Tension Compensator for Yarn Cabling

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Solution Overview

Problem

Existing systems for manufacturing alternating S/Z twist plied and cabled yarns face challenges such as uneven twist distribution, visible nodes, and longitudinal shifts due to unpredictable yarn contraction, leading to quality issues and inefficiencies in the production process.

Innovation Solution

A system with force compensation members between twist plying and cabling installations to adjust tractive forces and maintain constant tension, ensuring precise alignment and uniform twist, utilizing pneumatic or active force compensation to manage yarn length variations and prevent breakage or pattern distortion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If yarns are twisted and plied in a two-step process with alternating S/Z twist, then self-twist cabling is achieved with natural twist formation, but unpredictable yarn contraction causes longitudinal shifts and misalignment between twist plying and cabling installations

Engineering Contradiction:

Improveself-twist cabling processVSAvoidnode alignment between installations

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

A tension compensator device is introduced as an intermediary element between the twist plying and cabling installations. This device includes a drum with variable radius that acts as a mediator to absorb and compensate for yarn length variations and contraction, maintaining precise synchronization and alignment between the two installations throughout the manufacturing process.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system dynamically changes the effective radius of the drum in the tension compensator based on real-time yarn tension feedback. By varying the drum radius parameter, the system adjusts the yarn path length to compensate for contraction, ensuring continuous alignment between twist plying and cabling operations despite changes in yarn physical state.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If tractive forces are applied to feed yarns through twist plying and cabling installations, then continuous production is enabled, but uneven tension causes uneven twist distribution and visible nodes in the yarn

Engineering Contradiction:

Improvecontinuous yarn productionVSAvoidtwist uniformity and node visibility

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

A feedback control system continuously monitors yarn tension during the manufacturing process and dynamically adjusts the drum radius in the tension compensator. This closed-loop feedback mechanism ensures that tension remains within optimal ranges, preventing both excessive tension that causes uneven twist and insufficient tension that allows visible nodes to form, while maintaining continuous production.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The tension compensator employs a dynamic drum radius that can change during operation. This dynamic adjustment capability allows the system to adapt to varying yarn characteristics and processing conditions in real-time, maintaining optimal tension distribution throughout continuous production to ensure uniform twist and minimize visible nodes.

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If yarn length variations occur during twist plying, then yarn contraction is unpredictable, but without compensation this leads to breakage and pattern distortion in the final product

Engineering Contradiction:

Improveyarn length variation toleranceVSAvoidyarn integrity and pattern consistency

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The tension compensator with its variable radius drum provides beforehand cushioning by creating a buffer zone that absorbs anticipated yarn length variations and contraction. This preventive mechanism compensates for length changes before they can cause breakage or pattern distortion, protecting yarn integrity and maintaining pattern consistency throughout the manufacturing process.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS10895024B2Tension compensator

Publication Date: 2021.01.19 GILBOS NV

AI summary

The current invention concerns an improved system and method for the manufacturing of alternating S/Z cabled yarn 16) or connected alternating S/Z twist plied yarns, in which tension decrease or increase is avoided by variable longitudinal contraction when twist plying or overtwisting yarns. This longitudinal contraction Is very difficult to predict and leads to tension in the yarns, which can affect the quality. This tension can also be reproduced in the installations. This invention tries to improve this by providing a tension compensator (24) that (partially) compensates the tensions and forces between different, subsequent forces for processing yarns.