In the process of textile production, the stability of yarn tension is one of the key factors affecting fabric quality. Whether it is a shuttle loom, an air-jet loom, a rapier loom or a jacquard loom, the yarn must maintain a constant tension in the weaving process. Too much tension may lead to yarn breakage, while too little tension may lead to fabric looseness, wrinkling and even defects. Therefore, how to realize and maintain the constant tension of textile machine is an important subject to improve product quality and production efficiency.
First, the importance of constant tension
Stable yarn tension can ensure uniform fabric structure and consistent warp and weft density, thus improving the smoothness and feel of the fabric. In addition, in the process of high-speed weaving, if the tension is unstable, it will easily lead to an increase in the broken end rate, reduce the loom efficiency and increase the downtime for maintenance. Therefore, tension control is an indispensable part of weaving process.
Second, the main factors affecting the
tension
1. Raw material characteristics: Different kinds and specifications of yarns (such as cotton, polyester, spandex, etc.) have different elasticity and friction coefficient, which directly
affects their tension changes.
2. Environmental temperature and humidity: the change of temperature and humidity will affect the hygroscopicity of yarn and the friction between fibers.
3. Performance of yarn feeding mechanism: such as accuracy and stability of yarn storage device, Zhang Liqi and let-off device.
4. Running speed of loom: When running at high speed, the dynamic tension of yarn fluctuates more, which requires higher tension control system.
5. Operation and maintenance level: Improper daily maintenance or misoperation will
also cause tension instability.
Third, the technical means to achieve constant tension
# 1. Mechanical tension adjusting device
The traditional mechanical tension controller applies constant resistance through springs, weights or friction plates to maintain yarn tension. This kind of device has simple structure and low cost, but its adjustment accuracy is
limited and its adaptability is poor.
# 2. Electronic tension control system
Modern high-end textile machinery mostly adopts electronic induction and closed-loop control technology. The yarn tension is detected in real time by the tension sensor, and the output of the motor or electromagnetic brake is adjusted by the control system to dynamically adjust the yarn feeding speed and realize accurate tension control. This system has fast response and high adjustment precision, and is suitable for high-speed and high-quality weaving.
# 3. Pneumatic tension adjustment system
On some looms, pneumatic devices are used to control the pressure of the tension roller through compressed air, thus adjusting the yarn tension. This method has a stable response and is suitable for yarn varieties sensitive to tension fluctuation.
# 4. Integration of intelligent control system and
Internet of Things technology
With the development of Industry 4.0, more and more looms begin to integrate intelligent control systems, and use big data to analyze and predict the tension change trend, and realize real-time adjustment and fault early warning of tension state through remote monitoring, thus further improving the stability and intelligence of tension control system.
IV. Maintenance and management suggestions
In order to ensure the long-term stable operation of the tension system, enterprises should strengthen daily maintenance management, including cleaning the tension sensor regularly, calibrating the control system, and checking the wear of transmission parts. At the same time, strengthen the professional training of operators, so that they can correctly identify and deal with abnormal tension.
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To sum up, the realization of constant yarn tension in textile machines depends not only on advanced equipment and technology, but also on scientific management methods and good operating habits. With the development of intelligent manufacturing and automation technology, tension control will be more accurate and efficient, which will provide a strong guarantee for improving the quality of textile products and the competitiveness of enterprises.