Mainly reflected in the following aspects:
1. Unbalanced tension control, causing physical damage to the yarn
The speed ratio of the reducer directly determines the output torque and speed of the motor. If the speed ratio matching is unreasonable, it will lead to deviations in the tension control during the weaving beam winding or pulling process.
Excessive tension: It will cause the warp yarn to be over-stretched during unwinding, dipping or winding, resulting in excessive yarn elongation, damaged yarn strength, and increased end-breakage rate in subsequent weaving processes.
Tension is too small or unstable: it will cause the yarn to relax and not be wound tightly, and even the yarns will shift, twist, and cluster due to insufficient tension during splitting, resulting in serious defects such as bundling and inversion.
2. The tension between the wet zone and the dry zone is imbalanced, aggravating hairiness and breakage.
The sizing process is divided into wet zone and dry zone, and each zone has different requirements for tension. If the speed ratio of the reducer cannot accurately match the transmission of each process section, this balance will be destroyed.
Excessive tension in the wet zone: Yarns are prone to plastic elongation under high temperature and wet conditions, resulting in excessive elongation reduction of the sizing yarn and poor elasticity.
Abnormal tension in the dry area: Improper tension control after leaving the drying room will cause difficulty in splitting. If the tension is too small, the end will break due to friction blocking the telescopic reed; if the tension is too high, a large amount of regenerated hairiness will be produced at the splitting bar due to poor yarn splitting or the yarn will be broken.
3. Poor winding formation affects weaving efficiency
The speed ratio matching problem is particularly sensitive in the winding area. The winding tension directly determines the forming quality of the weaving beam.
Mismatch between roll diameter and tension: As the roll diameter of the weaving beam increases, if the reducer and transmission system cannot provide matching torque compensation, the winding tension will fluctuate. This will cause the weaving beam to be tight on the inside and loose on the outside or loose on the inside and tight on the outside, resulting in uneven winding, which can easily cause unwinding and warp breakage when the loom is unwinding.
Low-speed crawling jitter: When changing the axis of the sizing machine or sorting the yarn at low speed, if the speed ratio causes the motor to operate at an extremely low frequency and the torque output is insufficient, it will cause system jitter, causing the yarn tension to instantly lose control or even break.
4. Equipment wear and process parameter drift
An unreasonable speed ratio will cause the reducer and transmission components to operate under non-optimal working conditions for a long time.
Increased mechanical wear: Long-term overloading or excessive speed ratio leads to insufficient torque, which will accelerate the wear of mechanical parts such as gears and bearings. As wear intensifies and the transmission gap becomes larger, the originally set tension will gradually decrease or fluctuate periodically. This hidden process parameter drift is difficult for operators to detect in time, ultimately leading to a decline in batch yarn quality.
Summarize
The matching of the speed ratio of the sizing machine reducer is a systematic project and must be accurately calculated based on the motor power, maximum linear speed, roll diameter range and target tension (for example, through the formula: reduction ratio ≤ weaving shaft hollow core roll diameter × 3.14 × motor rated speed / maximum vehicle speed). The hidden effects caused by speed ratio mismatch are often gradual. In the early stage, they may only show a slight increase in hairiness or occasional breakage. However, as the equipment ages and the process shifts, it will eventually seriously deteriorate the yarn"s reinforcement rate, stretch reduction rate and overall weaving performance.
