Winding Machine Dynamic Pressure Control for Lap Roll Bubble Reduction
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Solution Overview
Problem
Existing winding machines produce uneven and low-quality laps due to air bubbles formed at high winding speeds, leading to decreased unwinding characteristics and increased hairiness, which negatively affect the subsequent combing process.
Innovation Solution
A winding machine with a sensor to determine the actual lap roll diameter and adjust the winding force continuously throughout the process, ensuring a steady increase in pressure to counteract bubble formation, and a controller to adjust the winding curve based on fiber quality and moisture, preventing sudden changes in unwinding behavior.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If winding speed is increased to improve productivity, then output increases, but air bubbles form during winding causing uneven and low-quality laps
Solution Approach 1:
The winding machine applies dynamic winding pressure that varies continuously during the winding process. The pressure is highest at the beginning when the roll diameter is small and decreases as the roll grows, preventing bubble formation while maintaining high winding speeds. This dynamic adjustment resolves the contradiction by adapting pressure to the changing geometry of the wound roll.
Solution Approach 2:
The invention changes the winding pressure parameter over time and roll diameter. By continuously adjusting the pressure parameter based on the current roll state, the system maintains optimal winding quality throughout the process. The pressure profile is specifically designed to be inversely proportional to the roll diameter, ensuring consistent lap density and preventing air entrapment.
2Manufacturing precision
If winding pressure is increased to prevent bubble formation, then lap uniformity improves, but the contact pressure between lap roll and winding rollers decreases as winding diameter increases
Solution Approach 1:
The winding machine employs dynamic pressure adjustment where the applied winding pressure increases as the roll diameter increases. This compensates for the natural decrease in contact pressure that occurs as the roll grows, maintaining consistent lap uniformity throughout the winding process.
Solution Approach 2:
The system continuously changes the winding pressure parameter to maintain optimal contact pressure. The pressure is adjusted as a function of roll diameter, ensuring that the product of pressure and contact area remains constant or increases, thereby preventing bubble formation and maintaining lap quality throughout the winding process.
3Manufacturing precision
If winding force is applied to compress layers, then bubble formation is reduced, but excessive fulling occurs on the winding rollers
Solution Approach 1:
The invention applies different winding pressures to different parts of the winding process. High pressure is applied only where needed (at the beginning and when bubbles are detected) while allowing lower pressure during stable winding phases. This localized pressure application prevents excessive fulling while maintaining bubble reduction effectiveness.
Solution Approach 2:
The winding machine incorporates sensors that detect bubble formation and provide feedback to the pressure control system. When bubbles are detected, the system automatically increases pressure locally and temporarily, then reduces it afterward. This feedback-based control prevents continuous excessive pressure application, thereby reducing fulling while maintaining bubble reduction.
Data Source
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AI summary
The invention relates to a winding machine (1) for winding slivers made of cotton, comprising a winding unit on or in which a compress is formed, wherein the winding machine has a device for producing a winding force on the cotton compress (15). The invention further relates to a method for winding slivers. The invention is characterized in that the winding force increases continually over the winding length, at least at the start of the winding process.