自动缫丝络交张力的降低及其对生丝的影响
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摘要
生产高等级生丝是扩大生丝出口和生产高档丝绸产品的基础。由于已广泛应用的自动缫丝机缫丝速度快，缫丝张力大，对生丝的圆整度、断裂强度和断裂伸长率等指标都会产生不利影响，难以达到高等级生丝的标准。为此，论文着眼于自动缫丝的络交工序来开展降低缫丝张力的研究，期望在缫丝速度不变的情况下降低缫丝张力，以提高生丝的圆整度等各项性能指标，保证生丝的等级。
自动缫丝络交工序中，络交瓷座带动生丝产生横向摆动，以实现生丝卷装的成型。湿态生丝与络交瓷座间存在滑动摩擦关系，络交瓷座前后生丝的张力相差3cN以上，具有很大的降低空间。根据绳与定滑轮间的作用原理，将络交瓷座改为络交鼓轮，生丝通过鼓轮后的张力增大值将可能大大降低。通过对生丝与鼓轮间的摩擦关系进行理论分析，论文得出了鼓轮制作所应该遵循的原则，即在选材和形状设计上要尽量做到质量轻、半径小，加工过程中要尽量通过润滑等措施来减小芯轴与芯轴支撑件之间的摩擦系数。
根据鼓轮的制作原则，选用不锈钢芯轴和ABS树脂制作了实物型的鼓轮。通过构建实验条件，使用德国施密特数字张力计DTMX-200对分别使用络交瓷座和络交鼓轮时的生丝张力进行了测量和对比分析。结果表明，络交鼓轮在静止和横动时生丝的张力增大值分别为0.73cN和0.78cN，而络交瓷座在静止和横动时的生丝张力增大值分别为3.08cN和5.49cN。充分验证了络交鼓轮在降低生丝张力方面的有效性。
将络交鼓轮整套部件安装于缫丝机上进行实际缫丝。利用YG020A型电子单纱强力机分别对使用络交瓷座和络交鼓轮所缫制的生丝的断裂强度和断裂伸长率进行测试。结果发现，两种生丝的断裂强度相差不大，但断裂伸长率方面，使用络交瓷座缫制的生丝为21.336%，使用络交鼓轮缫制的生丝为18.441%，降低了2.895%，这与提高生丝的断裂伸长率的目的不符。经分析，产生这种结果的原因是鼓轮设计上存在问题，实际应用中容易出现跳丝或卡鼓轮现象。为此，论文又提出了V字型鼓轮的设计方案。
此外，论文还利用生丝传动装置、光电传感器、数据采集卡等硬件和基于LabVIEW软件编写的测量程序，自行研制了一套生丝圆整度测量系统。利用该系统分别测量了使用络交瓷座和络交鼓轮所缫制生丝的圆整度。测量结果显示，使用络交瓷座所缫制的生丝的平均圆整度为0.7401，使用络交鼓轮所缫制生丝的平均圆整度为0.7706，使用络交鼓轮后生丝的圆整度有所提高。
本文的主要创新点包括以下三方面。
（1）首次提出在自动缫丝过程中以鼓轮传送方式替代传统的瓷座摩擦方式，有效实现了缫丝张力地降低和生丝圆整度的提高。
（2）发明了一种络交鼓轮及其附属装置，并进行了试验性缫丝，达到了预期的效果。
（3）研制了一套有效的生丝圆整度测量系统，该系统对生丝匀度等其他品质指标的检测也具有重要价值。
Production of high-grade raw silk is the foundation for increasing raw silk export andproducing high-end silk products. Due to the extensively applied automatic reelingmachine featured with high reeling rate and high reeling tension, the breaking elongationrate of the raw silk is difficult to meet the requirements of the high-end raw silk.Smoothness of the raw silk is difficult to meet the requirements of high-end raw silk. Forsuch a purpose, this paper aims at research on reducing the reeling tension by improvingthe crossed winding process. Based on our newly developed theory and instrument, weexpect to decrease the reeling tension without changing the reeling rate and increase thebreaking elongation to enhance the grade of raw silk as well.
In the automatic cross winding process, the cross winding ceramic stand drives the rawsilk to vibrate transversely and form the coiled thread of silks. The governing force of thesliding friction exists between the wet raw silk and the cross winding ceramic stand.Tension difference of the raw silk before and after the cross winding ceramic stand is over3cN, which indicate that the reduction of reeling tension still has the large space to beimproved. In accordance with the basic principle of the rope and the static pulley, wehypothesize that the cross winding ceramic stand were changed into cross winding tubwheel, which might significantly reduce the tension of the raw silk passing through the tubwheel. By analyzing the analytic friction relation between the raw silk and the tub wheel,we concludes the certain rules to principle to be complied with, which means theselection of light weight materials, shape design, smaller diameter, and lubrication shouldbe adopted in the process of machining to reduce the friction coefficient between themandrel and mandrel support piece.
Complied with the fabrication principle of the tub wheel, stainless steel mandrel andABS resin are used to fabricate a real tub wheel. During the experiments, the Schmidtdigital tension meter (DTMX-200made in Germany) is used to measure the quantitativetension values for raw silk tension by using the cross winding ceramic stand and crosswinding tub wheel. The results indicate that, the increases of the tension value are0.73cNand0.78cN respectively at the still and transverse movement period, while the increasedtension of the raw silk increasing value by using the cross winding ceramic stand is3.08cNand5.49cN. The above results demonstrate t effectiveness of the cross winding tub wheelfor lowering the raw silk tension.
The cross winding tub wheel is installed on the reeling machine. The electronicmachine with model YG020A is used to measure the breaking strength and elongation rateof the raw silks reeled by the cross winding ceramic stand and cross winding tub wheelrespectively. The results show that the breaking strength is almost same, while the breakingelongation of the raw silk reeled by the cross winding ceramic stand is21.336%and that ofthe raw silk reeled by cross winding tub wheel is18.441%. The latter elongation rate isdecreased by2.895%, which is inconsistent with our purpose of the design of the crosswinding tub wheel. The reason of such problem is due to the defective design of the tubwheel, which causes the silk jumping or tub wheel sticking in the real reeling process.Therefore, a new design of V-shaped tub wheel is proposed in the end of this thesis.
Apart from above works, a system consisting of the raw silk transmitter, photoelectricsensor, data acquisition card and software based on LabVIEW is designed to study theroundness of raw silks reeled by the cross winding ceramic stand and cross winding tubwheel. The measuring results show that average roundness of raw silk wound by crosswinding ceramic stand is0.7401and average roundness of raw silk wound by crosswinding tub wheel is0.7706. It indicates the roundness of the raw silk is improved after theusage of the cross winding tub wheel.
Three main innovations in this paper are listed as follows.
(1) we proposed that the cross winding ceramic stand were changed into crosswinding tub wheel in the automatic reeling process, which significantly reduce the tensionof the raw silk passing through the tub wheel and improve the silk roundness.
(2) A kind of tub wheel and its attachments were invented and were used in automaticreeling process. The experimental results show that the intended purpose was achieved.
(3) A system was developed to evaluate the silk roundness, which also can be used toevaluate the silk evenness. It has an important value to the evaluation of the silk qualityindicators.
自动缫丝络交工序中，络交瓷座带动生丝产生横向摆动，以实现生丝卷装的成型。湿态生丝与络交瓷座间存在滑动摩擦关系，络交瓷座前后生丝的张力相差3cN以上，具有很大的降低空间。根据绳与定滑轮间的作用原理，将络交瓷座改为络交鼓轮，生丝通过鼓轮后的张力增大值将可能大大降低。通过对生丝与鼓轮间的摩擦关系进行理论分析，论文得出了鼓轮制作所应该遵循的原则，即在选材和形状设计上要尽量做到质量轻、半径小，加工过程中要尽量通过润滑等措施来减小芯轴与芯轴支撑件之间的摩擦系数。
根据鼓轮的制作原则，选用不锈钢芯轴和ABS树脂制作了实物型的鼓轮。通过构建实验条件，使用德国施密特数字张力计DTMX-200对分别使用络交瓷座和络交鼓轮时的生丝张力进行了测量和对比分析。结果表明，络交鼓轮在静止和横动时生丝的张力增大值分别为0.73cN和0.78cN，而络交瓷座在静止和横动时的生丝张力增大值分别为3.08cN和5.49cN。充分验证了络交鼓轮在降低生丝张力方面的有效性。
将络交鼓轮整套部件安装于缫丝机上进行实际缫丝。利用YG020A型电子单纱强力机分别对使用络交瓷座和络交鼓轮所缫制的生丝的断裂强度和断裂伸长率进行测试。结果发现，两种生丝的断裂强度相差不大，但断裂伸长率方面，使用络交瓷座缫制的生丝为21.336%，使用络交鼓轮缫制的生丝为18.441%，降低了2.895%，这与提高生丝的断裂伸长率的目的不符。经分析，产生这种结果的原因是鼓轮设计上存在问题，实际应用中容易出现跳丝或卡鼓轮现象。为此，论文又提出了V字型鼓轮的设计方案。
此外，论文还利用生丝传动装置、光电传感器、数据采集卡等硬件和基于LabVIEW软件编写的测量程序，自行研制了一套生丝圆整度测量系统。利用该系统分别测量了使用络交瓷座和络交鼓轮所缫制生丝的圆整度。测量结果显示，使用络交瓷座所缫制的生丝的平均圆整度为0.7401，使用络交鼓轮所缫制生丝的平均圆整度为0.7706，使用络交鼓轮后生丝的圆整度有所提高。
本文的主要创新点包括以下三方面。
（1）首次提出在自动缫丝过程中以鼓轮传送方式替代传统的瓷座摩擦方式，有效实现了缫丝张力地降低和生丝圆整度的提高。
（2）发明了一种络交鼓轮及其附属装置，并进行了试验性缫丝，达到了预期的效果。
（3）研制了一套有效的生丝圆整度测量系统，该系统对生丝匀度等其他品质指标的检测也具有重要价值。
Production of high-grade raw silk is the foundation for increasing raw silk export andproducing high-end silk products. Due to the extensively applied automatic reelingmachine featured with high reeling rate and high reeling tension, the breaking elongationrate of the raw silk is difficult to meet the requirements of the high-end raw silk.Smoothness of the raw silk is difficult to meet the requirements of high-end raw silk. Forsuch a purpose, this paper aims at research on reducing the reeling tension by improvingthe crossed winding process. Based on our newly developed theory and instrument, weexpect to decrease the reeling tension without changing the reeling rate and increase thebreaking elongation to enhance the grade of raw silk as well.
In the automatic cross winding process, the cross winding ceramic stand drives the rawsilk to vibrate transversely and form the coiled thread of silks. The governing force of thesliding friction exists between the wet raw silk and the cross winding ceramic stand.Tension difference of the raw silk before and after the cross winding ceramic stand is over3cN, which indicate that the reduction of reeling tension still has the large space to beimproved. In accordance with the basic principle of the rope and the static pulley, wehypothesize that the cross winding ceramic stand were changed into cross winding tubwheel, which might significantly reduce the tension of the raw silk passing through the tubwheel. By analyzing the analytic friction relation between the raw silk and the tub wheel,we concludes the certain rules to principle to be complied with, which means theselection of light weight materials, shape design, smaller diameter, and lubrication shouldbe adopted in the process of machining to reduce the friction coefficient between themandrel and mandrel support piece.
Complied with the fabrication principle of the tub wheel, stainless steel mandrel andABS resin are used to fabricate a real tub wheel. During the experiments, the Schmidtdigital tension meter (DTMX-200made in Germany) is used to measure the quantitativetension values for raw silk tension by using the cross winding ceramic stand and crosswinding tub wheel. The results indicate that, the increases of the tension value are0.73cNand0.78cN respectively at the still and transverse movement period, while the increasedtension of the raw silk increasing value by using the cross winding ceramic stand is3.08cNand5.49cN. The above results demonstrate t effectiveness of the cross winding tub wheelfor lowering the raw silk tension.
The cross winding tub wheel is installed on the reeling machine. The electronicmachine with model YG020A is used to measure the breaking strength and elongation rateof the raw silks reeled by the cross winding ceramic stand and cross winding tub wheelrespectively. The results show that the breaking strength is almost same, while the breakingelongation of the raw silk reeled by the cross winding ceramic stand is21.336%and that ofthe raw silk reeled by cross winding tub wheel is18.441%. The latter elongation rate isdecreased by2.895%, which is inconsistent with our purpose of the design of the crosswinding tub wheel. The reason of such problem is due to the defective design of the tubwheel, which causes the silk jumping or tub wheel sticking in the real reeling process.Therefore, a new design of V-shaped tub wheel is proposed in the end of this thesis.
Apart from above works, a system consisting of the raw silk transmitter, photoelectricsensor, data acquisition card and software based on LabVIEW is designed to study theroundness of raw silks reeled by the cross winding ceramic stand and cross winding tubwheel. The measuring results show that average roundness of raw silk wound by crosswinding ceramic stand is0.7401and average roundness of raw silk wound by crosswinding tub wheel is0.7706. It indicates the roundness of the raw silk is improved after theusage of the cross winding tub wheel.
Three main innovations in this paper are listed as follows.
(1) we proposed that the cross winding ceramic stand were changed into crosswinding tub wheel in the automatic reeling process, which significantly reduce the tensionof the raw silk passing through the tub wheel and improve the silk roundness.
(2) A kind of tub wheel and its attachments were invented and were used in automaticreeling process. The experimental results show that the intended purpose was achieved.
(3) A system was developed to evaluate the silk roundness, which also can be used toevaluate the silk evenness. It has an important value to the evaluation of the silk qualityindicators.
引文
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[2]去年我国真丝绸商品出口增8.55％[J].江苏纺织.2012,3:29.
[3]高文庆.新世纪纺织技术发展趋势.纺织装饰科技.2001,03:1-1.
[4]徐作耀.微机化缫丝张力测试系统[J].丝绸.1990,12:54-54.
[5]陈绣华.国际丝绸业与国际丝绸市场现状研究[J].安徽纺织.1996,3:13-14.
[6]周颖.巴西、印度制丝业的发展及生丝质量状况[J].国外丝绸.2009,1:33-35.
[7]柳云青,朱毓秀,陈星山看,吴晓旭.缓解缫丝张力适应织绸要求—介绍一种自动缫异常张力缓解装置[J].丝绸.1985,4:14-16．
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