Rotatable Yarn Package Rack for Continuous Heat Setting Operation

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Solution Overview

Problem

Conventional heat setting machines require manual intervention to replace yarn packages, leading to operational delays and increased risk of injury or error due to the need for manual handling and positioning of yarn packages.

Innovation Solution

A feeding assembly with a pivotable yarn package rack that rotates to alternate between a yarn feed direction and a loading area, equipped with sensors to detect yarn quantity and indicators for operator notification, allowing for automated or remote-controlled operation to maintain continuous yarn supply to the heat setting apparatus.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual yarn package replacement is used, then the heat setting machine can be operated, but operational delays occur and injury risk increases

Engineering Contradiction:

Improvecontinuous operation capabilityVSAvoidstoppage time for rack replenishment

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The yarn package rack is made rotatable about a vertical axis, allowing it to dynamically change orientation between a first position (loading area accessible) and a second position (feed direction accessible). This dynamic positioning enables continuous operation by allowing yarn packages to be loaded from one side while feeding from the other, eliminating stoppage time for manual replacement.

Inventive Principle:

Principle #15Dynamics

2Ease of operation

If manual yarn package handling is used, then yarn packages can be positioned on the rack, but the risk of injury or error increases

Engineering Contradiction:

Improveyarn package positioningVSAvoidinjury risk

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The system incorporates sensors that automatically detect when yarn packages need replacement and activate indicators to alert operators. This self-monitoring and self-alerting system reduces the need for manual inspection and handling, thereby minimizing injury risk while maintaining ease of operation through automated notification.

Inventive Principle:

Principle #25Self-service

3Weight of stationary object

If the rack is designed to support heavy yarn packages, then substantial weight capacity is achieved, but the structure becomes more complex

Engineering Contradiction:

Improveyarn package weight capacityVSAvoidrack structure complexity

Core Design Contradiction:

Weight of stationary objectVSDevice complexity

Solution Approach 1:

The rack structure is segmented into multiple independent yarn package positions arranged on the rotatable rack. Each position can hold a yarn package independently, allowing the system to support substantial total weight through distributed loading rather than requiring a monolithic complex structure. The rotatable design provides a simple mechanical solution for managing multiple heavy packages.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS11905135B1Yarn feeding assembly for heat setting applications, and systems and methods of using same

Publication Date: 2024.02.20 COLUMBIA INSURANCE CO

AI summary

A heat setting apparatus feeding assembly can comprise a yarn package rack having a first side and an opposing second side. A plurality of yarn package engagement elements can be positioned on each of the first side and the second side of the yarn package rack. The yarn package rack can be configured to rotate about a pivotal axis to orient one of the first side or the second side toward a yarn package loading area and to orient the other of the first side and the second side toward a feed direction.