Spindle Start-Up Speed Ratio for Cabling Yarn Reserve
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Solution Overview
Problem
Cabling machines experience frequent yarn breaks during spindle run-up, especially when using yarns with high filament counts or friction-sensitive materials, leading to reduced efficiency due to increased friction and operational challenges.
Innovation Solution
Increasing the ratio of take-up speed to spindle rotation speed during the formation of a yarn reserve outside the winding zone, allowing the outer yarn to exit the spindle quickly and reduce friction time on the spindle pot, and accelerating the spindle rotor faster during start-up to minimize friction and yarn damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the spindle rotor is accelerated slowly during start-up, then yarn friction time on the spindle pot is reduced, but productivity decreases due to longer start-up time
Solution Approach 1:
A yarn reserve is formed on the empty take-up package outside the winding zone before actual production begins. This preliminary action allows the spindle to accelerate more quickly since less yarn needs to be wound during the critical acceleration phase, reducing friction time while maintaining reliability.
Solution Approach 2:
The take-up speed is dynamically adjusted during the start-up phase. The ratio of take-up speed to spindle rotation speed is increased during yarn reserve formation compared to production, allowing the system to adapt speed parameters to minimize friction during acceleration while maintaining productivity.
2Reliability
If the take-up speed is increased during yarn reserve formation, then friction time is reduced and yarn breaks decrease, but manufacturing precision of the yarn reserve may be compromised
Solution Approach 1:
Different quality standards are applied to different portions of the yarn. The yarn reserve formed during start-up with higher take-up speed is accepted with relaxed precision requirements, while the main production yarn is wound with precise control. This local quality differentiation allows high-speed start-up without compromising overall product quality.
3Productivity
If the spindle acceleration is increased during start-up, then friction time on the spindle pot is minimized, but the outer yarn may experience excessive friction and damage
Solution Approach 1:
The harmful friction effect is extracted and isolated to a specific phase. By forming a yarn reserve outside the winding zone first, the high-friction acceleration phase is separated from the main production phase. The outer yarn experiences controlled friction only during the reserved phase, protecting it during subsequent production.
Data Source
AI summary
A method for starting a spindle of a cabling or two-for-one twisting machine, wherein a yarn reserve is formed on a take-up package, the machine has a workstation having a spindle pot for holding a first feed package and having a spindle rotor with a lateral outlet below the spindle pot, an outer yarn from one feed package is wound around an inner yarn from another feed package and the outer yarn is guided through the spindle shaft and its lateral outlet in a balloon orbiting the spindle pot to a yarn-guiding device above the spindle which merges the two yarn supplies, and a winding device in which the produced twist is wound onto the take-up package. A ratio of the take-up speed of the twist to the rotation speed of the spindle rotor is increased in comparison with the production data is used during creation of the yarn reserve.