Yarn Winding Unit Waste Yarn Calculation by Breakage Factor
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Solution Overview
Problem
Conventional yarn winding machines struggle to identify the specific yarn breakage factors causing waste yarn generation, limiting the ability to effectively manage and improve waste reduction.
Innovation Solution
A yarn winding unit with a calculation section that determines the yarn breakage factors causing waste yarn generation, allowing for precise measurement and analysis of waste yarn amounts for each factor, including monitoring devices to classify and manage yarn breakages such as operator errors, tension fluctuations, and bobbin replacements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the total waste yarn amount is calculated for upper and lower yarns separately, then the waste yarn generation amount can be grasped, but it is difficult to identify the specific yarn breakage factors causing waste yarn generation
Solution Approach 1:
The patent segments the waste yarn amount calculation by yarn breakage factor, creating separate calculation categories for different breakage causes (yarn quality, device settings, device defects, operator errors). This segmentation allows the system to not only measure total waste yarn amount but also identify and quantify the specific factors contributing to waste generation, thereby resolving the contradiction between measurement precision and information loss.
2Ease of manufacture
If waste yarn amount is calculated only by total amount, then the calculation is simple, but it cannot provide detailed information for early improvement and targeted waste reduction
Solution Approach 1:
The patent implements segmentation by categorizing waste yarn amounts according to different yarn breakage factors (yarn quality, device settings, device defects, operator errors). This allows the system to maintain relatively simple calculation procedures while generating detailed segmented data that enables targeted improvement initiatives and precise waste reduction strategies.
Solution Approach 2:
The patent introduces a calculation section that acts as an intermediary between the yarn joining device and the display/management system. This calculation section automatically categorizes and computes waste yarn amounts by breakage factor, serving as a mediator that transforms raw waste yarn data into structured, factor-specific information without requiring complex manual analysis or additional hardware.
3Measurement precision
If detailed monitoring of each yarn breakage factor is implemented, then the waste yarn amount for each factor can be measured, but the device complexity increases
Solution Approach 1:
The patent employs a calculation section as an intermediary that automatically performs the complex task of categorizing waste yarn by breakage factor. This intermediary component processes the monitoring data and generates factor-specific waste yarn amounts without requiring the physical monitoring system itself to become more complex. The calculation section handles the analytical complexity, allowing the physical monitoring infrastructure to remain relatively simple.
Solution Approach 2:
The patent replaces complex mechanical or manual monitoring mechanisms with an automated calculation system that uses logical classification and computation. Instead of requiring separate physical sensors or monitoring devices for each yarn breakage factor, the system uses a calculation section that automatically categorizes waste yarn based on predefined breakage factor categories, thereby reducing device complexity while maintaining high measurement precision.
Data Source
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AI summary
A yarn winding unit (30) includes: a yarn supplying section (9) capable of supplying a yarn unwound from a yarn supplying bobbin (11B); a winding device (31) configured to wind the yarn supplied from the yarn supplying section (9) to form a package (P); a yarn joining device (36) configured to perform a yarn joining operation of an upper yarn and a lower yarn formed by disconnecting a yarn between the yarn supplying section (9) and the winding device (31); and a calculation section (41) configured to determine which yarn breakage factor causes yarn disconnecting when the yarn joining operation is performed, and calculate a waste yarn amount generated at the time of the yarn joining operation in the yarn joining device (36) for each yarn breakage factor.