Rotor Spinning with Asynchronous Feeding and Multi-Level Carding
Solution Overview
Problem
Existing rotor spinning technologies cannot produce yarn with both invariable linear density and adjustable blending ratios, and they often result in inadequate fiber mixing and yarn defects due to the limitations of single carding rollers and fixed feeding ratios.
Innovation Solution
A rotor spinning method utilizing a multi-level carding system with three combined feeding rollers and a multi-level carding roller, driven by a servo motor, allows for asynchronous feeding and dynamic control of fiber feeding ratios, enabling the production of yarns with variable linear density and blending ratios through a computer-controlled system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional single carding roller is used to feed three slivers simultaneously, then the feeding process is simple, but the carding and drafting system cannot adequately strip, card, separate and mix the slivers, causing blocking and yarn defects
Solution Approach 1:
The single carding roller is divided into three separate carding rollers (first, second, and third carding rollers), each independently processing one sliver. This segmentation allows each roller to adequately strip, card, separate and mix its assigned sliver without overload, eliminating blocking and yarn defects while maintaining the capability to handle multiple slivers simultaneously
Solution Approach 2:
The patent introduces a vertical stacking arrangement of the three carding rollers, transforming the horizontal single-roller configuration into a vertical multi-level structure. This dimensional change enables independent processing of multiple slivers while maintaining compact space utilization and effective carding action for each sliver
2Device complexity
If the carding area is short, then the device structure is compact, but there is little chance of horizontal fiber mixing, resulting in unsatisfactory color blending effect
Solution Approach 1:
The three carding rollers are arranged in sequence with continuous fiber flow from one roller to the next, ensuring that fibers undergo continuous carding and mixing actions throughout the extended carding path. This continuous action maximizes horizontal fiber mixing and color blending effectiveness within the available space
Solution Approach 2:
Each carding roller is equipped with specific needle configurations and rotation speeds optimized for its position in the sequence, creating localized carding zones with different mixing intensities. This allows progressive blending of colors throughout the carding process, achieving satisfactory color blending effect
3Manufacturing precision
If the feeding roller speed is controlled to keep feeding in an invariable amount, then the linear density is invariable, but the blending ratio cannot be adjusted
Solution Approach 1:
The feeding roller speeds are made dynamically adjustable through independent motor control for each feeding roller. This allows the system to transition from fixed-speed operation to variable-speed operation, enabling both invariable linear density control (when speeds are fixed) and adjustable blending ratios (when speeds are varied) according to production requirements
Solution Approach 2:
The patent introduces speed ratio as a controllable parameter for the feeding rollers. By changing the speed parameters of individual feeding rollers while maintaining their sum constant, the system can adjust blending ratios without affecting linear density, achieving both precision control and adaptability
4Adaptability or versatility
If two or more drafted slivers are fed in segments in different amounts, then the blending ratio can be adjusted, but the carding roller and rotor are prone to blocking
Solution Approach 1:
The patent assigns each drafted sliver to a dedicated carding roller, segmenting the carding process so that each roller handles one sliver independently. This prevents overload and blocking of individual rollers even when feeding amounts vary, while still allowing blending ratio adjustment through differential feeding speeds
Solution Approach 2:
The system incorporates feedback control mechanisms that monitor the feeding amounts and carding performance of each sliver. When variation in feeding amounts is detected, the system adjusts the operation of individual carding rollers to maintain optimal loading and prevent blocking, ensuring reliable operation with adjustable blending ratios
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 approach enhances fiber mixing, reduces yarn defects, and allows for the production of yarns with precise control over linear density and blending ratios, achieving flexible and efficient spinning with improved color blending effects.
Implementation Method 1
driven by a servo motor
Implementation Method 2
The sliver is opened and stripped, carded separately and mixed by the carding roller, which rotates at a high speed in the carding area, so that the sliver becomes single fibers which are separated and arranged parallel to each other
Implementation Method 3
Under the centrifugal force of the rapidly rotating rotor, the fibers in the collection groove are further piled up and mixed
Implementation Method 4
Under the action of air flow, the fiber flows into the rotor through the fiber transport channel
Implementation Method 5
the fibers are jointed with the mother-yarn and twisted by a navel to form a yarn
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
A device for a rotor spinning method using multi-level carding includes a spinning system and a computer control system. The spinning system includes a feeding and carding mechanism, a collecting and twisting mechanism, and a winding mechanism. The device is characterized in that the feeding and carding mechanism includes combined feeding rollers (2-4, 2-5, 2-6) having three rotation freedom degrees and multi-level carding rollers (2-8, 2-9, 2-10), the speed ratio of three rollers of the combined feeding rollers (2-4, 2-5, 2-6) having three rotation freedom degrees is adjustable, and therefore the linear density and blending ratio of rotor spun yarn can be regulated and controlled randomly. A rotor spinning method using three- sliver asynchronous input and multi-level carding is also disclosed.