-winding machines face challenges in achieving uniform thread distribution due to the inertia and mass of traditional thread-guide devices, leading to irregular bobbin density and shape, especially at high collection rates where the thread-guide's alternating movement struggles with rapid acceleration and braking, resulting in increased yarn quantity at the ends and an irregular profile.
Innovation Solution
A thread-guide device activated by at least two smaller synchronous motors, coordinated by a control unit, with elastic means to assist during movement inversion points, allowing for higher accelerations and reducing overall inertia by distributing torque and stress more efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single motor activates the thread-guide device, then the structure is simpler, but the acceleration and braking performance deteriorates due to high inertia
Solution Approach 1:
The patent divides the single motor activation system into multiple independent motors (at least two synchronous motors), each responsible for specific phases of the thread-guide movement. This segmentation reduces the inertia load on each motor while maintaining the overall functionality of the system, enabling faster acceleration and braking without excessive structural complexity.
Solution Approach 2:
The patent implements dynamic activation where motors are selectively engaged and disengaged based on the movement phase. During inversion points, elastic means store and release energy to assist acceleration, while motors are coordinated to provide torque only when needed. This dynamic approach optimizes performance without requiring a continuously powered high-inertia system.
2Productivity
If the thread-guide device operates at high collection rates, then productivity increases, but the yarn distribution uniformity deteriorates due to insufficient acceleration and braking control
Solution Approach 1:
The patent employs a control unit that coordinates multiple motors based on real-time movement phase detection. The system monitors the thread-guide position and adjusts motor activation accordingly, ensuring precise acceleration and braking control even at high collection rates. This feedback mechanism maintains yarn distribution uniformity while enabling high-speed operation.
Solution Approach 2:
The patent utilizes periodic activation of motors synchronized with the oscillation cycle of the thread-guide. Motors are activated in specific phases (during acceleration and braking) and deactivated during intermediate phases, creating a rhythmic pattern of energy input that maintains precision at high speeds. The elastic means further enhance this periodic action by storing energy during deceleration and releasing it during acceleration phases.
3Stability of the object's composition
If the thread-guide device has high mass for structural stability, then the bobbin shape quality improves, but the acceleration performance deteriorates due to increased inertia
Solution Approach 1:
The patent segments the mass distribution by using multiple smaller motors instead of one large motor, and by distributing the activation timing across different phases of the oscillation cycle. This allows the thread-guide structure to maintain sufficient mass for stability while the segmented motor system can accelerate and decelerate more efficiently by applying force only when needed.
Solution Approach 2:
The patent uses elastic means (springs) that are pre-loaded during the intermediate phases of the thread-guide movement. This preliminary action stores energy that is then released during acceleration phases, providing additional force without requiring the motor to continuously overcome the full inertia of the system. This allows high acceleration performance while maintaining structural stability.
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 solution enables higher accelerations and more uniform yarn distribution, resulting in higher-quality bobbins with improved density and shape consistency, even at extremely high collection rates, by optimizing the torque-inertia ratio and reducing stress on the system.
Implementation Method 1
with elastic means to assist during movement inversion points, allowing for higher accelerations and reducing overall inertia by distributing torque and stress more efficiently
Data Source
Figure 1A~1B
Figure 1C
AI summary
Thread-guide device with modulated traversing with an individual thread-guide having a back-and-forth movement fixed to a flexible element, moved between two pulleys in an alternating clockwise/anticlockwise movement, each driven by its own electric motor, both motors being piloted and coordinated to a control unit.