Winding Machine Yarn Tension Control via Optical Imaging
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Solution Overview
Problem
Existing winding machines lack precise control over winding speed and thread tension during the unwinding process, leading to inefficiencies and potential thread tension increases due to yarn tension forces, which are not effectively managed by existing sensors and control methods.
Innovation Solution
A method utilizing imaging sensors to create digital images of reference and actual bobbins, determining the cross-sectional area and thread length, and linking this information to control the winding machine, eliminating the need for additional sensors at each winding position and allowing for real-time adaptation of winding speed and thread tension based on changing bobbin shape and thread length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional sensors and control methods are used to manage yarn tension, then thread tension can be monitored, but the control precision over winding speed and thread tension is insufficient, leading to yarn tension forces increasing to a multiple of initial tension
Solution Approach 1:
The patent replaces mechanical tension sensors with an optical imaging system. A camera captures images of the yarn balloon, and image processing algorithms calculate the cross-sectional area and derive thread length and tension information. This substitution of mechanical sensing with optical-field methods enables more precise and reliable tension control without physical contact with the yarn.
Solution Approach 2:
The system dynamically adjusts winding speed and take-off accelerator position based on real-time analysis of yarn balloon images. By continuously monitoring changes in balloon cross-sectional area and adapting process parameters accordingly, the system maintains thread tension within optimal ranges, preventing tension from increasing to harmful multiples of initial tension.
2Measurement precision
If additional sensors are installed at each winding position to improve control precision, then winding speed and thread tension can be controlled more precisely, but device complexity and cost increase
Solution Approach 1:
The imaging system serves multiple functions: it captures yarn balloon images for tension analysis, tracks bobbin position, monitors yarn path geometry, and provides data for both winding speed control and tension management. This multi-functional approach eliminates the need for separate sensors at each winding position, reducing device complexity while maintaining high control precision.
Solution Approach 2:
The patent introduces an image processing algorithm as an intermediary between the optical sensor and control system. The algorithm extracts meaningful parameters (balloon cross-sectional area, yarn path geometry) from raw images and translates them into control signals. This intermediary layer enables precise control without requiring complex sensor arrays, simplifying the overall system architecture.
3Productivity
If winding speed is increased to improve productivity, then output increases, but yarn tension forces increase limiting the withdrawal speed and winding speed
Solution Approach 1:
The system implements closed-loop feedback control by continuously capturing images of the yarn balloon, analyzing balloon cross-sectional area changes, and adjusting winding speed and take-off accelerator position in real-time. This feedback mechanism allows the system to operate at high speeds while automatically compensating for tension increases, maintaining optimal tension levels even at elevated productivity rates.
Solution Approach 2:
The patent employs dynamic adjustment of winding parameters based on real-time yarn balloon analysis. The take-off accelerator position and winding speed are continuously adapted according to the detected balloon geometry and yarn tension state. This dynamic control enables the system to maximize productivity while preventing yarn tension from becoming limiting, allowing higher sustainable winding speeds compared to static control systems.
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
Enables precise control of winding speed and thread tension during unwinding, effectively managing yarn tension forces and ensuring optimal operation even with deviations in bobbin shape, without the need for additional sensors, thus improving the efficiency and reliability of the winding process.
Implementation Method 1
an imaging sensor (42) for creating a digital image of the spinning cops (9) fed to the transport system (3)
Data Source
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AI summary
The invention relates to a method of operating a winding machine and a winding machine. The winding machine (1) comprises a plurality of winding units (2) and a transport system (3) for traceable transport of spools (9) to winding stations (2). The method comprises the steps of creating a digital image of a reference spool (9A) with a known length of thread by means of an imaging sensor (42, 42A), determining a variable representing a cross-sectional area of a package (48A) of the reference spool (9A), determining the ratio of the thread length of the reference spool (9A) to the cross-sectional area of the package (48A) of the reference spool (9A), creating a digital image of the transport system (3) supplied to the spool (9) by means of an imaging sensor (42), detecting the length of yarn withdrawn from the spool (9) during winding.