Yarn Spool Rotation Against Winding Direction for Manual Search
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Operators face laborious manual intervention when searching for yarn ends on textile machine spools, especially in machines with multiple workstations, as automatic yarn search processes often fail, requiring manual rotation and visual inspection which can be cumbersome and time-consuming.
Innovation Solution
The method involves rotating the yarn spool against its winding direction using a winding roller drive during manual search processes, allowing operators to focus on finding the yarn end without physical effort, and utilizing suction nozzles and sensors to aid in detection, with optional optical and acoustic signals for operator notification and automated processes to minimize downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual yarn search is performed without automated assistance, then the operator can search for yarn ends, but the operator must manually rotate and lift heavy yarn spools which is laborious and time-consuming
Solution Approach 1:
The yarn spool performs self-service by automatically rotating itself via the winding roller drive during manual search mode, eliminating the need for the operator to manually rotate heavy spools. The operator only needs to provide minimal input signals while the system handles the physically demanding rotation task autonomously.
Solution Approach 2:
The patent replaces manual mechanical operations (operator lifting and rotating spools) with an automated mechanical system (winding roller drive controlled by the control unit). This substitution transforms a labor-intensive manual process into an automated assisted process, reducing both physical effort and time requirements.
2Extent of automation
If automatic yarn search processes are used, then the search for yarn ends can be automated, but the automatic processes often fail requiring manual intervention
Solution Approach 1:
The system dynamically adapts its operation mode based on the situation. It transitions from fully automatic yarn search to manually assisted yarn search when automatic detection fails or when yarn spool rotation is detected, ensuring both high automation where possible and reliable manual backup when needed, thus balancing automation extent with operational reliability.
Solution Approach 2:
The yarn search function is segmented into distinct operational modes: automatic yarn search mode and manually assisted yarn search mode. This segmentation allows the system to use automated detection methods when conditions are favorable while providing a reliable manual alternative when automatic methods fail, thereby improving overall system reliability without sacrificing automation benefits.
3Productivity
If yarn spools are arranged at higher levels on the machine, then space is optimized, but operator access and manual handling becomes more difficult
Solution Approach 1:
The patent replaces the operator's mechanical actions (lifting and rotating spools by hand) with an automated mechanical system (winding roller drive). This allows yarn spools to be positioned at optimized heights for productivity while the automated system handles the physically demanding tasks of rotation and positioning, eliminating the trade-off between space utilization and operator accessibility.
4Difficulty of detecting and measuring
If the operator manually rotates the yarn spool in the opposite direction, then the yarn end can be searched for, but this requires significant physical effort from the operator
Solution Approach 1:
The yarn spool performs self-service by automatically rotating itself in the opposite direction during manual search mode through the winding roller drive. This eliminates the need for the operator to apply physical force to rotate heavy spools, reducing physical effort to minimal levels while maintaining the ability to detect yarn ends effectively.
Solution Approach 2:
The winding roller drive acts as an intermediary between the operator's minimal input signal and the yarn spool's rotation. Instead of the operator directly applying force to rotate the spool, the control unit mediates by activating the winding roller drive, which then performs the force-intensive rotation task, significantly reducing the operator's physical burden.
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 reduces operator burden and time by automating the search process, enabling efficient yarn end detection and reconnection, thus minimizing manual intervention and maintaining machine operation with reduced downtime.
Implementation Method 1
the yarn spool is rotated counter to its winding direction by means of a winding roller drive
Implementation Method 2
utilizing suction nozzles and sensors to aid in detection
Data Source
Figure 1
AI summary
The invention relates to a method for operating a workstation (1) of a textile machine producing yarn spools (8), wherein, in the event of a yarn break at the workstation (1), at least one automatic yarn search operation is first performed, the aim of which is to pick up a yarn end that has wound onto the yarn spool (8), and wherein, if a predetermined maximum number of automatic yarn search operations fail, a manually assisted yarn search operation is performed. The method is characterized in that, during the manually assisted yarn search operation, the yarn spool (8) is rotated against its winding direction by means of a spool roller drive (11). Furthermore, the invention relates to a textile machine producing yarn spools (8), which is characterized in that the control system (16) is configured to operate at least one of the workstations according to the method according to the invention.