Yarn Spooling Device with Overlapping Spirals for High Density
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Solution Overview
Problem
Current spooling methods for yarns face limitations in production speed, reel density, yarn tension, and uniformity, leading to issues in dyeing, handling, and storage, with restricted movement of spirals and increased risk of breakages due to excessive tension.
Innovation Solution
A spooling method and device that unwind yarns in layers with overlapping spirals, allowing for variable geometry and distribution without a central support, enabling continuous deposition and reduced tension, thus increasing density and freedom of movement, and allowing for higher speeds and improved handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If yarn is wound onto a spool in traditional crossed spirals, then the reel forms a compact shape suitable for storage and transport, but the yarn density is limited (0.30-0.45 g/cm³) and production speed is restricted (1000-1500 m/min)
Solution Approach 1:
The patent transitions from traditional circumferential winding (2D spiral pattern around a central axis) to a three-dimensional layered deposition system where yarn is distributed across multiple levels and directions, creating a volumetric filling pattern that increases density while enabling higher production speeds
2Manufacturing precision
If the winding cylinder uses fixed helical grooves to guide yarn, then the reel formation is controlled, but the yarn cannot be properly controlled at inversion points causing overlappings at critical diameters
Solution Approach 1:
The patent replaces fixed helical grooves with a dynamic multi-directional distribution system that can adapt its guidance pattern based on the reel's current diameter and winding state, preventing overlappings by continuously adjusting yarn path control as the reel grows
Solution Approach 2:
The system incorporates control mechanisms that monitor the reel formation process and adjust yarn distribution in real-time, detecting and preventing overlapping conditions before they occur by modifying the deposition pattern based on current reel geometry
3Reliability
If the slub-catcher cuts yarn to eliminate defects, then yarn quality is improved, but the reel must be stopped and yarn tension increases causing possible slipping and damage
Solution Approach 1:
The patent prepares alternative yarn paths and tension distribution mechanisms in advance that can be activated during defect removal operations, allowing the reel to maintain operational continuity and reduced tension even when yarn is being cut and reconnected
Solution Approach 2:
The system dynamically changes operational parameters such as winding tension, speed, and distribution pattern during defect handling operations, reducing tension and adjusting parameters to prevent yarn damage while maintaining quality control
4Shape
If yarn is deposited in successive circumferential layers on a spool, then the reel assumes a truncated cone or cylindrical shape, but the spirals have restricted movement and handling becomes difficult
Solution Approach 1:
The patent creates a three-dimensional layered structure with intentional void spaces and less dense regions that allow spirals to move more freely, improving handling and subsequent processing while maintaining an organized deposited shape
5Quantity of substance
If the traversing device varies its travel to distribute yarn deposition, then edge concentration is reduced and density is improved, but the device complexity increases
Solution Approach 1:
The patent designs the multi-directional distribution system to perform multiple functions simultaneously: it distributes yarn across different areas, controls deposition density, prevents overlappings, and manages tension, thereby achieving improved density without proportionally increasing device complexity
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 approach results in increased yarn density, reduced production times, improved dyeing uniformity, and enhanced handling capabilities, enabling higher loads and reduced costs in dyeing and storage, while maintaining yarn quality and preventing breakages.
Implementation Method 1
The support, or spool, is drawn in rotation due to friction by a winding cylinder, on which it rests with a certain pressure.
Implementation Method 2
The winding cylinder can have, engraved on its surface, helical traversing grooves, on which the yarn slides.
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
Method for spooling yarns comprising at least a first unwinding step in which the yarn (17) is unwound from a support member (13, 15, 16), and a second spooling step, in which said yarn (17) is disposed in layers according to a desired order. In the second spooling step, the yarn (17) is disposed inside a containing means (46) in overlapping layers, in which each of said layers (117) consists of a plurality of contiguous spirals (116) of yarn (17) and distributed according to the geometry of said containing means (46). The spirals (116) are formed by deposition means (35, 36, 37) able to rotate around a second forming axis (X) of said spirals (116). The spirals (116) are deposited on collection means (39) able to rotate and/or move linearly around/with respect to a relative first forming axis (Y; Y, Y1, Y2, Y3) of said layers (117), wherein said second forming axis (X) of said spirals (116) does not coincide with said forming axis (Y; Y, Y1, Y2, Y3) of said layers (117).