Spindle Yarn Balloon Diameter Reduction
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Solution Overview
Problem
Current two-for-one twister or cabling machines face challenges in minimizing energy consumption due to the formation of a free yarn balloon, which is influenced by limited variables such as spindle diameter, rotational speed, and yarn titre, leading to increased energy consumption and productivity losses.
Innovation Solution
A method and machine design that adjusts the yarn feed speed to minimize the diameter of the free yarn balloon by controlling yarn tension using a regulatable device upstream of the twisted yarn plate, eliminating the need for storage discs or pots, thereby reducing energy consumption by 20-30%.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a free yarn balloon is formed around the spindle, then yarn tension can be compensated for supply fluctuations, but energy consumption increases due to the large balloon diameter
Solution Approach 1:
The patent extracts the yarn tension compensation function from the large free yarn balloon and transfers it to a small storage disc. The storage disc is arranged below the twisted yarn plate and has a diameter significantly smaller than the spindle diameter. The storage disc compensates for yarn supply fluctuations by storing and releasing yarn as needed, while the yarn forms only a small balloon around the spindle rather than a large free balloon, thereby reducing the energy consumption of the spindle drive.
Solution Approach 2:
The storage disc acts as an intermediary element between the yarn supply and the spindle. It mediates the yarn tension by absorbing supply fluctuations and providing controlled yarn feed to the spindle, enabling tension compensation without requiring a large free yarn balloon that would increase energy consumption.
2Use of energy by moving object
If the rotational speed of the spindle is reduced to optimize balloon shape, then energy consumption decreases, but productivity is lost
Solution Approach 1:
The patent changes the parameter of balloon diameter by introducing a storage disc with small diameter below the twisted yarn plate. This parameter change allows the system to maintain effective yarn tension compensation with a minimized balloon diameter, enabling the spindle to operate at higher rotational speeds for improved productivity without excessive energy consumption.
3Reliability
If a storage disc is used to control yarn tension, then yarn supply fluctuations are compensated, but device complexity increases
Solution Approach 1:
The storage disc performs multiple functions: it compensates for yarn supply fluctuations, controls yarn tension, and enables the spindle to operate with a minimized balloon diameter. By consolidating these functions into a single compact component, the patent avoids the complexity of more elaborate tension control mechanisms while achieving reliable yarn supply stabilization.
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
The method achieves reduced energy consumption and improved productivity by minimizing the diameter of the free yarn balloon, allowing for precise control of yarn tension and adapting to fluctuations in yarn supply, thus optimizing spindle drive power usage.
Implementation Method 1
the yarn exits virtually perpendicular to the longitudinal axis of the spindle and is deflected to the outer edge of the twisted yarn plate and runs along the spindle as a free yarn balloon encompassing the spindle
Implementation Method 2
the supply speed of the yarn is adjusted in such a way that the yarn tension adopts a value which minimizes the diameter of the free yarn balloon
Data Source
AI summary
A two-for-one twister or cabling machine and a method for operation thereof, wherein a yarn (5, 25) is withdrawn from a supply bobbin (7, 21) and fed to a guide device below a twisted yarn plate (8, 24) of the spindle (2, 22) and from which the yarn (5, 25) exits virtually perpendicular to the axis of the spindle (2, 22) and is deflected to the outer edge of the twisted yarn plate (8, 24) and runs along the spindle (2, 22) as a free yarn balloon (B) encompassing the spindle (2, 22), until the yarn (5, 25) is fed into the twist or cabling point of a yarn guide device (9, 27) above the spindle (2, 22). The supply speed of the yarn (5, 25) is adjusted to achieve a yarn tension which minimizes the yarn balloon diameter as a function of the spindle geometry.