Yarn Winding Tension Control for Innermost Layer Quality
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing yarn winding apparatuses face issues with high initial tension causing quality defects in the innermost layer of yarn packages, leading to dyeability problems in textiles.
Innovation Solution
A yarn winding apparatus with a tension measurement unit and controller that performs preliminary tension control by adjusting winding speed based on measured tension, reducing tension before the formation of the yarn layer, and incorporating a traverse unit that functions as both a traverse and bunch winding unit to stabilize tension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high tension is applied to the yarn at the start of winding to ensure reliable capture by the take up tube, then the yarn threading reliability is improved, but the quality of the innermost layer deteriorates due to excessive pulling
Solution Approach 1:
The winding process is divided into distinct phases: bunch winding phase (where high tension is acceptable) and layer winding phase (where controlled tension is required). The controller manages this segmentation by switching control modes between phases, allowing high tension during bunch winding to ensure reliable yarn capture while preventing excessive tension during layer winding to maintain yarn quality.
Solution Approach 2:
The bunch winding unit performs preliminary winding action before the traverse unit forms the yarn layer. During this preliminary bunch winding phase, the system allows higher tension to reliably secure the yarn onto the take up tube. Once the bunch winding is complete and the yarn layer formation begins, the controller switches to tension control mode to prevent excessive pulling and maintain quality.
2Manufacturing precision
If the tension of the yarn is reduced before the formation of the yarn layer, then the quality of the innermost layer is improved, but the control complexity increases due to the need for tension measurement and preliminary tension control
Solution Approach 1:
The tension measurement unit continuously measures the yarn tension and provides feedback to the controller. The controller uses this feedback information to adjust the winding speed and apply preliminary tension control, ensuring that the tension is reduced to appropriate levels before yarn layer formation begins. This feedback mechanism enables precise tension management while maintaining a relatively simple control architecture.
3Device complexity
If the traverse unit is used for both traverse and bunch winding functions, then the device complexity is reduced, but the measurement precision requirement increases to accurately detect tension changes during different winding phases
Solution Approach 1:
The traverse unit is designed with multi-functionality, serving both as the traverse unit for layer winding and as the bunch winding unit for preliminary winding. The controller manages this universality by detecting the winding phase and switching control modes accordingly, allowing a single unit to perform multiple functions while maintaining operational precision through phase-aware control.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The quality of the innermost layer of a yarn in a package is improved. A yarn winding apparatus 13 includes a winding motor 102 and a traverse device 30 configured to traverse a yarn Y. The winding motor 102 and a traverse motor 31 of the traverse device 30 performs bunch winding of the yarn Y on an empty bobbin B. The yarn winding apparatus 13 further includes a tensiometer 28 and a controller 26. After the bunch winding of the yarn Y on the bobbin B starts and before normal control of causing the traverse device 30 to traverse the yarn Y starts, the controller 26 starts preliminary tension control of controlling the winding speed of the yarn Y by the winding motor 102 based on a result of measurement of the tension by the tensiometer 28.