Spindle Balloon Tension Control via Fixed Ejection Point
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Solution Overview
Problem
Two-for-one twisting or cabling machines face challenges in optimizing thread tension and balloon diameter, leading to inefficient energy consumption and potential thread storage issues, especially when using storage discs or co-rotating balloon limiting pots, which result in suboptimal thread balloon geometry and increased energy usage.
Innovation Solution
A method for operating a spindle in a two-for-one twisting or cabling machine that eliminates the use of storage discs and co-rotating balloon limiting pots by employing a rotatably mounted thread deflection device with a fixed ejection point and a control circuit to regulate thread tension, ensuring a minimum thread balloon size and optimal thread tension, thereby minimizing the diameter of the free thread balloon.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a storage disc is used to compensate for thread delivery fluctuations, then thread tension is regulated, but the device complexity increases and energy consumption rises
Solution Approach 1:
The patent removes the storage disc from the system entirely, extracting the problematic component that caused complexity and energy consumption issues. Thread delivery fluctuations are compensated through the interaction between the balloon limiting pot and the thread balloon dynamics, eliminating the need for the storage disc while maintaining thread tension regulation.
Solution Approach 2:
The balloon limiting pot serves multiple functions: it limits the maximum balloon diameter, regulates thread tension, and compensates for thread delivery fluctuations. This multi-functional component replaces the storage disc's tension regulation function while adding balloon diameter control capabilities.
2Reliability
If a co-rotating balloon limiting pot is used to regulate thread tension, then thread tension is reduced, but energy consumption increases due to air friction and constant movement
Solution Approach 1:
The patent eliminates the co-rotating balloon limiting pot from the system, removing the source of continuous energy consumption through air friction and constant movement. Thread tension is instead regulated through the interaction between the fixed balloon limiting pot and the thread balloon dynamics during normal operation.
Solution Approach 2:
Instead of actively moving a balloon limiting pot to regulate tension, the system uses a fixed balloon limiting pot that passively interacts with the thread balloon. The thread balloon's own dynamics, combined with the fixed pot's geometric constraint, automatically regulate tension without requiring continuous active movement.
3Reliability
If the thread balloon diameter is increased to compensate for delivery fluctuations, then thread storage is improved, but energy consumption increases
Solution Approach 1:
The system dynamically adjusts the thread balloon diameter within optimized bounds rather than maintaining a consistently large diameter. The balloon limiting pot sets a maximum diameter threshold, and the actual diameter varies based on thread delivery conditions, optimizing the balance between compensation capability and energy consumption.
4Ease of operation
If a fixed ejection point on a rotatably mounted thread deflection device is used, then accessibility and concentricity are improved, but thread tension control complexity increases
Solution Approach 1:
The fixed ejection point on the rotatably mounted thread deflection device automatically maintains optimal thread tension through the geometric relationship between the ejection point, the balloon limiting pot, and the thread balloon. The system self-regulates tension through its geometry and dynamics without requiring additional active control mechanisms, despite the apparent complexity of the rotating assembly.
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 reduces energy consumption, minimizes thread storage, and enhances the operational efficiency and accessibility of the spindle, while preventing thread damage and improving concentricity and vibration behavior, allowing for easier thread tension adjustment and reduced component wear.
Implementation Method 1
due to the friction of the running outer thread on the inner wall of the balloon containment pot, the thread tension is regulated
Implementation Method 2
The air friction of the co-rotating balloon limiting pot creates additional losses that have to be compensated for by the spindle drive
Data Source
Figure 1
Figure 2a~2c
Figure 3a~4
AI summary
The invention relates to a method for operating a spindle (2) of a double-wire twisting or cabling machine, in which an outer thread (5) is drawn from a first feed spool (7) and orbits the spindle (2) in a thread balloon (B), wherein the spindle (2) has a device (6) for influencing the balloon thread tension of an outer thread (5), which is connected to a control loop (18), a spool pot (19) for receiving a second feed spool (15), a thread deflection device (20), a compensation system (9) for forming a twisting or cabling point, and a winding and winding device (12). According to the invention, the drive of the thread balloon (B) is provided via a fixed discharge point (21) on the thread deflection device (20).