Yarn Storage Roller Surface Roughness for Fluff Laying
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Solution Overview
Problem
Conventional yarn winding devices struggle to reliably achieve a consistent fluff laying effect due to variations in surface roughness between the storage and pull-out regions of the yarn storage drum, leading to reduced fluffing efficiency and stability.
Innovation Solution
A yarn winding device configuration featuring a rotating body with distinct surface roughness between the storage region, where yarns are wound smoothly, and the pull-out region, where yarns are rolled without sliding, ensuring effective fluff laying. The pull-out region surface has a greater surface roughness (≥1 µm and ≤2 µm) compared to the storage region, allowing for enhanced yarn rolling and fluff generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If buffing is carried out on the entire surface of the yarn storage roller, then the yarn storage is smooth, but the fluff laying effect is reduced by about 30% and becomes unstable
Solution Approach 1:
The patent applies different surface roughness characteristics to different regions of the yarn storage roller. The storage region surface is buffed to be smooth for stable yarn winding, while the pull-out region surface is left rough (with arithmetic average roughness of 1-2 μm) to ensure reliable fluff laying. This local differentiation resolves the contradiction by optimizing each region for its specific function rather than applying uniform treatment.
2Productivity
If the yarn storage device is introduced to enable continuous winding, then productivity increases, but the fluff laying effect becomes variable and difficult to control
Solution Approach 1:
The patent introduces a yarn storage device with differentiated surface regions to maintain manufacturing precision during continuous operation. The storage region provides smooth yarn accumulation while the rough pull-out region (Ra 1-2 μm) ensures consistent fluff laying even during continuous high-speed winding, thus resolving the contradiction between productivity and precision.
Solution Approach 2:
The patent controls the arithmetic average roughness of the pull-out region surface within a specific range of 1-2 μm to optimize fluff laying effect during continuous winding operations. This parameter control ensures that the fluff laying consistency is maintained at high production speeds.
3Reliability
If the pull-out region surface roughness is increased to enhance fluff laying, then fluff generation improves, but yarn storage smoothness deteriorates
Solution Approach 1:
The patent divides the yarn storage roller surface into two distinct functional regions: a storage region with smooth surface for yarn accumulation and a pull-out region with rough surface (Ra 1-2 μm) for fluff laying. This segmentation allows each region to optimize its performance without compromising the other, resolving the contradiction between fluff laying reliability and storage smoothness.
Solution Approach 2:
The patent applies different surface quality characteristics to different locations on the yarn storage roller. The storage region maintains smoothness for easy yarn winding, while the pull-out region specifically at the yarn extraction point has increased roughness (Ra 1-2 μm) to enhance fluff laying effect, thus resolving the local contradiction.
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 configuration ensures smooth yarn storage and effective fluff laying, reducing fluff generation variability by up to 30% compared to conventional systems, while maintaining high-speed yarn winding without interruptions.
Implementation Method 1
a surface roughness of the pull-out region surface is greater than a surface roughness of the storage region surface... the spun yarn wound around the rotary storage drum travels while rolling on a surface of the relevant portion of the rotary storage drum
Data Source
AI summary
Provided is a configuration for reliably obtaining the fluff laying effect in a yarn winding machine including a yarn storage device (5). An automatic winder includes a yarn supplying section, a yarn storage device (5), and a package forming section. The yarn storage device (5) winds and stores a yarn (20) of the yarn supplying section. The package forming section winds the yarn (20) pulled out from the yarn storage device (5) to form a package. The yarn storage device (5) includes a yarn storage roller (32) around which the yarn (20) is wound. An outer circumferential surface of the yarn storage roller (32) includes a storage region surface (32e) in which the yarn (20) is wound in an aligned manner, and a pull-out region surface (32f) through which the yarn (20) passes when the yarn (20) wound in the storage region surface (32e) is pulled out toward the package forming section side. A surface roughness of the pull-out region surface, which is a surface that the yarn (20) passing the pull-out region surface (32f) contacts, is greater than a surface roughness of the storage region surface (32e), which is a surface that the yarn (20) wound in the storage region surface (32e) contacts.