Yarn Winding Machine Controller Defect Segmentation
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Solution Overview
Problem
Conventional yarn winding machines face inefficiencies due to the frequent removal of yarn defects and splicing issues, leading to the discarding of normal yarn quality portions from the bobbin, which decreases production efficiency.
Innovation Solution
A yarn winding machine equipped with a controller that acquires defect information from the spinning frame and stops winding at the defect point, allowing the normal yarn portion to be wound without waste, and discharges the defective bobbin, thereby preventing the winding of defective yarn and reducing splicing occurrences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the yarn winding machine prevents winding of defective yarn feeding bobbins, then yarn quality is improved, but production efficiency decreases due to discarding normal yarn portions
Solution Approach 1:
The yarn feeding bobbin is divided into defective and non-defective portions. The controller segments the winding process by identifying the defect location and winding only the valid yarn portions, thereby separating useful yarn from defective yarn and preventing waste of normal yarn while maintaining quality standards.
Solution Approach 2:
The spinning frame performs preliminary detection of yarn defects before the yarn reaches the winding machine. The defect information is acquired in advance and transmitted to the controller, which pre-plans the winding strategy to skip defective portions and continue winding valid yarn, thus avoiding unnecessary stops and waste.
2Reliability
If the yarn winding machine performs frequent yarn defect removal and splicing, then yarn quality is maintained, but production efficiency decreases
Solution Approach 1:
The spinning frame performs preliminary detection of yarn defects and transmits defect information to the winding machine before the defective yarn is wound. This advance notification allows the winding machine to skip defective portions without stopping for defect removal or splicing operations, thereby maintaining yarn quality while avoiding efficiency loss from frequent interventions.
Solution Approach 2:
The controller acts as an intermediary between the spinning frame and the winding machine. It receives defect information from the spinning frame, processes this information to identify valid yarn portions, and controls the winding machine to wind only the good yarn, thereby eliminating the need for frequent defect removal and splicing operations at the winding stage.
3Productivity
If the spinning frame produces yarn with partial defects, then production volume is maintained, but yarn quality consistency deteriorates
Solution Approach 1:
The yarn feeding bobbin is segmented into defective and non-defective portions based on defect location information. The controller identifies and separates valid yarn from defective yarn, winding only the good portions onto the package. This segmentation allows continuous production while maintaining quality consistency by excluding defective segments from the final product.
Solution Approach 2:
The spinning frame provides feedback on yarn defects to the winding machine controller. This feedback loop enables the winding machine to adjust its operation in real-time, skipping defective portions and continuing to wind valid yarn. The feedback mechanism ensures that production volume is maintained while yarn quality consistency is preserved by preventing defective yarn from being wound.
Data Source
Figure 1
Figure 2A~2C
Figure 3
AI summary
A yarn winding machine (1) winds yarn of a yarn feeding bobbin (B) transferred from a spinning frame (2) by a bobbin transfer device (3) to form a package (P), and includes a controller (17). When a partial defect has occurred in the yarn of the yarn feeding bobbin (B) in the spinning frame (2), the controller (17) acquires first yarn-defect information prepared by the spinning frame (2) about the occurrence of the partial defect. The controller (17) stops winding of the yarn from the yarn feeding bobbin (B) upon determining that the yarn has been unwound from the yarn feeding bobbin (B) up to a position corresponding to the partial defect of the first yarn-defect information, based on yarn information of the yarn wound from the yarn feeding bobbin (B) related to the first yarn-defect information acquired and the first yarn-defect information prepared by the spinning frame (2), when the first yarn-defect information of the yarn feeding bobbin (B) has been acquired.