How does the split yarn warping machine achieve efficient and stable tension control?

In the textile industry, the warping process is to simultaneously draw a certain number of warp yarns from the bobbin to form warp yarn sheets with uniform tension and parallel arrangement, and to wind them parallel to the warp beam or weaving beam according to the specified length and width. As an important type of warping equipment, the performance of the split yarn warping machine directly affects the smooth progress of the subsequent weaving process and the quality of textiles. Among them, tension control is one of the core functions of the split yarn warping machine, which is of great significance for ensuring yarn quality, improving production efficiency and reducing production costs.

During the warping process, the yarn needs to withstand a certain tension. If the tension is too small, the yarn is easy to relax and bend, resulting in uneven warp arrangement, forming "straight stripe" defects, affecting the appearance and performance of the fabric; if the tension is too large, it will increase the tensile stress of the yarn, which may cause the yarn to break and increase the warping breakage rate. At the same time, it will also affect the elasticity and strength of the yarn and reduce the quality of the fabric. Therefore, maintaining appropriate tension is crucial to ensuring the quality of the yarn.

Reasonable tension control can reduce the friction between yarn and equipment parts, reduce equipment wear and extend the service life of equipment. Stable tension can make the equipment run more smoothly, reduce vibration and noise, and improve the reliability and stability of the equipment.

Uneven tension can cause problems such as knotting and entanglement of warp yarn during winding, increase the labor intensity of operators and reduce production efficiency. Good tension control can ensure smooth winding of warp yarn, reduce downtime and improve the production efficiency of warping machine.

The tension control of split yarn warping machine is mainly achieved through tension device. Common tension devices include disc tensioner, liquid damping tensioner, etc.

The disc tensioner is installed in front of the bobbin. After the warp yarn is drawn out from the bobbin, it passes through the baffle and penetrates from the magnetic hole, and then passes between the upper and lower tension disks, bypasses one or more columns and then leads out. By adjusting the position of the tension disk, the surrounding angle of the warp yarn to the tension disk is changed, thereby adjusting the tension of the warp yarn. The more the number of tension disks that the warp yarn bypasses, the larger the surrounding angle to the column, and the heavier the weight of the upper tension disk, the greater the tension of the warp yarn.

The liquid damping tensioner is also called KFD tensioner. When the warp passes through the balloon disk and passes around the rod, the balloon disk can be rotated to change the surrounding angle between the yarn and the rod, thereby adjusting the pre-tension of the single yarn. At the same time, the tension rod controlled by the tension spring is located on a small movable platform. The tension obtained after the warp passes around the tension rod is determined by the tension of the tension spring. The tension of the tension spring is controlled by a collective adjustment shaft in the same longitudinal column of the yarn frame. By changing the tension of the tension spring, the tension of the warp can be adjusted. When the warp tension increases (greater than the preset tension value), the tension rod begins to change its position under the action of the tension spring, so that the surrounding angle between the yarn and the rod is reduced, so as to achieve the purpose of reducing the tension until the tension returns to the preset value; when the warp tension decreases (less than the preset tension value), the tension rod changes its position again, so that the surrounding angle between the yarn and the tension rod is increased, thereby increasing the tension of the warp until the tension returns to the preset value.

In order to achieve accurate tension control, a high-precision tension detection device is required to monitor the tension changes of the yarn in real time. Common tension detection methods include resistance strain gauge, capacitance, piezoelectric, etc. These detection devices can convert the tension signal of the yarn into an electrical signal and transmit it to the control system so as to adjust the tension in time.

The control system is the core of the tension control of the split yarn warping machine. It adjusts the tension device in real time according to the signal fed back by the tension detection device to maintain the stability of the yarn tension. Modern split yarn warping machines usually use programmable logic controllers (PLC) or single-chip microcomputers as control systems, which have the advantages of fast operation speed, high control accuracy, and good reliability. At the same time, the control system can also implement a variety of control algorithms, such as PID control, fuzzy control, etc., to improve the performance of tension control.

The stability of the transmission system is crucial to tension control. If there are problems such as vibration and wear in the transmission system, it will cause fluctuations in yarn tension. Therefore, high-precision transmission components, such as reducers, synchronous belts, etc., need to be used, and they need to be regularly maintained and maintained to ensure the normal operation of the transmission system.

Uneven tension is one of the common problems of split yarn warping machines, which may be caused by various reasons, such as improper adjustment of the tension device, differences in yarn quality, and equipment wear. To address this problem, the following measures can be taken: First, regularly check and adjust the tension device to ensure that it works properly; second, strengthen the inspection of yarn quality to avoid using unqualified yarn; finally, replace worn parts in time to ensure the accuracy and stability of the equipment.

Tension fluctuations will affect the quality of the yarn and the operating stability of the equipment. The causes of tension fluctuations may include unstable power supply voltage, ambient temperature changes, equipment vibration, etc. In order to reduce tension fluctuations, a stabilized power supply can be used to power the equipment, the equipment can be vibration-isolated, and the appropriate temperature and humidity can be maintained in the workshop.

Tension out-of-control is a more serious problem that may cause yarn breakage, equipment damage, etc. Tension out-of-control is usually caused by control system failure, sensor damage, etc. Once tension out-of-control is found, the equipment should be stopped immediately, the working status of the control system and sensor should be checked, and the fault should be eliminated in time.