The invention relates to a winding apparatus for winding the yarn or the slit film
tapes that continuously arrive from a feeding apparatus. It also relates to a method
for controlling winding tension in a winding apparatus during winding of
5 continuously arriving slit film tape or yarn (1). More particularly, it relates to an
apparatus and a method for controlling yarn winding tension in a winder system.
Even more particularly, it relates to an apparatus for reducing variations or
fluctuations in thread tension during winding operations.
10 Background of Invention:
A yarn winder is used for winding of continuously arriving yarn of polyolefin —
flat/fibrillated or any similar type— onto a bobbin. Here, yarn defines flat tapes,
multifilament and monofilament yarns or any similar type of yarns or tapes. In
general, bobbin holders, also known as mandrel cores, are mounted on spindles of
15 each winder head that are in turn assembled on a winder machine frame. Each
spindle needs precisely controlled rotation, so may be driven independently by an
electric motor through a suitable mechanism such as a belt and pulley
arrangement or with a direct driving system. Conventionally, the encoders or
other similar devices for pulse generation are mounted on the motor for
20 monitoring the motor revolutions, and the signal therefrom is communicated to
the electronic controller with the help of suitable cable. The controller further
sends the electrical signals to the inverter/drive of the active motor which
determines the power to be given for the motor driving the spindle.
25 The conventional winders of the above type are widely used. Some of these are
disclosed in the US Patent Nos. 5228630, 4765552 and DE 3723593.
In winding operations, it is essential that the thread or other material being wound
is maintained at a substantially constant tension in order to achieve a uniform
30 product. It is, therefore, necessary to monitor and control thread tension and to
3
make adjustments when the tension varies from some predetermined value.
Obviously, it is most desirable to have the monitoring and regulation of thread
tension accomplished automatically during the winding process.
5 In conventional winders, yarn winding tension is controlled by regulating
tightening of the oscillating arm tensioning spring (hereinafter referred to as a,
dancing arm resistance for onwards references). The to and fro motion of dancing
arm is monitored electronically to keep yarn delivery at nearly uniform tension
with constant linear speed to bobbin spindle.
10
Also in conventional winders, winding tension of yarn is maintained by providing
resistance to the motion of the dancing arm by adjusting spring attached to it.
Position feedback of dancing arm is routed to the control logic of winders, which
in turn rotate the bobbin mandrel (also known as bobbin spindle) such that a
15 position of dancing arm is maintained consistently with least oscillation. To
maintain the winding tension for various types of yarn of different properties
(such as denier, width etc.), the spring attached to the dancing arm is adjusted
such that its variation is minimized as much as possible to achieve good quality of
produced bobbins. Conventionally, spring associated with dancing arm is set once
20 at the start of the winding process, which remains constant throughout build of the
bobbin as product, however, this is not compatible with the yarn tension which
varies with the package size during the unwinding process.
Further, on any given slit film manufacturing machine generally known as tape
25 extrusion lines, there are multiple winders, their numbers ranging from 50 to 500,
all working at same linear speed as tape extrusion line. However, it is laborious to
precisely adjust each winder head dancer arm spring position and tension, which
is conventionally done manually.
4
The dancer arm is influenced by a spring force or gravitational force, in order to
produce a thread tension which must be applied on the other hand over the bobbin
spindle during the winding operation by controlling the winding motor speed.
This thread tension can be very small or very high in the specific cases. As the
5 bobbin diameter increases, the winding/spindle motor has to be controlled with
reducing speed for keeping same linear speed. For this, the winding/spindle motor
is provided with a known phase angle control. In order, to control the lowering of
speed of the winding motor, the angular position of the dancer arm is used by a
correction voltage generator according to the respective angular position. In this
10 case, a center position of the dancer arm of the correction voltage value of zero is
assigned, being followed in opposite direction correction voltages to both sides.
This scheme has the disadvantage that for the derivation of the correction voltage,
the current angular position of the dancer arm must be detected. A change in angle
15 of the dancer arm is thus a necessary condition for generating the correction
voltage and thus the functioning of the control device. At each variation of the
angular position of the dancer arm from the central position, the yarn tension
changes, depending on the deflection of, the dancer arm spring loading at an angle
change of the dancer arm and thus a different spring force is required for different
20 tension values. This has a disadvantageous effect as a given spring will be able to
create certain range of spring force which then generates tension for particular
linear density (denier) range of yarn being wound. So if there is an increase or
decrease in yarn denier beyond the given range then spring has to be changed
which is not only laborious but also not feasible.
25
Another possible problem associated with spring-loaded dancer arms is the fact
that the nominal position of the dancer arm tends to be quite different during
different phases of the operation of the winder. Even at constant thread tension
unwinding during weaving, thus different moments arise depending on the
30 diameter of the bobbin, may cause variation in fabric width.
5
Even with the pneumatic piston used in place of spring, causes variation in
unwinding tension due to friction (stick-slip) effect of pneumatic cylinder and its
maintenance.
5 Further, there is constant increase in demand for winding of sensitive lighter
denier yarn material and also, coarser denier yarn on same winding system, which
makes difficult for conventional tensioning system like spring, due to space
constraints and limited range of tension/force.
10 Thus, there is a requirement for a winding apparatus for overcoming above stated
issues of dancer arm on winding machine.
Objects of Invention:
The main objective of the present invention is to provide a winding
15 apparatus/device which has overcome the inherent drawbacks of spring loaded
dancer arm yarn tensioning system in winder at one hand and provides a smooth
tension mechanism on the other hand.
Another objective of the present invention is to provide a winding
20 apparatus/device which is independent of friction/stick slip effect of conventional
pneumatic cylinder.
Yet another objective of the present invention is to provide a compact
apparatus/device compact yarn tensioning system to overcome space constraint.
25
Further objective of the present invention is that apparatus/device system is
capable of handling lighter to coarser denier yarn.
Further objective of the present invention is ease setting of tension on plurality of
30 winder heads through centralized system.
6
Another objective of this invention is to control winding tension such that there is
almost constant unwinding tension in subsequent operation like weaving.
5 Brief Description Of Figures:
Figure 1 shows a general set-up of a winding apparatus
Figures 2, 2A, 2B, 2C shows the tensioning device of the invention in its various
embodiments
10
Figure 3 shows a schematic of the man machine interface (MMI), parent
controller and winder head controllers
Summary Of Invention:
15 A winding apparatus is disclosed for winding continuously arriving yarn (1) or slit
film tapes. The invention relates to slit film tape or yarn winding type device and
a process to control yarn tension during winding. More particularly, it relates to
an apparatus and a method for controlling yarn tension using fluidic tension
actuator (8) in a winder system. Even more particularly, it relates to an apparatus
20 for reducing variations or fluctuations in yarn tension during winding operations.
The present invention also relates to a winding machine for winding up bobbin
with yarn (1) or slit film tape material arriving from a plurality of feeding
apparatuses. The winding machine includes a plurality of winding heads/winders
25 each having at least one winding spindle (2), each being designed and arranged to
be rotated by a drive. A plurality of traversing apparatuses are designed and
arranged to cooperate with one of the winding spindles (2) to wind up the material
onto bobbins. The plurality of dancer arms (3) have each provided with a
tensioning device, which in turn has at least one tension actuator (8) which serves
7
to determine an instantaneous signal which is approximately proportional to the
required tension of the continuously arriving yarn (1).
The winding apparatus of the invention for winding continuously arriving yarn or
5 slit film tapes in a winder system has at least one winder controlled by an
individual winder head controller (13) which are controlled by a parent controller
(12), a dancing arm (3) associated with each of the winders and provided with a
tensioning device, wherein the instantaneous angular position (3F) of said dancing
arm (3) is variable during the yarn winding operation, a man machine interface
10 (MMI - 11) interacting with the parent controller (12). The key aspect of the
invention is that the tensioning device consists of at least one sealed polymeric
fluidic tension actuator (8) which is attached to dancer arm (3) unit with a
rotatable mechanism to create required resistance to the movement of the dancer
arm (3). A lever (9) and a link (20) are used to connect the tension actuator (8) to
15 the dancer arm (3). The tension actuator (8) generates required resistance on the
dancer arm (3) in proportion to the required tension (or winding tension) in the
winding yarn. The change in said instantaneous angular position (3F) of said
dancer arm (3) is monitored and used to regulate winding tension by changing
rotational speed of spindle (2) through the individual winder head controller (13)
20 in required proportion.
Another embodiment of the present invention provides a method for controlling
winding tension in a winding apparatus during winding of continuously arriving
slit film tape or yarn (1) on winder. In particular, a method for controlling winding
25 tension in a slit film tape or yarn (1) during its winding process is also disclosed.
The method comprises using the apparatus disclosed herein, using which the
method determines the winding tension dependent on yarn denier or tape size
running on individual winders. The key aspect of the method of invention is that
generation of the winding tension is carried out using a sealed polymeric fluidic
8
tension actuator (8), which is controlled either manually or through an electropneumatic regulator valve (17).
List of parts:
5 Slit film tape/yarn (1)
Spindle with Bobbin (2)
Dancing Arm (3)
Dancing Arm Rollers (3A)
Tensioning device (3B)
10 Dancing Arm Movement
Delimiter (3C)
Dancing Arm in optimal operating
Position (3D)
Dancing Arm in End Position (3E)
15 Dancing arm at instantaneous
angular position (3F)
Lower end of dancing arm (3G)
Tensioning Bow (4)
CAM Box (5)
20 Pressure Roller (6)
Traverse Guide (7)
Tension actuator (8)
First end of tension actuator (8A)
Second end of tension actuator
25 (8B)
Lever (9)
Third rotatable connection (10)
MMI (11)
Parent Controller (12)
30 Winder Head controller (13)
Pressure line (14)
Position sensor (15)
Angular arm (16)
Electro-pneumatic regulator valve
35 (17)
Pneumatic connector (18)
Pneumatic pipe/ hose (19)
Link (20); hole (20A)
Encoder (21)
40 First angle (22)
First rotatable connection (23)
Second rotatable connection (24)
Detail Description Of Invention
45 The general set-up for a winding apparatus is shown figure 1 which includes set of
rollers for delivering continuously arriving yarn (1) onto the winding spindle
mounted with bobbin (2) through the pressure roller (6) mounted with cam box
(5) having traverse guide for laying of yarn and dancer arm with roller for
regulating the yarn winding tension. In the conventional apparatus for regulating
9
winding tension, a spring based tension setting device (3B) is used for changing
the resistance/tension of dancer arm as function of linear density of slit film tape
or yarn (1) which is being wound on bobbins (2) to form packages.
5 Typically, in conventional winders, the resistance of the dancing arm (3) to its
oscillating movement during the winding process is controlled by settings of a
knob (3B – see figure 1) which can be set at various positions by adjusting torsion
of the spring that is provided in the knob, which effectively increases stiffness of
the dancing arm (3) system according to yarn (1) properties.
10
In Figures 1, yarn (1) is delivered continuously from direction ‘a’ from a feeding
apparatus such as stretching and conditioning rollers of a tape line machine. The
continuously arriving yarn (1) passes through a dancing arm roller (3A) onto
winding spindle (2) fitted with a bobbin. A winder starts winding as the running
15 yarn (1) passing through dancing arm (3) roller (3A) causes the dancing arm (3) to
assume its instantaneous angular position (3F) due to the yarn tension required for
winding. As shown in Figure 1, the position 3E represents the limit of the angular
movement of the dancer arm (3)
20 Also as shown in Figures 1, a to-and-fro traverse assembly or a cam box (5)
constitutes a pressure roller (6), a traverse guide (7), and a tensioning bow (4)
along with other assembly parts as the arriving yarn (1) it winds onto the bobbin.
The yarn (1) travels over the tensioning bow (4) before passing through the split
film tape traverse guide (7).
25
The pressure roller (6) presses the spindle (2) to maintain winding tension in the
yarn (1). The spindle rotational speed is electronically controlled in a closed loop
as per feedback provided on the dancing arm (3) deflection – i.e. information on
the instantaneous angular position (3F) of the dancing arm (3) is monitored using
30 a position sensor (16) or an encoder (21), relative to its optimal operating position
10
(3D) during the winding operation) so as to provide optimal winding tension in
the yarn. The optimal operating position (3D), as the name indicates, is the target
position of the dancing arm (3) during the winding operation to achieve optimal
package characteristics. However, during the winding operation, depending on the
5 winding process parameters, the dancing arm (3) typically deviates from its
optimal operating position (3D). The dancing arm (3) is arranged or designed
such that as it is deflected angularly from its optimal operating position (3D)
position, the spindle (2) starts rotating and thus yarn winding starts on spindle (2).
The extreme positions (3E) which the dancing arm (3) is allowed to assume
10 during a winding operation are facilitated by provision of a dancing arm (3)
movement delimiter (3C – not shown).
Typically, in the conventional devices, the setting of the tension setting knob (3B)
is not changed during entire winding process. As a part of the closed loop, a
15 position sensor (16) which is mounted on dancing arm (3) regularly transmits
details of the instantaneous angular position (3F) of dancing arm (3) to a winder
head controller (13) which controls the speed of spindle motor.
During the winding operation on conventional winder with a spring based dancer
20 arm, the machine operator can make a decision regarding manually tightening or
loosening of the yarn (1) based on his observation. For instance, if the
instantaneous angular position (3F) of the dancing arm (3) is such that the dancing
arm (3) deflects from its optimal operating position (3D) towards the winding
bobbin (2), then yarn (1) is travelling in a looser-than-desired state. On the other
25 hand, if the dancing arm deflects away from its optimal operating position (3D) in
a direction away from the winding bobbin 2), then yarn is traveling in a tighterthan-desired state. According to the instantaneous position (3F) of the dancing
arm (3) deflection, positional details of the dancing arm (3) are communicated to
the winder head controller (13) and thus the rotational speed of spindle (2) is
30 regulated to control yarn tensioning/yarn winding tension.
11
As stated earlier, a major disadvantage of conventional spring-based dancer
tension/resistance setting, are non-consistent settings of individual winder heads,
ultimately resulting in necking or shrinkage of the fabric produced due to varying
resultant winding tension, and sometimes in undesired frequent weft breakages.
5
As an alternative to the fluidic muscle, the tension actuator (8) may be an electric
actuator, a hydraulic actuator, a link motion system, and/or so-called “smart
materials”, including piezo-electric materials, magnetostrictive and
electrostrictive materials, i.e. materials with a capability to change viscosity, e.g.
10 from liquid to almost solid state, shape alloy materials (SMA), thermo-responsive
materials and/or conducting polymers.
The tension actuator (8) used in the winding apparatus of the invention for
winding continuously arriving yarn or slit film tapes is shown in Figures 2, 2A,
15 2B, and 2C in its various embodiments. The tension actuator (8) is connected to
the dancer arm (3) using a rotatable mechanism.
Specifically, the tension actuator (8) used in the present invention is a fluidic
muscle or a sealed polymeric fluidic tension actuator which are also commercially
20 available. In general, a fluidic muscle is a linear member which may be
constructed by wrapping a synthetic or natural rubber tube with a woven sheath.
This forms an expansible chamber. When a pressurized fluid is applied to the
chamber of the fluidic muscle, the chamber expands radially and is accompanied
by a corresponding contraction in its length, resulting in linear motion. Metallic or
25 plastic fittings may be secured at both ends to transmit the resultant motion.
The tension actuator (8) is typically a linear element having a first end (8A) and a
second end (8B). It is provided with a pneumatic connector (18) at its first end
(8A) through which a pneumatic pipe/hose (19) supplies pressure generated by
12
the pressure line (14) which is connected to an electro-pneumatic regulator valve
(17).
At its second end (8B), the tension actuator (8) is connected to the lower end (3G)
5 of the dancer arm (3). In order to generate resistance to the movement of the
dancer arm, it is important that the connection between the tension actuator (8)
and the dancer arm is constructed in a specific manner while allowing the free
rotational movement of the connection itself. For this purpose, a lever arm (9) is
provided at the second end (8B) of the tension actuator (8) which is connected
10 with a first rotatable connection (23) to a link (20). Both the lever arm (9) and the
link (20) are freely rotatable with respect to each other at the end of the link (20)
that is close to the lever arm (9). The other end of the link (20) is connected to the
lower end (3G) of the dancer arm (3). There is a first angle (22) formed between
the link (20) and the lower end (3G) of the dancer arm (3), the value of which is
15 dependent on the design of the winder system. The junction of the link (20) and
the lower end (3G) of the dancer arm (3) is rotatable through a second rotatable
connection (24) as a unit around a fulcrum or a pivot point. Thus, the junction
itself is freely rotatable around a fulcrum point while the first angle (22) between
the link and the dancer arm (3) is constant. Because the first angle (22) is
20 constant, the tension generated by the action of the tension actuator (8) is
transferred to the dancer arm (3) as resistance to its angular movement. The
tension actuator (8) is connected to the winder surface or optionally on the winder
frame using a third rotatable connection (10).
25 The first, second, and third rotatable connections (23, 24, and 10) can be done by
any of mechanical joints such as screw-nut arrangement, bush pin arrangement or
bearing pin arrangement.
In one embodiment, there is multiple tension actuators (8) connected to any single
30 winder head. To facilitate this, there are provided multiple locations on the link
13
(20) where the respective first rotatable connections (23) may be provided. In one
embodiment, (see Figures 2B and 2C), the link (20) comprises of multiple holes
(20A) which can be provided for the respective first rotatable connections (23).
The provision of multiple connection points on the link (20) also allows changing
5 the position of the connection between lever (9) and link (20) from one hole to
another for any given tension actuator (8), which permits changing the applied
pneumatic pressure, which in turn causes increase or decrease in tension
transferred to the dancer arm (3).
10 The common state of art term for sealed polymeric fluidic tension actuator is
“fluidic muscle”, as it is commonly termed (along with pneumatic artificial
muscle), is in part the progeny of an invention by Richard Gaylord. Gaylord, in
1955, received U.S. Pat. No. 2,844,126 for a “Fluid Actuated Motor System and
Stroking Device.”
15
In general, a fluidic muscle may be constructed by wrapping a synthetic or natural
rubber tube with a woven sheath. This forms an expansible chamber. When a
pressurized fluid is applied to the chamber of the fluidic muscle, the chamber
expands radially and is accompanied by a corresponding contraction in its length,
20 resulting in linear motion. Metallic or plastic fittings may be secured at both ends
to transmit the resultant motion.
In the simplest possible embodiment of the invention, a single fluidic muscle/
sealed polymeric fluidic tension actuator is used to replicate the restoring force
25 provided by the spring.
The sealed polymeric fluidic tension actuator is reinforced resilient bladder having
a shape which changes in a predetermined way under variations in its internal
pressure. Fluid muscles are available commercially, and may be operated using
30 pressurized air, other gases, or hydraulic fluid.
14
For the purpose of this disclosure the terms ‘tension actuator’ or ‘sealed
polymeric fluidic tension actuator’ (8) will be used interchangeably. A pneumatic
hose (19) supplying pneumatic pressure is connected to the tension actuator (8) so
5 as to create required resistance onto the rotational movement of the dancer arm
(3) in proportion to the fluidic pressure supplied to said tension actuator (8). The
source of pressurized fluid is housed in a reservoir kept at distant location. The
generated resistance in turn controls the uniformity of tension applied by the
dancer arm (3) on the continuously arriving yarn or tape for winding. Any change
10 in the tension of incoming yarn/tape results in swinging of dancer arm (3) to a
position depending on difference between arriving yarn tension and required/set
winding tension. Thus change in the instantaneous angular position (3F) of dancer
arm (3) (indicated by various positions of the dancer arm (3) in Figure 1) – the
change being monitored by encoders (21) which can be optical type, magnetic
15 based or other similar device for pulse generation – is communicated to the
individual winder’s head controller (13) for changing the motor speed of the
spindle (2) in required proportion such that the dancer arm (3) remains in steady
condition near the optimal position (3D), thereby maintaining a constant winding
tension across the winding system. The steadying of dancer arm (3) at said
20 optimal operational position (3D) is carried out by communicating the data
gathered by sensor (15) or the encoder (21) to the individual winder’s head
controller (13) on the basis of which the motor speed of the spindle (2) is
adjusted.
25 In another embodiment, a cost effective angular position monitor through position
sensor (15) and angular arm (16) can be used for determining instantaneous
angular position (3F) of dancer arm (3) which is communicated to the individual
winder’s head controller (13).
15
The unique feature of the invention is that generated resistance on dancer
arm/winding tension can be controlled through pneumatic/fluidic pressure applied
to the tension actuator (8) without any friction or stick slip effect. Also, the
tension in more than one winder head can be set through single a control point
5 such as a parent controller (12). Further, as the tension actuator (8) used in the
invention does not have any moving part like piston, there no friction effect and at
the same time very precise setting of required tension/force can be done. Another,
important factor is that sealed polymeric fluidic tension actuator (8) has
comparative smaller space requirement than equivalent force pneumatic cylinder
10 used in the conventional winders.
The sealed polymeric fluidic tension actuator (8) is housed on the winder
compartment, preferably on back-side. The sealed polymeric fluidic tension
actuator (8) is in close proximity of dancer arm (3) such that it can be accessed
15 easily for maintenance purpose.
The first end (8A) of sealed polymeric fluidic tension actuator (8) is connected
with winder body surface.
20 The sealed polymeric fluidic tension actuator (8) can be arranged in required
orientation with dancer arm based on the actual yarn path in winder and space
availability. The sealed polymeric fluidic tension actuator (8) can be in parallel to
dancer arm or can be perpendicular. As shown in figure 2, in one of embodiment,
the sealed polymeric fluidic tension actuator (8) is connected below dancer arm
25 (3).
In an embodiment, yarn braids are used in polymer tension actuator (8). The
dimension of said polymeric tension actuator (8) is directly governed by applied
pneumatic pressure which in turn cause increase or decrease in tension transferred
16
to the dancer arm roller (3A), through a parameter such as the deflection
resistance/force of dancer arm (3).
The pneumatic pressure settings of the polymeric tension actuator (8) can be
5 changed manually or automatically through the parent controller (12) according to
the required pressure adjustment suitable for proper bobbin/package winding. The
pressure settings of the tension actuator (8), which are proportional to the yarn
winding tension, depend on yarn properties particular yarn denier, thickness, type
of yarn, required for optimal winding. Preferably, the pressure settings, the
10 package cutoff size, and the final package size, are input using the suitable input
interface to system controller prior to starting the winding operation. However,
the settings may be adjusted during the winding process, without halting the
winding operations.
15 In fig 3, the functional diagram with preferred embodiments is described. A Man
machine interface (MMI) (11) is provided for entering the desired
machine/process related parameters of the winder machine (such as yarn, denier,
weight, speed, the tube outer diameter), which is known to person skilled in art.
The MMI (11), a parent controller (12) and winder head controller (13)
20 communicates with each other either over serial or parallel bus backbone. The
parent controller (12) is a channel for data-entering-point into an assembly of such
winder units, whereas a winder head controller (13) (or simply a head controller)
is a controller for each winder unit. There may be more than one winder unit/head
in a winder family.
25
The parent controller (12) is provided to transfer data to all winder head
controllers (13) for their operational requirements and functionality. Parent
controller (12) thus transfers process data such as the line speed, winding recipe,
etc. from each winder to respective winder head controllers (13) are connected to
30 single ‘parent’ controller (12) (also termed as the ‘gateway’ controller).
17
In one embodiment of the invention, the man machine interface (11) is capable of
changing the pressure of supplied fluid to the tension actuator (8) at a predetermined time interval by manual input or inputting pre-programmed values in
5 the parent controller (12) optionally during course of winding operation.
As an illustration, Figure 3 shows a pressure line (14). According to the invention,
pressure line (14) from electro- pneumatic regulator valve (17) is connected to the
tension actuator (8) of the dancer arm (3) of individual winder unit. The pressure
10 line (14) thus replaces the conventional torsional spring force for adjusting
oscillating resistance of the dancing arm (3).
In case of electro-pneumatic regulator valve (17), using the parent controller (12),
directly a voltage or current base signal value can be used for precise controlling
15 of applied pneumatic pressure to at least one tension actuator (8).
The invention also discloses a method for controlling winding tension in a
winding apparatus during winding of continuously arriving slit film tape or yarn
(1). The method uses the apparatus that has been described in detail in the
20 foregoing description. As a part of the method, the winding tension dependent on
yarn denier or tape size running on individual winders is determined. The required
winding tension is generated using the tension actuator (8) of the sealed polymeric
type as described. The value of the pressure supplied to the tension actuator (8) is
adjusted centrally using the parent controller (12) to match the winding tension
25 value that has been determined. The method also allows that the pressure supplied
to the tension actuator (8) is controlled through the electro-pneumatic regulator
valve (17).
The pressure setting of pressure line (14) or pressure at the tension actuator (8)
30 can be changed according to the required pressure adjustment suitable for proper
winding through MMI (11). For example, the inventive winder set values can be
18
defined as for denier range 200 – 6000, pressure can varies from 0.5 – 7.5 bar.
Thus, said pressure variation changes the dimension of said tension actuator (8)
and required resistance is created on dancer arm (3).
5 In working comparative example (prior art), for the winding of continuously
arriving slit film tape yarn of 850 denier at speed of 450 m/min, on conventional
winder with spring base dancer arm system, the winding tension was set at around
75 gram. The resultant yarn bobbins showed normal winding shape and during
subsequent usage as weft yarn on circular fabric of 500 mm tube, showed width
10 variation along the tube length by ±10 mm.
On the same extrusion line, on other position the inventive winder with sealed
polymeric fluidic tension actuator (8) were used for winding of continuously
arriving slit film tape yarn of 850 denier at speed of 450 m/min, the winding
15 tension was precisely set to around 75 gram. The resultant yarn bobbins showed
normal winding shape and during subsequent usage as weft yarn on circular fabric
of 500 mm tube, showed width variation along the tube length by ±6 mm. The
pressure applied was set at 0.8 bars.
20 Further, on same inventive winder was used for winding of continuously arriving
slit film tape yarn of 450 denier at speed of 550 m/min, the winding tension was
precisely set to around 25 gram. The resultant yarn bobbins showed normal
winding shape and during subsequent usage as weft yarn on circular fabric of 500
mm tube, showed width variation along the tube length by ±3 mm.
25
A person skilled in the art would understand that such reduction in fabric width
variation (from ±10mm to ±6mm to ±3mm) enhances the quality of winding
significantly.
19
It is evident from the foregoing discussion that there are a number of
embodiments of the invention.
In the preferred embodiment, a winding apparatus for winding continuously
5 arriving yarn (1) or slit film tapes is disclosed having at least one winder having a
spindle, and controlled by an individual winder head controller (13); a parent
controller (12) to control said individual winder head controllers (13); a dancing
arm (3) associated with each of said at least one winder and provided with a
tensioning device, wherein the instantaneous angular position (3F) of said dancing
10 arm (3) is variable during the yarn winding operation; and a man machine
interface (11) interacting with said parent controller (12). The key aspect of this
embodiment is that the tensioning device is in the form of at least tension actuator
(8) having a first end (8A) and a second end (8B) and which is attached to said
dancer arm (3) at its second end (8B) using a rotatable mechanism.
15
In another embodiment the aforementioned rotatable mechanism is formed by
providing a first rotatable connection (23) between a lever (9) provided at said
second end (8B) and a link (20), and a second rotatable connection (24) formed
between said link (20) and the lower end (3G) of said dancer arm (3).
20
In a further embodiment, a first angle (22) is formed between said link (20) and
the lower end (3G) of said dancer arm (3), said first angle (22) being constant.
In a yet further embodiment, the tension actuator (8) is connected with a third
25 rotatable connection (10) to the winder frame on which said apparatus is mounted.
In a still further embodiment, the first, second, and third rotatable connections
(23, 24, and 10) are of the type selected from a group comprising screw-nut
arrangement, bush pin arrangement or bearing pin arrangement, or a hinge.
30
20
In another embodiment, the tension actuator (8) is a fluidic muscle or a sealed
polymeric fluidic tension actuator (8).
In still another embodiment, near the first end (8A) of said tension actuator (8), a
5 pneumatic connector (18) is provided to which a pneumatic pipe/ hose (19) is
attached to supply pressure from a pneumatic pressure line (14).
In a further embodiment, the tension actuator (8) is configured to generate
resistance to rotational movement of said dancer arm (3) in proportion to required
10 winding tension in said arriving yarn (1).
In a still further embodiment, the dancer arm (3) is provided with an angular arm
(16) whose instantaneous position is monitored using a positional sensor (15).
15 In one more embodiment, the instantaneous angular position (3F) of said dancer
arm (3) is monitor by an encoder (21) based system mounted on individual
winders.
In a further embodiment, the winding tension in more than one winder head is set
20 through a parent controller (12).
In a still further embodiment, the pneumatic pressure applied to said tension
actuator (8) through said pressure line (14) is controlled manually or
automatically with an electro-pneumatic regulator valve (17).
25
In another embodiment, the encoder (21) is of a type selected from a group
consisting of optical type, magnetic type, or other similar pulse generation type.
In yet another embodiment, the pressure setting of pressure line (14) or pressure at
30 the tension actuator (8) is set through said man machine interface (11).
21
In a still another embodiment, the link (20) has a plurality of locations said lever
(9) of any tension actuator (8) is connected to said link (20).
5 In a further embodiment, at least one hole (20A) is provided on said link (20)
where said lever (9) of any tension actuator (8) is connected to said link (20).
In a still further embodiment, the man machine interface (11) is capable of
changing the pressure of supplied fluid to the tension actuator (8) at a pre10 determined time interval by manual input or inputting pre-programmed values in
the parent controller (12).
In a yet further embodiment, the number of tension actuators (8) provided on any
winder head is more than one.
15
In one more embodiment, the first rotatable connection (23) is formed at one of
said holes (20A) provided in said link (20).
In another embodiment, a method for controlling winding tension in a winding
20 apparatus during winding of continuously arriving slit film tape or yarn (1) on
winder is disclosed. It comprised the steps of:
a. providing an apparatus as has been disclosed herein;
b. determining the winding tension dependent on yarn denier or tape size
running on individual winders;
25 c. generating said winding tension using said sealed polymeric tension
actuator (8);
d. centrally adjusting pneumatic pressure value proportionately to said
winding tension; and
e. optionally controlling the tension actuator pressure through the electro30 pneumatic regulator valve (17).
22
In another embodiment of the method of invention, the adjustment of pneumatic
pressure of step d is made by making dancer arm position steady at optimal
operation position (3D) which regulates the rotational speed of said spindle in
5 proportional to the tension generated in the aforementioned step c.
In a further embodiment, the steadying of dancer arm (3) at said optimal
operational position (3D) is carried out by communicating the data gathered by
sensor (15) or the encoder (21) to the individual winder’s head controller (13) on
10 the basis of which the motor speed of the spindle (2) is adjusted.
In yet another embodiment of the method disclosed here, the pressure the
centrally adjusted pneumatic pressure is adjusted without halting the winding
operation of said apparatus.
15
While the above description contains much specificity, these should not be
construed as limitation in the scope of the invention, but rather as an
exemplification of the preferred embodiments thereof. It must be realized that
modifications and variations are possible based on the disclosure given above
20 without departing from the spirit and scope of the invention. Accordingly, the
scope of the invention should be determined not by the embodiments illustrated,
but by the appended claims and their legal equivalents.

We claim:

1. A winding apparatus for winding continuously arriving yarn (1) or slit
film tapes having:
- at least one winder having a spindle, and controlled by an individual
5 winder head controller (13),
- a parent controller (12) to control said individual winder head
controllers (13),
- a dancing arm (3) associated with each of said at least one winder and
provided with at least one tensioning device, wherein the instantaneous
10 angular position (3F) of said dancing arm (3) is variable during the
yarn winding operation,
- a man machine interface (11) interacting with said parent controller
(12),
characterized in that said tensioning device is in the form of at least
15 tension actuator (8) having a first end (8A) and a second end (8B) and
which is attached to said dancer arm (3) at its second end (8B) using a
rotatable mechanism.
2. The apparatus as claimed in claim 1, wherein said rotatable mechanism is
formed by providing a first rotatable connection (23) between a lever (9)
20 provided at said second end (8B) and a link (20), and a second rotatable
connection (24) formed between said link (20) and the lower end (3G) of
said dancer arm (3).
3. The apparatus as claimed in claim 2, wherein a first angle (22) is formed
between said link (20) and the lower end (3G) of said dancer arm (3), said
25 first angle (22) being constant.
4. The apparatus as claimed in claims 1 to 3, wherein said tension actuator
(8) is connected with a third rotatable connection (10) to the winder frame
on which said apparatus is mounted.
5. The apparatus as claimed in claims 1 and 2, wherein said first, second, and
30 third rotatable connections (23, 24, and 10) are of the type selected from a
24
group comprising screw-nut arrangement, bush pin arrangement or
bearing pin arrangement, or a hinge.
6. The apparatus as claimed in claims 1 to 5, wherein said tension actuator
(8) is a fluidic muscle or a sealed polymeric fluidic tension actuator (8).
5 7. The apparatus as claimed in claims 1 to 6, wherein near said first end (8A)
of said tension actuator (8), a pneumatic connector (18) is provided to
which a pneumatic pipe/ hose (19) is attached to supply pressure from a
pneumatic pressure line (14).
8. The apparatus as claimed in claims 1 to 7, wherein the tension actuator (8)
10 is configured to generate resistance to rotational movement of said dancer
arm (3) in proportion to required winding tension in said arriving yarn (1).
9. The apparatus as claimed in claims 1 to 8, wherein said dancer arm (3) is
provided with an angular arm (16) whose instantaneous position is
monitored using a positional sensor (15).
15 10. The apparatus as claimed in claims 1 to 9, wherein said instantaneous
angular position (3F) of said dancer arm (3) is monitor by an encoder (21)
based system mounted on individual winders.
11. The apparatus as claimed in claims 1 to 10, wherein the winding tension in
more than one winder head is set through a parent controller (12).
20 12. The apparatus as claimed in claims 1 to 11, wherein pneumatic pressure
applied to said tension actuator (8) through said pressure line (14) is
controlled manually or automatically with an electro-pneumatic regulator
valve (17).
13. The apparatus as claimed in claims 9 to 12, wherein said encoder (21) is of
25 a type selected from a group consisting of optical type, magnetic type, or
other similar pulse generation type.
14. The apparatus as claimed in claims 1 to 13, wherein the pressure setting of
pressure line (14) or pressure at the tension actuator (8) is set through said
man machine interface (11).
25
15. The apparatus as claimed in claims 1 to 14, wherein said link (20) has a
plurality of locations said lever (9) of any tension actuator (8) is connected
to said link (20).
16. The apparatus as claimed in claims 1 to 15, wherein at least one hole
5 (20A) is provided on said link (20) where said lever (9) of any tension
actuator (8) is connected to said link (20).
17. The apparatus as claimed in claims 1 to 16, wherein said man machine
interface (11) is capable of changing the pressure of supplied fluid to the
tension actuator (8) at a pre-determined time interval by manual input or
10 inputting pre-programmed values in the parent controller (12).
18. The apparatus as claimed in claims 1 to 17, wherein the number of tension
actuators (8) provided on any winder head is more than one.
19. The apparatus as claimed in claims 15 to 18 wherein said first rotatable
connection (23) is formed at one of said holes provided in said link (20).
15 20. A winding apparatus for winding continuously arriving yarn (1) or slit
film tapes characterized in that said method comprises the steps of:
a. providing an apparatus as claimed in any one of claims 1 to 19;
b. determining the winding tension dependent on yarn denier or tape size
running on individual winders;
20 c. generating said winding tension using said sealed polymeric tension
actuator (8);
d. centrally adjusting pneumatic pressure value proportionately to said
winding tension;
e. optionally controlling the tension actuator pressure through the electro25 pneumatic regulator valve (17).
21. The method as claimed in claim 19, wherein said adjustment of pneumatic
pressure of step d is made by making dancer arm position steady at
optimal operational position (3D) which regulates the rotational speed of
said spindle in proportional to the tension generated in step c.
26
22. The method as claimed in claim 21, wherein said steadying of dancer arm
(3) at said optimal operational position (3D) is carried out by
communicating the data gathered by sensor (15) or the encoder (21) to the
individual winder’s head controller (13) on the basis of which the motor
5 speed of the spindle (2) is adjusted.
23. The method as claimed in claims 20 to 22, wherein the pressure the
centrally adjusted pneumatic pressure is adjusted without halting the
winding operation of said apparatus.