Contact Drum Winder Yarn Speed Control via Feedback
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Solution Overview
Problem
In contact drum type winders, controlling the yarn speed is challenging due to the varying driving point and diameter of the cone-shaped package, leading to unpredictable yarn speed and tension, which affects yarn quality and production efficiency.
Innovation Solution
An automatic winder with a yarn speed control mechanism that uses a yarn speed sensor and sequencer to maintain a fixed yarn speed by adjusting the rotation speed of the traverse drum, ensuring consistent tension and uniform package shape through a variable tension device and unwinding assisting mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the rotation speed of the drum is controlled to be fixed, then the drum rotation speed is stable, but the yarn speed becomes unpredictable due to varying package diameter and driving point position
Solution Approach 1:
The patent implements a feedback control system where a sensor detects the actual yarn speed and feeds this information back to the control unit. The control unit then adjusts the drum rotation speed based on the detected yarn speed to maintain the desired yarn speed, resolving the issue of unpredictable yarn speed when drum speed is fixed.
Solution Approach 2:
The patent transitions from a static fixed drum rotation speed control to a dynamic control system where the drum rotation speed is continuously adjusted based on real-time yarn speed detection. This allows the system to adapt to changing package diameter and driving point position while maintaining reliable yarn speed control.
2Quantity of substance
If the package diameter increases, then more yarn is wound onto the package, but the yarn speed decreases due to the moving driving point toward larger diameter side
Solution Approach 1:
The feedback control system continuously monitors yarn speed and adjusts drum rotation speed to compensate for the speed reduction caused by increasing package diameter. This ensures that yarn speed remains constant even as more yarn is wound onto the package.
Solution Approach 2:
The patent changes the operating parameters of the drum rotation speed dynamically in response to package diameter increase. By adjusting the drum rotation speed parameter based on detected yarn speed, the system maintains constant yarn speed despite the changing package characteristics.
3Length of moving object
If the driving point position shifts toward larger diameter side, then the outer peripheral length of the package increases, but the rotation speed of the package decreases
Solution Approach 1:
The feedback control system detects the actual yarn speed (which reflects package rotation speed) and adjusts the drum rotation speed accordingly. This compensates for the rotation speed decrease caused by the driving point shifting toward the larger diameter side, maintaining consistent yarn winding speed.
4Speed
If drum rotation speed is controlled based on drum detection, then drum speed is stable, but yarn tension varies due to yarn speed variations
Solution Approach 1:
The patent implements feedback control based on yarn speed detection rather than drum speed detection. The control unit adjusts drum rotation speed based on actual yarn speed, which directly controls yarn tension by maintaining constant yarn speed, thereby eliminating yarn tension variations.
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 solution ensures a fixed yarn speed is maintained, improving yarn quality and production efficiency by preventing variations in yarn tension and unwinding speed, even as the package diameter increases.
Implementation Method 1
a yarn speed sensor (7) which detects the speed of the yarn (3)
Implementation Method 2
a traverse drum (10) which rotates the winding package (4)... The package 4 is rotated by contacting with the drum to receive a rotational driving force from the drum 10
Data Source
Figure 1
Figure 2
Figure 3
AI summary
With a contact drum type winder, even when the rotation speed of the drum is controlled on the basis of detection of the drum rotation speed, the actual yarn speed may reach an unexpected value. The present invention provides a winding unit 1 including a traverse drum 10 that rotates in contact with a winding package 4 to concurrently rotate the winding package 4, and a drum driver 10 that rotationally drives the traverse drum 11. The winding unit further includes a yarn speed sensor 7 that detects an instantaneous value of the yarn speed, a traveling speed of a yarn being wound into the winding package 4, and a sequencer 12 which calculates a traverse average value of the yarn speed from the instantaneous value of the yarn speed and which controls the drum driver by setting an instruction value for the rotation speed of the drum so that the traverse average value of the yarn speed is equal to a target value of the yarn speed (Fig. 1).