Yarn Winding Production Simulation for Defect-Volume Tradeoffs
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Solution Overview
Problem
Existing methods for calculating the predicted production volume of packages formed by yarn winding machines are inaccurate due to variations in factors like count, winding speed, and machine efficiency, and differ between users, leading to personal discrepancies in calculation methods.
Innovation Solution
A production volume simulation apparatus equipped with yarn feeding, winding, and defect detecting devices, which includes a storage section for operation data, a calculating section for predicted production volume, and an input receiving section for changed yarn defects, allowing for accurate calculation of winding speed and production volume based on actual conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a predicted production volume is calculated based on user experience and conventional formulas, then the calculation can be performed quickly, but the accuracy varies significantly between different users and factors like count, winding speed, and machine efficiency cannot be adequately considered
Solution Approach 1:
The patent creates a virtual simulation model that copies the actual yarn winding machine's operations, defects, and parameters. This simulation model allows accurate prediction of production volume by replicating real-world conditions without requiring complex manual calculations by different users, thus improving accuracy while maintaining manageable system complexity.
Solution Approach 2:
The system performs preliminary simulation of the yarn winding process before actual production to predict the production volume. By pre-calculating the expected output based on simulated defect removal and winding parameters, the system provides accurate predictions without requiring complex real-time calculations during operation.
2Reliability
If the number of removed yarn defects is increased to improve package quality, then the production volume decreases due to more frequent interruptions, but if defects are not removed, package quality deteriorates
Solution Approach 1:
The simulation system incorporates feedback from the virtual defect detecting device and clearer to predict how different defect removal strategies affect both package quality and production volume. This feedback mechanism allows users to optimize the balance between reliability and productivity by visualizing the consequences of different clearing conditions before actual production.
Solution Approach 2:
The system dynamically simulates the interaction between defect removal actions and production continuity. By modeling the variable winding speed and intermittent stops based on defect occurrence and removal, the system helps determine optimal defect removal thresholds that maintain package quality while minimizing productivity loss.
Data Source
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AI summary
A production volume simulation apparatus (40) includes a storage section (41) that stores therein operation data of winding units (10) of a yarn winding machine (1), an arithmetic section (42) that calculates a predicted production volume of packages (P) formed by the winding units (10) by using the stored operation data, a displaying and input receiving section (45) that displays the calculated predicted production volume and receives a changed number of removed yarn defects as a simulatable item. When the displaying and input receiving section (45) receives the changed number of removed yarn defects, the arithmetic section (42) calculates a winding speed for simulation based on the changed number of removed yarn defect, and then calculates the predicted production volume based on the winding speed for simulation.