Winding Station Balloon Limiter Control for Stable Yarn Tension
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Solution Overview
Problem
Existing winding machines face challenges in maintaining a constant winding speed and minimizing yarn tension fluctuations during the rewinding process, leading to potential yarn breaks and impaired quality.
Innovation Solution
A method and device that utilize a balloon limiting device with movable yarn guide surfaces, activated based on yarn take-off force measurements, to control the yarn balloon and maintain consistent tension by adjusting the distance of the guide surfaces from the spinning spool's axis, thereby regulating the winding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the balloon limiting device is continuously advanced downwards during the winding process, then the yarn balloon can be limited throughout the entire winding process, but the device becomes comparatively complex and high thread tensions can still occur
Solution Approach 1:
The balloon limiting device is divided into multiple independent balloon limiters (first balloon limiter, second balloon limiter) that can be individually activated. Each balloon limiter has its own yarn guide surface and can be independently positioned, allowing the system to manage different sections of the yarn path separately rather than requiring continuous adjustment of a single complex device.
Solution Approach 2:
The balloon limiters are designed to be movable between rest position and working position based on real-time yarn take-off force measurements. The system dynamically activates or deactivates balloon limiters and adjusts their positions during the winding process, transitioning from static continuous advancement to dynamic on-demand positioning based on actual yarn tension conditions.
2Manufacturing precision
If multiple balloon limiters are arranged one above the other and closed sequentially, then the yarn balloon can be controlled at different stages, but the device complexity increases and the winding speed may fluctuate
Solution Approach 1:
The system continuously measures the yarn take-off force during the winding process and uses this feedback information to determine when to activate or deactivate balloon limiters. The control device receives real-time tension data and automatically adjusts the balloon limiter configuration, creating a closed-loop control system that maintains constant winding speed while achieving precise yarn tension control.
Solution Approach 2:
The balloon limiters are pre-positioned in rest positions during head changing and initial winding phases. The system prepares the balloon limiting configuration in advance based on predicted yarn tension requirements, rather than reactively adjusting during high-speed winding, thereby maintaining speed constancy while ensuring tension control readiness.
3Productivity
If the balloon limiter is moved from rest position to working position based on yarn take-off force, then the winding speed can be kept constant, but the device requires complex control mechanisms
Solution Approach 1:
The balloon limiting system operates autonomously by continuously measuring yarn take-off force and automatically activating or deactivating balloon limiters based on predefined tension thresholds. The control device independently manages the positioning and activation of balloon limiters without requiring external intervention or complex coordination with other winding machine systems, allowing constant winding speed to be maintained through self-regulating tension-based control.
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 consistent winding tension and speed, reducing yarn breaks and enhancing yarn quality by dynamically responding to yarn tension changes.
Implementation Method 1
This yarn balloon forms due to centrifugal forces acting on the yarn as it is unwound from the spinning helix
Data Source
Figure 1
Figure 2~3
Figure 4~6
AI summary
In a method for operating a work station (2) of a winding machine (1), a yarn (3) is wound from a cop (22) onto a spool (6) by means of a winding device (5), wherein a yarn balloon (14) is limited at least in one width direction by means of a balloon limiting device (18). The balloon limiting device (18) comprises at least one balloon limiter (23, 26) with a yarn guide surface (24, 27). A first part of the yarn (3) located on the spinning spool (4) is wound onto the spool (6), whereby a yarn take-off force of the yarn (3) and/or a measured quantity representing the yarn take-off force is recorded. Upon detection of an increase in the yarn take-off force, the at least one balloon limiter (23, 26) is moved from a rest position (R) to a working position (A) and then a second part of the yarn (3) is rewound onto the spool sleeve (6).Alternatively, the distance (a1, a2) of a yarn guide surface (24, 27) of the at least one balloon limiter (23, 26) to the axis of rotation (25) of the spinning sleeve (4) is reduced, and then a second part of the yarn (3) located on the spinning sleeve (4) is rewound onto the winding sleeve (6). Alternatively, a second balloon limiter (26) with a second yarn guide surface (27) is moved from a rest position (R) to a working position (A). For this purpose, a working station (2) of a winding machine (1) has a detection device (17) for detecting a yarn take-off force of the yarn (3) and/or a measured quantity representing the yarn take-off force and a control unit (13).