Variable Resistance Dancing Arm for Yarn Winding Tension Control
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Solution Overview
Problem
Conventional yarn winding machines maintain constant tension throughout the winding process, leading to increased unwinding tension as the bobbin size decreases, causing fabric width variations and potential breakages due to high weft tension.
Innovation Solution
An apparatus that dynamically varies the dancing arm's resistance as a function of bobbin diameter using a pressure line multiplexer, allowing for discrete or continuous changes in tension to maintain consistent yarn tension during winding, thereby reducing fabric width variations and necking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If constant tension is maintained throughout the winding process, then winding simplicity is preserved, but fabric width variation increases from 4-6% to 10-12%
Solution Approach 1:
The patent applies dynamics by making the dancing arm resistance variable instead of constant. The resistance changes dynamically as the bobbin diameter changes during winding, allowing the system to adapt to different stages of the winding process. This resolves the contradiction by maintaining operational simplicity while achieving consistent fabric width through dynamic tension adjustment.
Solution Approach 2:
The patent changes the tension parameter throughout the winding process rather than keeping it constant. By adjusting the dancing arm resistance as a function of bobbin diameter, the system modifies the tension parameter to compensate for changes in unwinding conditions, thereby maintaining fabric width consistency without complicating the overall winding operation.
2Device complexity
If constant dancing arm resistance is used, then device complexity is minimized, but yarn breakage risk increases due to high weft tension at small bobbin sizes
Solution Approach 1:
The dancing arm resistance is made dynamic rather than static, allowing it to adapt to changing bobbin sizes. This prevents yarn breakage at small bobbin sizes by automatically reducing resistance when the bobbin is small, while maintaining system simplicity through a single integrated mechanism rather than multiple complex control systems.
Solution Approach 2:
The dancing arm mechanism serves itself by automatically adjusting resistance based on bobbin diameter changes during winding. The system self-regulates tension without external intervention, preventing yarn breakage while maintaining device simplicity through inherent feedback mechanisms rather than complex external control systems.
3Manufacturing precision
If dancing arm resistance is increased to maintain tension at large bobbin sizes, then winding quality improves, but fabric necking increases due to excessive tension at small bobbin sizes
Solution Approach 1:
The patent changes the tension parameter as a function of bobbin diameter, using different resistance levels for different winding stages. This allows optimal tension for large bobbins while preventing excessive tension at small bobbins, thereby maintaining both winding quality and fabric uniformity through parameter adaptation rather than fixed settings.
Solution Approach 2:
The patent applies different tension levels locally appropriate to each bobbin size stage. Instead of uniform tension throughout, the system provides high tension when needed (large bobbins) and low tension when needed (small bobbins), achieving local optimization that maintains overall fabric uniformity while ensuring winding quality at each stage.
Data Source
AI summary
The invention discloses an apparatus for regulating winding tension as function of bobbin (2) diameter in a slit film tape or yarn (1) winder system carrying at least one automated winder. It comprises a dancing arm (3) equipped with a tension setting means or device (3B) which regulates the yarn tension. The inventive feature of the invention is that tension setting means (3B) is capable of changing resistance ‘R’ of the dancing arm (3) as a function of the bobbin (2) diameter ‘D’ during the winding process. The invention also provides a method for regulating winding tension as function of bobbin (2) diameter. The invention helps overcome a number of problems related to uniformness and consistency of package the fabric making industry is currently facing. It solves technical problem of winding bobbin throughout using same tension adjusted for dancing arm, resulting higher tension during unwinding at low bobbin sizes. It also helps reduce the necking or shrinkage of the fabric produced due to varying resultant winding tension.