3.1  Applied range

It's a cone-to-cone winding machine can be used of various yarns such as cotton,wool,nylon,chemical filament, rayon, spandex and so on. Also according to the requirement , it can be used to combining two ply or three ply into cheese packages.

3.2            Yarn winding process

Put the raw yarn in the yarn seat under machine, the yarn through the yarn guide ring and yarn guide ceramic part of panel into tensioner, then through yarn detector and enter overfeed yarn device or constant tension device, at last via the yarn guide move back and forth to winding on the take up bobbin. According to different demands, some winder need through overfeed pulley, lubrication system, air jet when traverse.

3.3  Machine basic structure

Machine compose of three function part

·Motive power parts

Contain frequency converter( or brushless motor drive),sensor,  electrical control box, operation element/executive component

·Winding structure part

Machine is single side working structure, adopt metal plate structure , each section is compose of four combine structure units

·Driving parts

Machine is single spindle individual drive, motor drive overfeed directly and take-up active winding cheese axis.

3.4  Winding unit structure

3.4-1  Yarn tension device

One tension method is weighted gate tension device, based on the different yarn, increase and reduce pressure to adjust the yarn tension, to get the good package from the stable tension.

Another tension method is constant tension controller, ensure the yarn tension precision, can make stretch yarn such as difficult to good forming to good forming shape.

Third tension method is automatically control tension of stepper motor, according to the tension requirement of pressure sensor  to provide tension data as needed.

3.4-2 Yarn break automatic detection system

Adopt photoelectric or level type yarn sensor, send the signal to controller when yarn brake, also turn off the motor running automatically; At the same time, the signal lamp shining to prompt the machine have already stop.

3.4-3Overfeed device

Overfeed device use independent motor for synchronous operation. According to different yarn, overfeed ratio 100%-200% can be arbitrarily set, to make sure the winding forming beautiful.

3.4-4 Constant tension device

When adopt constant tension device, install a pressure sensor at top of constant tension. Constant tension device adopt a overfeed pulley which driven by a sensitive, independent drive motor. Yarn wind this overfeed pulley through pressure sensor and reach take up bobbin, after set the pressure, through sensor's signal to control. When over pressure, overfeed increase the speed to feed yarn; When pressure are smaller, overfeed decrease the speed to feed yarn, to reach the yarn tension consistent and the good yarn forming.

3.5 Electronic yarn guide forming device

Via positive inversion of stepper motor, adopt wire rope to drive and take fixed yarn guide head, in the running of the motor, making yarn guide head do back and forth at high speed winding and forming.

We have research and development the control system of yarn guide winding forming of stepper motor, realize yarn guide forming automation:

With the help of Wuhan Textile University, we have research and development the control automation system of yarn guide forming of stepper motor; This system can make precise control the positive inversion distance of the stepper motor, the running can reach 1200 rounds per minute, we can change path freely in the movement path at the same time. So that the winding forming can according to the need density, soft side, different retract side angle, forming length etc.. To realize the forming electrical automation.

The method of forming guide yarn:

In the motor install plate and cheese tangent horizontal plane location, both forming side fix a active steel wire rope support wheel, install stepper motor at below, the wheel of stepper motor have some bolt shape's groove so that can match with the steel wire rope winding. On both ends of steel wire rope as rotating band, stuck the bolt of both sides of the motor wheel, one end of steel wire rope winding two circles in the one side of motor wheel, through the active roller which at the same side and top end of the wheel, then level to the other side of the roller, then return to the motor wheel winding two circles, finally get stuck the other end of steel wire rope to the other side bolt of motor wheel and fixed; Under the tension of motor install plate, make the steel wire rope to be triangle without load and fix to the three wheels stably. Install fix yarn guide head to the center steel wire rope which between the two active roller, when motor do forward and reverse movement, yarn guide head follow the steel wire rope do back and forth movement; Our machine forming max length is 290mm, so the distance of two horizontal active roller is exceed 290mm. The motor wheel rotate on the same direction also smaller than 290mm, winder forming motor do forward and reverse movement, to make the yarn guide do horizontal bank and forth movement.

The setting of forming length :

Control center will let the motor along the same direction rotate slowly at start, when the yarn guide head touch the roller of one side and automatic reversing to another side roller, return to the midpoint of the two roller ans stop, then make the stepper motor find the center point, in the next work always turning around this point to work.

The setting of soft side and density:

Soft side refer to yarn forming from the longest yarn traverse gradually reduce a certain length to the middle and return back to the original length such a constantly circulation process, make yarn cheese forming after setting forming length, the motor will automatically take this basis point do positive inversion movement in the setted length range, to make the guide head do horizontal reciprocate motion as the requirement of forming length when winding.

Both end and middle density is consistent.

In the reciprocating motion of yarn cheese forming, yarn guide always reach both end, the density of ends will more closer than the middles, so the finish yarn cheese's ends will more harder than the middles, that is to say the cheese's tightness density is not same. Actual production has many different requirement of density. To ensure the tightness of ends consistent with the middles', that is to say hand feeling of ends need same soft with the middle, we call it soft side; Forming path of soft side is when the reciprocate yarn guide forming, in the forming process of yarn guide head move back and forth at both ends, it can not be always fixed at both ends, but in the winding process, yarn guide traverse gradually shorten from both ends to the midpoint, after reach the certain suitable requirement, next gradually increase length to the original length, do cyclical motion all the time, to reach the soft side requirement.

Density is the number of turns of yarn winding on the bobbin, in the same length, how many turns can change the density of elastic; This winding turns is changed as the proportion of the revolving turns of take up bobbin and number of yarn guide, through control design, you can set and change the winding turns as required on the panel freely, to reach the density requirement as required.