Automated Yarn Fixing Device for Textile Reels
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Solution Overview
Problem
Manual fixing of yarn ends on textile reels is labor-intensive and prone to human errors, especially during the transition from horizontal to vertical reel orientation in production processes, necessitating automation to prevent outer loops from coming off and reduce skilled labor costs.
Innovation Solution
A device comprising a supporting base with a yarn positioning unit, suction unit, and blocking unit, utilizing a motor-driven approach cylinder, pulleys, and a tape sealing machine to form a noose and secure the yarn end with adhesive tape, allowing for automatic fixation and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual knotting of yarn ends is performed by operators, then the yarn can be fixed on the reel, but labor costs increase and human errors occur
Solution Approach 1:
The patent replaces the manual mechanical knotting system with an automated system combining suction cups for yarn end detection and positioning, a rotating blade for cutting excess yarn, and adhesive tape application for securing. This substitution eliminates human labor while maintaining fixation reliability through consistent automated operations.
Solution Approach 2:
The device enables self-service automation where the system automatically detects the yarn end position using suction cups, positions the cutting blade, applies adhesive tape, and completes the fixation process without human intervention. The reel itself rotates to present the yarn end to the fixing mechanism, utilizing the existing reel motion for positioning.
2Ease of operation
If manual knotting is used to fix yarn ends, then yarn retention is achieved, but skilled labor is required increasing operational costs
Solution Approach 1:
The fixation device is segmented into distinct functional modules: suction cup units for yarn end detection and positioning, a rotating blade mechanism for cutting, and an adhesive tape application system. Each module performs a specific function independently, simplifying the overall operation while managing device complexity through modular design.
Solution Approach 2:
The device is designed to handle multiple yarn types (natural and synthetic fibers) and reel configurations through adjustable suction cup positions and versatile adhesive tape application. The same basic mechanism serves different textile sectors including carpet, artificial grass, tyre cord, cotton, and wool production lines.
3Productivity
If automated fixation is implemented, then labor costs are reduced, but the device complexity increases
Solution Approach 1:
The device utilizes pneumatic suction cups to detect and position the yarn end automatically. The suction mechanism provides precise positioning without mechanical contact, simplifying the automation process while maintaining high production speed through rapid yarn end detection and positioning operations.
Solution Approach 2:
The device employs adjustable parameters including suction cup position, blade rotation speed, and adhesive tape application timing to optimize fixation for different yarn types and production requirements. These parameter adjustments enable versatile automation without requiring complex mechanical reconfigurations.
4Manufacturing precision
If manual knotting is performed, then yarn ends are secured, but human errors increase affecting product quality
Solution Approach 1:
The suction cup mechanism provides feedback on yarn end position detection, allowing the control system to adjust the cutting blade position and adhesive tape application timing accordingly. This feedback loop ensures consistent fixation precision across all operations, eliminating the variability inherent in manual knotting.
Solution Approach 2:
The device performs preliminary positioning of the yarn end using suction cups before the actual cutting and adhesive application. This preliminary action ensures the yarn end is correctly positioned and secured, preventing fixation errors and ensuring consistent manufacturing precision across all yarn types.
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
Automates the yarn fixation process, reducing human errors and labor costs, ensuring consistent yarn retention on textile reels across various applications and machine types, enhancing production efficiency and flexibility.
Implementation Method 1
a suction unit (6) for suction of a free end (7) of the yarn
Data Source
Figure 1
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AI summary
The device (1) for fixing a yarn (8) on a textile reel (10) comprises a base (2) for supporting a first column (3), supporting a yarn positioning unit (4), and supporting a second column (5) supporting both a suction unit (6) for suction of a free end (7) of said yarn and a blocking unit (9) for blocking said free end, first and second feed means (11) and (16) being also provided for the movement of said suction and blocking units.