An upgraded soft winding machines based on advanced yarn tension modelling for using polyester

No doubt, the textile business is one of the oldest and important industries worldwide but it still needs a lot of efforts and development. In this paper, an upgraded soft winding machine is targeted based on a modified variable speed yarn tension modeling. Soft winding is a very critical process, because it could affect the dyeing quality throughout controlling the package density as well as the yarn imperfections. Product quality is considered a major competition edge against market rivals. In this study, micro-controller, tension sensor, tension brake, servo motor “feeder” and personal computer will be used to measure the actual yarn tension on the soft winding machine. Stack tank and noise filtering techniques will be used to filter and save the signal values from the tension sensor for durable industry application. Various tests will be applied on polyester yarn, fine, medium and coarse yarn counts will be used to cover most yarn types used in the industry. Unwinding tension equations before and after the feeder are disused and explained, in addition to the tension brake, servo motor “feeder” and winding speed tension. Curve fitting tool inside Matlab software is used to determine the new effective equations. Therefore, maximum yarn quality can be achieved at higher production capacity and machine efficiency. Implementation of Advanced yarn tension modeling can be applied to new soft winding machines generations and for modifying old machinery. The new advanced yarn tension model is tested on a soft winding machine and good results were reported in addition to recommended tension values for the different polyester yarn counts tested.