Self-Walking Yarn Loading Trolley for Continuous Twisting
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Solution Overview
Problem
Current yarn loading systems in twisting machines are inefficient, labor-intensive, and have low automation, requiring manual handling and significant reformation of workshops, with existing automatic systems lacking data interaction and intelligent control.
Innovation Solution
An intelligent yarn loading system comprising a self-walking trolley and a dispatching control system that communicates with the twisting machine, allowing for real-time yarn loading and unloading without stopping the machine, using navigation and manipulator technologies to accurately position and handle yarns, and a rotatable creel for efficient yarn management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a movable creel walks above the twisting machine for automatic yarn loading, then automation degree is improved, but productivity is reduced because nearly 100 spindles must be used up before moving and replacing
Solution Approach 1:
The system divides the yarn loading task into individual spindle-level operations. Instead of moving all creels at once after 100 spindles are used, the dispatching control system enables independent, on-demand yarn loading for each spindle or small groups of spindles, segmenting the batch operation into fine-grained tasks that maintain productivity while achieving automation.
Solution Approach 2:
The creel walks to the twisting machine and positions itself at the required station before the yarn is completely consumed. The dispatching control system monitors yarn consumption and triggers the creel movement in advance, performing the yarn replacement action before it becomes critical, thus avoiding production stoppage and maintaining continuous productivity.
2Extent of automation
If a manipulator slides along linear modules to grab basic yarns from hopper area, then automation degree is improved, but device complexity increases due to large number of supporting frames and linear modules
Solution Approach 1:
The system extracts the creel movement function from the complex manipulator-with-linear-modules system. The creel itself performs the walking and positioning function along the track, while the manipulator only needs to perform simple yarn grabbing and placement operations. This separation eliminates the need for complex supporting frames and linear modules, reducing device complexity while maintaining automation.
Solution Approach 2:
The creel is designed with multi-functionality: it serves as both the yarn carrier and the moving platform that walks along the track to reach different twisting machine stations. This eliminates the need for separate manipulator systems with complex linear modules, as the creel itself performs the transportation function, simplifying the overall device structure.
3Device complexity
If robot walks on ground to load yarn using navigation and vision technologies, then device complexity is reduced, but productivity is reduced due to low cost and small scale applicability
Solution Approach 1:
The creel employs a dynamic walking mechanism that allows it to move along the track and position itself at different twisting machine stations. This dynamic positioning capability, combined with the dispatching control system's intelligent task allocation, enables the system to handle multiple spindles efficiently, significantly improving productivity compared to static or single-station ground-based robot systems.
Solution Approach 2:
The dispatching control system implements feedback mechanisms to monitor yarn consumption, creel position, and twisting machine status. This feedback enables real-time decision-making and dynamic task adjustment, allowing the system to optimize yarn loading operations and maintain high productivity levels while keeping device complexity manageable through intelligent control rather than mechanical complexity.
4Ease of operation
If yarn loading is performed after doffing and stopping of twisting machine, then ease of operation is improved, but productivity is reduced due to machine stoppage
Solution Approach 1:
The system enables continuous yarn loading operations during twisting machine operation. The dispatching control system coordinates the creel movement and yarn replacement tasks to occur concurrently with the twisting process, eliminating machine stoppage. The creel walks to the station, performs yarn replacement, and returns while the twisting machine continues production, maintaining continuous useful action and high productivity.
Data Source
AI summary
An intelligent yarn loading system and a control method are provided. The intelligent yarn loading system comprises a twisting machine, a self-walking trolley and a dispatching control system; the twisting machine is provided with a twisting machine wireless communication module for sending a working state of the twisting machine to the dispatching control system; the self-walking trolley is provided with a trolley wireless controller and a self-walking device for receiving an instruction of the dispatching control system and walking to a station of the twisting machine to take off an empty bobbin, and put a basic yarn on a creel of the twisting machine or take off a finished product package for stacking.