Winding Tension Control via Movable Containment Elements
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Solution Overview
Problem
High-speed winding machines face limitations in productivity due to excessive yarn tension, which leads to yarn deterioration and breakage, and existing control methods require significant speed reduction, restricting production capacity.
Innovation Solution
A method for controlling winding tension using a programmable control unit that adjusts winding speed and employs a tension control device with movable containment elements to manage yarn tension, allowing higher initial speeds and delayed speed reduction, thereby maintaining nominal speed until the spool is nearly exhausted.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the collection speed is increased to improve productivity, then the production capacity increases, but the yarn tension increases causing deterioration and breakage
Solution Approach 1:
The spool unwinding process is divided into multiple phases: initial phase with balloon formation, intermediate phase with controlled tension, and final phase with balloon collapse. Each phase has specific tension characteristics that are managed separately through the containment elements and thread tensioner coordination
Solution Approach 2:
Two containment elements are introduced as intermediary devices between the spool and the thread tensioner. These elements actively manage the balloon formation and collapse, mediating the tension transmission to the yarn and preventing direct high-tension冲击 that would cause breakage
2Stability of the object's composition
If the winding speed is reduced to control yarn tension, then the yarn tension is homogenized, but the productivity decreases significantly
Solution Approach 1:
The containment elements are made movable rather than fixed, allowing them to dynamically adapt to changing tension conditions throughout the spool unwinding process. Their position and configuration can be adjusted in real-time to maintain optimal tension control
Solution Approach 2:
The system changes multiple parameters simultaneously: containment element position, containment element configuration, and thread tensioner pressure. These coordinated parameter changes allow tension control without requiring significant speed reduction
3Stability of the object's composition
If the thread tensioner pressure is increased to compensate for initial under-tensioning, then the initial tension is improved, but the tension control range is reduced
Solution Approach 1:
The containment elements are positioned and configured in advance to pre-manage the balloon formation during initial unwinding. This preliminary action reduces the burden on the thread tensioner, allowing it to operate within an optimal pressure range throughout the entire process
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 method enhances production capacity by maintaining higher winding speeds and reducing yarn tension peaks, delaying the need for speed reduction, thus increasing productivity and extending the operational range of the thread tensioner.
Implementation Method 1
The increase in the diameter of the balloon causes a progressive increase in the tension of the yarn due to the centrifugal effect as the unravelling proceeds.
Implementation Method 2
the yarn wound in a spool is unwound, subjected to a quality control, and subsequently rewound on a tube to form a reel. Typically, the yarn is collected by a thread guide cylinder, which drags the rotating reel by friction
Data Source
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AI summary
A method for controlling the winding tension of a yarn (12) in a winding unit (14) comprises a tension sensor (16), a thread tensioner (18), and an unravelling tension control device (20). The unravelling tension control device (20) comprises a first containment element (22) operable on command, and a second containment element (24) fixed and arranged downstream of the first containment element (22) along the winding direction of the yarn (12). The method comprises the following steps: (a) start of the winding step with winding speed equal to vmax; (b) upon reaching a predetermined tension value measured by the tension sensor (16), the winding speed is brought to a predetermined percentage of vmax; (c) upon reaching said predetermined percentage of vmax, from here on the unravelling tension is controlled by the thread tensioner (18); and (d) upon reaching a predetermined operating parameter of the winding, operating the first containment element (22) of the unravelling tension control device (20).