Yarn Guide Roller Cover Design for Power Reduction
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Solution Overview
Problem
The existing yarn processing apparatuses consume high power due to the stirring of circumambient air by guide rollers during yarn conveyance, leading to increased energy consumption.
Innovation Solution
A roller cover is designed to surround the yarn conveyance roller, with a specific distance between the roller's outer circumference and the inner wall surface of the cover, ranging from 1.6 to 1.9 times the roller's radius, to minimize air disturbance and reduce power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the gap between the roller and the inner wall surface of the roller cover is minimized to reduce the amount of surrounding air, then the power consumption is reduced, but the airflow in the gap becomes disturbed due to the influence of airflow flowing in and out of the roller cover
Solution Approach 1:
The patent applies parameter changes by optimizing the gap distance between the yarn conveyance roller and the inner wall surface of the roller cover to a specific range (1.6 to 1.9 times the roller radius). This parameter optimization balances two competing requirements: reducing the volume of air to be stirred (lowering power consumption) while maintaining sufficient gap space to prevent airflow disturbance from inlet/outlet effects. The specific numerical range represents a carefully determined parameter that resolves the contradiction between energy efficiency and airflow stability.
2Volume of stationary object
If the capacity of the gap between the outer circumferential surface of the yarn conveyance roller and the inner wall surface of the roller cover is made too small, then the amount of air surrounding the roller is reduced, but the airflow in the gap is significantly influenced by airflow flowing into and out of the space
Solution Approach 1:
The patent resolves this contradiction by changing the parameter of gap capacity to a specific optimal range. By setting the distance from the central axis to the inner wall surface at 1.6 to 1.9 times the roller radius, the patent determines the precise gap capacity that minimizes air volume while preventing harmful airflow disturbance. This parameter change transforms the trade-off into an optimized design point.
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
The roller cover effectively reduces power consumption by stabilizing airflow and minimizing air disturbance, achieving a power reduction of at least 25% as demonstrated in analysis and experimentation results.
Implementation Method 1
when the yarn is conveyed by the guide roller, the rotating guide roller stirs circumambient air
Data Source
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AI summary
Power consumption when a yarn is conveyed by a yarn conveyance roller is effectively reduced. A guide roller 18 conveying yarns Y is covered with a roller cover 40. The roller cover 40 includes a first part 41 formed to be cylindrical and surround an outer circumferential surface 18a of a guide roller 18 and a circular second part 42 provided to face a leading end surface 18b of the guide roller 18 and connected to a leading end portion of the first part 41. The inner diameter Dc of the first part 41 is 1.6 times or more as long as and 1.9 times or less as long as the outer diameter Dr of the guide roller 18. In regard to the outer circumferential surface 18a of the guide roller 18 and the inner wall surface 41a of the first part 41, a difference between the distance (=Dc/2) from the axis J of the guide roller 18 and the radius (=Dr/2) of the guide roller 18 is constant and is equal to or longer than 40mm and equal to or shorter than 55mm.