Winding Machine Suction Nozzle Electronic Distance Control
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Solution Overview
Problem
Existing automatic winding machines require manual adjustment of the distance between the suction nozzle and the reel, leading to inefficiencies, potential damage, and production losses due to human error and mechanical limitations.
Innovation Solution
An automatic winding machine equipped with a control unit that calculates and maintains a predetermined distance between the suction nozzle and the reel using real-time diameter measurements, replacing the need for mechanical cams and allowing for adjustable working positions based on reel diameter and geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual adjustment of the distance between the suction nozzle and the reel is performed by the operator, then the adjustment can be made for different yarn types, but the process requires human time and is prone to adjustment errors between winding units
Solution Approach 1:
The patent replaces the manual mechanical adjustment system with an electronic control system. A sensor detects the reel diameter, and a control unit automatically calculates and adjusts the suction nozzle position based on the detected diameter, eliminating the need for manual operator intervention and ensuring consistent adjustments across all winding units.
Solution Approach 2:
The winding machine performs self-adjustment through an automated feedback loop. The sensor continuously monitors reel diameter, the control unit processes this information, and the suction nozzle position is automatically adjusted without human intervention, making the system self-regulating and adaptive to different reel sizes.
2Productivity
If the distance between the suction nozzle and the reel is too large, then the picking-up efficiency becomes very low, but increasing the distance reduces the risk of damage from contact
Solution Approach 1:
The patent implements a feedback control system where a sensor continuously detects the reel diameter, and this information is fed back to the control unit. The control unit automatically adjusts the suction nozzle position to maintain an optimal distance that maximizes picking-up efficiency while preventing contact with the reel, thus resolving the contradiction between productivity and reliability.
Solution Approach 2:
The suction nozzle position is made dynamically adjustable rather than fixed. The system continuously adapts the nozzle-reel distance based on real-time reel diameter measurements, allowing the distance to optimize for both high picking-up efficiency and prevention of contact damage during different stages of reel filling.
3Productivity
If the distance between the suction nozzle and the reel is too small, then the picking-up efficiency improves, but the excessive vacuum may cause surface loops on the reel to become disarrayed
Solution Approach 1:
The sensor-based feedback system continuously monitors reel diameter and automatically adjusts the suction nozzle position to maintain an optimal distance. This prevents the nozzle from being too close to the reel, which would cause excessive vacuum and disarray surface loops, while still maintaining close enough proximity for efficient picking-up.
4Reliability
If mechanical cam profile is used to dynamically change the end stop position, then the distance can be maintained at each diameter, but the device complexity increases
Solution Approach 1:
The patent replaces the complex mechanical cam profile system with an electronic control system. Instead of using physical cams to dynamically adjust the end stop position, the system uses a sensor to detect reel diameter and a control unit to electronically adjust the suction nozzle position, significantly reducing mechanical complexity while maintaining or improving distance maintenance reliability.
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 solution reduces setup times, ensures reliable and consistent adjustments, improves picking-up efficiency, and reduces energy consumption by using a closed-loop motor control system, thereby enhancing productivity and final product quality.
Implementation Method 1
aspirating the end of the yarn on the reel side and the particular piece comprising the defect from the reel
Data Source
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AI summary
An automatic winding machine (4) comprising at least one winding unit (8) for unwinding a yarn from a spool (12) and winding it onto a tube of a reel (16) with an external diameter that varies according to the winding of the yarn unwound from the spool (12), the winding unit (8) being equipped with: - a gripping arm (20) having a suction nozzle (24) on the reel side, configured to abut in proximity to said reel (16) and aspirate a yarn end on the reel side, - the gripping arm (20) being connected to suction means to create a vacuum at the suction nozzle (24) and being provided with drive means (28) for the rotation of said gripping arm (20) from a rest position to a working position in which it moves closer to the reel (16) so as to aspirate the yarn end. The automatic winding machine (4) is equipped with a control unit (32) programmed to calculate the working position of the suction nozzle (24) on the reel side according to the contingent outer diameter of the reel (16) being formed, and to control the drive means (28) in order to bring the suction nozzle (24) into said working position.