Semi-Automatic Rotor Spinning Machine Group Control
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Solution Overview
Problem
Semi-automatic open-end rotor spinning machines are inflexible, allowing only one yarn lot to be produced on each side, limiting their ability to meet diverse customer demands and increasing production costs due to the need for complex service units and self-sufficient workstations.
Innovation Solution
The central control device and workstation control devices are designed to manage groups of workstations flexibly, allowing for variable batch sizes and independent operation of parameters such as yarn quality, bobbin diameter, and sliver feed rates, enabling the simultaneous production of multiple yarn lots with different specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If each workstation is designed to be self-sufficient with individual drives for spinning and winding devices, then the machine can automatically rectify faults and operate independently, but the device complexity and production costs increase significantly
Solution Approach 1:
The machine is divided into semi-autonomous groups of workstations (e.g., 10-20 stations per group), where each group shares common drive mechanisms rather than every station having completely independent drives. This segmentation maintains operational independence at a group level while reducing individual complexity.
Solution Approach 2:
Common drive shafts and mechanisms are designed to serve multiple workstations simultaneously. For example, a single drive shaft can power multiple spinning rotors and winding devices across several workstations, making the drive system universal rather than dedicated to each individual station.
2Productivity
If the machine is configured to produce only one yarn lot per side, then the production process is simplified and more stable, but the adaptability to diverse customer demands decreases
Solution Approach 1:
The control system is designed to dynamically reconfigure which workstations produce which yarn lots. Groups of workstations can be flexibly assigned to different yarn lot specifications (yarn count, quality parameters, bobbin diameter) based on customer demand, allowing the production configuration to change without physical reconfiguration of the machine.
Solution Approach 2:
The machine allows changing of production parameters (yarn count, quality settings, bobbin diameter) through software control rather than physical reconfiguration. This enables different yarn lots to be produced by adjusting control parameters while maintaining the same physical workstation configuration.
3Loss of time
If smaller batches of yarn are produced, then customer demand diversity is met and downtime is reduced, but the frequency of parameter changes and setup adjustments increases
Solution Approach 1:
The control system pre-configures groups of workstations for different yarn lot specifications before production begins. This preliminary grouping allows quick switching between yarn lots by simply changing which pre-configured group is active, rather than adjusting individual parameters at each workstation during production.
Solution Approach 2:
Successful production parameters and configurations from one yarn lot can be copied and applied to other workstations or future yarn lots. The control system stores parameter sets that can be replicated across multiple workstations, reducing the complexity of managing unique parameters for each station.
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 flexibility allows for the production of various yarn lots simultaneously, improving economic efficiency and responsiveness to customer requests, while minimizing downtime and increasing productivity by allowing smaller batches to be produced without halting the entire machine.
Implementation Method 1
The supplied sliver is fed by means of a sliver draw-in cylinder to the opening roller
Implementation Method 2
the opening roller, which opens the sliver into individual fibers with its clothing and transports it to the fiber guide channel
Implementation Method 3
The fiber transport is supported by the negative pressure in the rotor housing, which creates an air flow in the fiber guide channel, loosens the fibers from the opening assembly and conveys them through the so-called channel plate adapter into the spinning rotor
Implementation Method 4
The centrifugal acceleration causes the fibers to slip into the collecting groove of the spinning rotor
Implementation Method 5
where they are collected, drawn off axially through the draw-off nozzle in the axis of rotation and twisted into a yarn
Implementation Method 6
a winding device for producing a cheese rotatably mounted in a creel... and wound onto a cross-wound bobbin
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a semi-automatic open-end rotor spinning machine (1) with work stations (2), each of which has a spinning device (3) for producing a yarn (30), a yarn cleaner for checking the quality of the produced yarn (30), a yarn take-up device (18), a winding device (33) for producing a cross-wound bobbin (22) rotatably held in a bobbin frame (21), and a work station control device (9), wherein the spinning devices (33) have spinning rotors (4) rotating at high speed in their spinning housing, as well as fiber ribbon feeding devices and unwinding rollers (12), wherein the spinning rotors (4), unwinding rollers (12), bobbin drive rollers (23), and yarn guides of the winding devices (33) have machine-length drives, and wherein the fiber ribbon feed cylinders (14) of the fiber ribbon feeding devices are driven individually by motors.According to the invention, the control devices (9, 41) of groups of work stations (2) of freely selectable size are each designed in such a way that they differ from other groups in the control of at least one of the functions cleaner setting, spinner setting, fiber tape feed, spool diameter, yarn fineness and effect setting.