Spun Yarn Drawing Apparatus with Speed Deceleration Control
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Solution Overview
Problem
Existing spun yarn drawing apparatuses face significant energy loss due to high surface temperatures of heat-setting rollers required for producing yarns with low boiling water shrinkage, leading to inefficient heat energy usage.
Innovation Solution
A spun yarn drawing apparatus with a speed controller that adjusts yarn feeding speeds across multiple rollers to achieve a deceleration rate of 2% or higher between the most upstream and downstream rollers, while maintaining a winding angle of less than 270 degrees, thereby relaxing and thermally setting yarns at lower surface temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the surface temperature of heat-setting rollers is increased to produce yarns with low boiling water shrinkage, then the boiling water shrinkage of yarns is reduced, but the energy consumption and heat loss increase significantly
Solution Approach 1:
The yarn is preliminarily heated by the heating roller before entering the heat-setting roller. This preliminary heating action prepares the yarn for thermal setting at a lower temperature, reducing the energy requirement of the subsequent heat-setting process while achieving the desired low boiling water shrinkage
Solution Approach 2:
The patent maintains continuous thermal action on the yarn through the heating roller and heat-setting roller sequence. The yarn receives continuous heating and thermal setting treatment without interruption, ensuring efficient energy utilization and consistent product quality with reduced energy loss
2Manufacturing precision
If the surface temperature of heat-setting rollers is increased to reduce boiling water shrinkage, then the yarn thermal setting is improved, but the heat radiation loss increases
Solution Approach 1:
The patent changes the temperature parameter distribution along the yarn processing path. Instead of using a single high-temperature heat-setting roller, the system uses a lower-temperature heating roller for preliminary heating followed by a heat-setting roller at optimized temperature, reducing heat radiation loss while maintaining effective thermal setting
Solution Approach 2:
The heating roller acts as an intermediary device between the yarn and the heat-setting roller. It performs preliminary heating of the yarn, reducing the temperature burden on the heat-setting roller and thereby decreasing heat radiation loss from the heat-setting roller while still achieving proper thermal setting
3Manufacturing precision
If high surface temperature rollers are used to achieve low boiling water shrinkage, then the yarn shrinkage is reduced, but the accompanying heated airflow causes additional energy waste
Solution Approach 1:
The heating roller performs preliminary heating of the yarn before it reaches the heat-setting roller. This preliminary action reduces the temperature differential required at the heat-setting stage, minimizing the generation of heated airflow and associated energy losses from the thermal insulation box
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 allows for the production of yarns with small boiling water shrinkage while keeping the surface temperatures of heat-setting rollers low, reducing energy waste and maintaining a stable yarn path.
Implementation Method 1
a heating roller for preliminary heating and heat-setting rollers for heat-setting, wherein the yarns are wound onto the heating roller for preliminary heating, and are then wound onto the heat-setting rollers
Implementation Method 2
the drawn yarns are thermally set by the heating rollers for heat-setting
Data Source
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AI summary
A spun yarn drawing apparatus by which yarns with a low boiling water shrinkage are obtained while surface temperatures of heat-setting heating rollers are restrained to be low is provided. The spun yarn drawing apparatus includes preliminary heating godet rollers 14 and 15 and heat-setting godet rollers 16 to 18 which are heating rollers rotating at higher yarn feeding speeds than the godet rollers 14 and 15. Onto each of these godet rollers 14 to 18, the yarns are wound at a winding angle of smaller than 270 degrees. In the heat-setting godet rollers 16 to 18, the yarn feeding speed of a roller on the downstream side is equal to or lower than the yarn feeding speed of a roller on the upstream side. Furthermore, the deceleration rate between the yarn feeding speed of the most upstream godet roller 16 in the yarn running direction and the yarn feeding speed of the most downstream godet roller 18 in the yarn running direction is 2% or higher.