Spindle Positioning in Turret Winders via Motor Current Sensing
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Solution Overview
Problem
Conventional automatic turret type winders face issues with precise spindle positioning due to mechanical glitches and particulate matter accumulation, leading to uneven winding tension and non-uniform package density, as they rely on less sensitive positioning methods that can result in gaps or excessive pressure between the spindle and pressure roller.
Innovation Solution
The system employs at least two discrete rotational movements at controlled speeds to position the spindle accurately, with the turret rotation controlled by sensing the current in the spindle motor to ensure precise alignment and prevent intermediate or excessive positioning, utilizing a master control system to monitor and stop the turret rotation when the spindle motor current reaches a predetermined threshold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional positioning methods are used with single turret rotation, then the system structure remains simple, but spindle positioning precision deteriorates due to mechanical glitches and dust accumulation
Solution Approach 1:
The turret rotation is divided into two discrete rotational movements instead of a single continuous rotation. The first rotation moves the spindle close to the pressure roller, and the second rotation completes the positioning. This segmentation allows for more precise control and reduces the impact of mechanical glitches and dust accumulation on positioning accuracy.
2Productivity
If turret rotation speed is increased to improve productivity, then output increases, but positioning accuracy deteriorates due to mechanical vibrations and instability
Solution Approach 1:
The turret rotation is performed in two periodic stages with different speeds. The first rotation occurs at a higher speed to maintain productivity, while the second rotation occurs at a slower speed to ensure precise positioning. This periodic variation in rotation speed allows the system to maintain high overall productivity while achieving accurate positioning during the critical final stage.
3Reliability
If mechanical components are operated for extended periods, then productivity is maintained, but positioning reliability deteriorates due to dust accumulation and wear
Solution Approach 1:
The system uses feedback from encoders mounted on the motors to monitor the actual position of the turret and spindles. This feedback mechanism allows the control system to detect and compensate for positioning deviations caused by dust accumulation and mechanical wear, maintaining reliable positioning accuracy over extended operational periods without requiring frequent maintenance.
4Measurement precision
If encoders are mounted on motors for monitoring, then positioning information is obtained, but signal transmission complexity increases due to cable requirements
Solution Approach 1:
The system replaces traditional mechanical cable-based signal transmission with wireless communication technology. Encoders mounted on the motors transmit positioning information wirelessly to the control system, eliminating the need for physical cable connections while maintaining accurate monitoring of motor revolutions and turret position.
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 the accuracy and responsiveness of spindle positioning, reducing the likelihood of gaps or excessive pressure, resulting in consistent and uniform winding tension and improved bobbin quality by ensuring the spindle touches the pressure roller at the correct position.
Implementation Method 1
sensing the current in the motors controlling the spindles
Data Source
Figure 1~1a
Figure 2~3
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AI summary
The invention relates to an automatic turret type yarn winding device. The invention provides a device and a method to position spindle precisely in turret type automatic winder, during the bobbin changeover. It involves, during the bobbin changeover process, the step of rotating the turret in at least two discrete rotational movements carried out at controlled speeds, whereby the empty bobbin assumes its accurate winding position. In an important inventive aspect of the invention, the turret rotation is controlled by sensing the current in the motors controlling the spindles. The present invention also discloses a system to control motions of the turret and the spindles. It comprises a first control system (10) to control the rotational motion of the turret and a second control system (11) to control the rotational motion of the spindle. It also comprises a master control system (12) which controls both systems (10, 11) and receives signal/information from and sends command to the two control systems (10, 11).