Yarn Processor Controller for Wound Package Quality
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Solution Overview
Problem
Yarn packages formed by winding yarn onto a supplying bobbin with slits can result in lower-quality yarn on the inner layers due to higher tension and potential damage during the winding process, which can contaminate final products and decrease their grade.
Innovation Solution
A yarn processor with a cutting unit, bobbin replacement unit, and controller that determines when to terminate the winding process and replace the bobbin to avoid including low-quality inner layer yarn in the final product, and stores information for distinguishing different types of wound packages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the yarn is wound onto the yarn supplying bobbin with slits to form a yarn supply package, then the yarn can be reliably held at the slit parts, but the yarn on the inner layer part may be damaged due to higher tension and contact with the harder bobbin
Solution Approach 1:
The controller calculates the remaining yarn amount in advance and determines the optimal termination timing before the inner layer yarn is damaged. By performing preliminary calculation and planning of the winding termination point, the system avoids the harmful effects of winding inner layer yarn while maintaining the benefits of secure yarn holding at slit parts.
Solution Approach 2:
The controller continuously monitors the remaining yarn amount and uses this feedback information to dynamically adjust the winding process. Based on the calculated remaining amount, the controller determines when to terminate winding, ensuring that damaged inner layer yarn does not contaminate the final wound package while maintaining production efficiency.
2Productivity
If the winding process continues until the yarn supply package is fully depleted, then productivity is maximized, but the wound package may be contaminated with low-quality inner layer yarn
Solution Approach 1:
The controller performs preliminary calculation of the remaining yarn amount and determines the optimal termination point in advance. This allows the system to stop winding at the precise moment before quality degradation occurs, maximizing productivity while ensuring yarn quality consistency in the final product.
Solution Approach 2:
The continuous monitoring of remaining yarn amount provides real-time feedback to the controller, which adjusts the winding termination timing accordingly. This feedback mechanism ensures that the winding process is terminated at the optimal point to maintain yarn quality while maximizing production efficiency.
3Reliability
If the yarn tension is increased at the start of winding to cause the yarn to be reliably held, then the yarn securing is improved, but the yarn may be damaged due to contact with the harder yarn supplying bobbin
Solution Approach 1:
The controller calculates the remaining yarn amount in advance and determines the optimal termination timing before yarn damage occurs. By planning the winding termination point preliminarily, the system maintains high yarn securing reliability through proper tension control while avoiding the harmful effects of excessive tension on yarn integrity.
Solution Approach 2:
The controller uses real-time feedback on the remaining yarn amount to dynamically adjust the winding process parameters. This feedback mechanism ensures that yarn tension is maintained at appropriate levels to secure the yarn reliably while preventing damage to yarn integrity, especially as the yarn supply package depletes.
Data Source
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AI summary
Contamination of a wound package that is a product with a low-quality yarn is avoided. A machine controller 5 of a false-twist texturing machine 1 generates, by calculation, remaining amount-related information that is numerical information regarding the remaining amount of a yarn Y remaining in a yarn supply package Ps1. When determining that a yarn Y in a wound package Pw reaches a predetermined target wound amount, the machine controller 5 performs a formation termination process so that a cutter of an automatic doffer 10 is controlled to cut the yarn Y and a winding device 19 is controlled to terminate the formation of the wound package Pw. Thereafter, the machine controller 5 performs a replacement process to cause the automatic doffer 10 to replace the wound package Pw with a new winding bobbin Bw. When determining that the numerical value of the remaining amount-related information becomes not larger than a predetermined value, the machine controller 5 performs a formation termination process to form, at the winding device 19, a wound package Pw3s (formation forcible termination wound package) having a smaller amount of the yarn Y than a target wound amount.