Robotic Piecing Mechanism for Ring Spinning Yarn Breakage Repair
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Solution Overview
Problem
Existing ring spinning machines face inefficiencies due to human intervention in detecting and addressing yarn breakages and spindle defects, leading to increased production costs and unreliable processes, as well as the limitations of existing automated systems in terms of speed and effectiveness.
Innovation Solution
A robotic mechanism integrated with a ring spinning machine for automated yarn piecing, comprising yarn holding, traveller positioning, threading, and piecing means, which uses pneumatic, mechanical, and magnetic components to detect, transport, and repair yarn breakages and spindle defects without human intervention, allowing for continuous operation and improved efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If human intervention is used to monitor and repair yarn breakages, then the process is simple and flexible, but the detection speed is slow and production losses increase
Solution Approach 1:
The system enables automatic detection and self-service repair of yarn breakages through robotic mechanisms that can identify defects and perform piecing operations without human intervention, thereby increasing detection speed while managing system complexity through automated functions
Solution Approach 2:
Manual mechanical monitoring and repair operations are replaced with an automated robotic system that uses sensors for detection and robotic arms for piecing operations, significantly improving detection speed while the complexity is managed through integrated control systems
2Reliability
If multiple labourers are hired to attend multiple defect points, then all defects can be monitored, but the initial cost increases
Solution Approach 1:
A single robotic mechanism is designed to perform multiple functions including detecting yarn breakages, positioning travellers, threading yarn through guides, and executing piecing operations at various defect points along the spinning machine, thereby achieving reliable multi-point monitoring with one universal system rather than multiple individual workers
Solution Approach 2:
The robotic system replicates the functions of multiple human labourers through automated detection sensors and robotic manipulation mechanisms, creating a virtual copy of human monitoring and repair capabilities that can operate simultaneously at multiple defect points without increasing labour costs
3Reliability
If automated piecing systems are used, then human error is reduced, but the system complexity and initial cost increase
Solution Approach 1:
The automated piecing system performs self-service operations by automatically detecting yarn breakages, retrieving broken yarn ends, positioning travellers, threading yarn through guides, and executing piecing operations without human intervention, thereby eliminating human error while the system complexity is managed through integrated automated functions
Solution Approach 2:
Manual piecing operations are replaced with an automated robotic system that uses sensors for detection, robotic arms for manipulation, and controlled mechanisms for threading and piecing, significantly improving reliability while the complexity is justified through the elimination of human error and increased efficiency
4Productivity
If the spinning machine operates at high speed, then productivity increases, but yarn breakages occur more frequently
Solution Approach 1:
The system implements continuous feedback monitoring through sensors that detect yarn breakages in real-time during high-speed spinning operations, enabling immediate automatic response through the robotic piecing mechanism, thereby maintaining high productivity while minimizing yarn loss through rapid defect detection and repair
Solution Approach 2:
The automated piecing system ensures continuity of useful action by immediately repairing yarn breakages during high-speed spinning operations, minimizing interruptions and maintaining continuous yarn production, thereby preserving productivity while reducing the impact of breakages that occur at high speeds
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 system enables automated and efficient detection and repair of yarn breakages and spindle defects, reducing production losses and increasing the effectiveness and efficiency of yarn production by minimizing human error and enhancing the speed of defect resolution.
Implementation Method 1
suction slot (20) for sucking the broken yarn
Implementation Method 2
magnetic strip (39) for positioning the traveller by means of magnetism
Implementation Method 3
move the yarn in parallel to a tangent of the traveller ring
Implementation Method 4
piecing means for piecing together a held yarn and/or a loose end of a yarn with a drafted material
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A piecing arrangement in a ring spinning machine comprising: • yarn holding means for holding a yarn and/or a loose end of a yarn of a spindle of a ring spinning machine in form of a yarn picker arm (15) and a yarn piecing arm (18); • traveller positioning means for positioning of a traveller of a spindle in form of a yarn picker arm (15); • first yarn threading means for threading a held yarn and/or a loose end of a yarn into a positioned traveller of a spindle in form of a yarn picker arm (15) and a yarn positioning arm (29); • second yarn threading means for threading a held yarn and/or a loose end of a yarn into guide elements of a ring spindle machine in form of a yarn picker arm (15) and/or a yarn piecing arm (18); and • yarn piecing means for piecing together a held yarn and/or a loose end of a yarn with a drafted material in form of a yarn piecing arm (18).