Splicing Head Segmentation for Cross-Winder Conversion Time
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Solution Overview
Problem
Existing thread splicing devices for automatic cheese winders require time-consuming and costly conversions when switching between different yarn materials, leading to potential installation errors and significant machine downtime.
Innovation Solution
A method where the splicing head is designed as a preassembled structural unit with a fastening device accessible from the front, allowing for quick removal and replacement of compressed air lines and thread treatment elements, enabling simplified conversions without the need for extensive tooling or complex component changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the splicing head is designed as a permanently installed unit with fixed compressed air lines, then the structural stability is improved, but the conversion time and machine downtime increase significantly
Solution Approach 1:
The splicing head is separated from the compressed air lines, allowing the splicing head to be exchanged independently while the compressed air lines remain permanently installed in the splicer housing. This segmentation enables quick conversion by replacing only the splicing head unit without disturbing the air supply infrastructure.
Solution Approach 2:
The compressed air lines are pre-installed and permanently fixed in the splicer housing before the splicing head is attached. This preliminary action ensures that when a splicing head needs replacement, the air connection points are already in place, eliminating the need to reinstall air lines during conversion.
2Manufacturing precision
If the splicing head is designed as a permanently installed unit with fixed compressed air lines, then the manufacturing precision is improved, but the ease of operation deteriorates
Solution Approach 1:
By separating the splicing head from the compressed air lines, the system allows operators to exchange splicing heads without needing to handle or reconnect air lines. This segmentation simplifies the conversion operation while maintaining precise installation through standardized mounting interfaces.
Solution Approach 2:
The splicing head is designed to be self-contained with integrated thread treatment elements that are pre-matched to specific yarn lots. This self-service design allows operators to simply replace the entire splicing head unit without needing to individually adjust or reconfigure multiple components, reducing both complexity and potential for error.
3Device complexity
If the splicing head is designed as a permanently installed unit, then the device complexity is reduced, but the adaptability deteriorates
Solution Approach 1:
The splicing head is segmented from the permanent splicer housing and compressed air lines, creating a modular unit that can be easily exchanged. This segmentation maintains simple permanent infrastructure while enabling flexible adaptation to different yarn materials through splicing head replacement.
Solution Approach 2:
The system transitions from a static, permanently installed splicing head to a dynamic configuration where the splicing head can be quickly exchanged to match different yarn lot requirements. This dynamic adaptability allows the same splicer housing to handle various yarn materials by simply changing the splicing head unit.
4Ease of manufacture
If the splicing head is designed as a permanently installed unit, then the ease of manufacture is improved, but the productivity deteriorates
Solution Approach 1:
By segmenting the splicing head from the permanent splicer housing and compressed air lines, the system simplifies the conversion process to a simple unit replacement operation. This segmentation enables rapid changeover between yarn lots, minimizing machine downtime and maximizing productivity while keeping the permanent infrastructure simple to manufacture.
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 conversion time and minimizes machine downtime, allowing less qualified personnel to perform batch changes efficiently, ensuring correct installation of thread treatment elements and maintaining optimal thread connections.
Implementation Method 1
the upper thread, which has run up onto the surface of a cross-wound bobbin held in the creel of a work station after a bobbin interruption, is picked up by a work station's own suction nozzle
Implementation Method 2
the so-called lower thread is also picked up by a gripper tube from a pay-off spool positioned in an unwinding position and also inserted into the splicing channel of the splicing prism
Implementation Method 3
two thread ends that have arisen after a winding interruption, for example after a thread breakage or a controlled clearer cut, can be pneumatically rejoined
Data Source
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AI summary
The method involves forming a splicing head (18) as a premounted structural unit with a fastening device (44) attached at an accommodation device (30) of a work location. The head is removed from the accommodation device and compressed air lines (27) and replaced by a new splicing head, where the accommodation device is arranged at a splicing housing (31). Thread treatment elements such as splicing prisms (19), holding pipes and disintegrating pipes, are individually aligned based on available yarn lots. The head is fixed at the accommodation device by a screw bolt. An independent claim is also included for a thread splicing device for performing a method for operating a work location of a cross-winding machine.