In recent years, there has been a significant increase in China's demand for automatic winder metal troughs. By 2005, the consumption had already surpassed 30,000 units, and this year, it is expected to exceed 40,000. However, due to the limited capabilities of machining equipment in the country, it has been challenging to produce complex grooved components. As a result, China has largely relied on imported parts to meet this demand. Although some major companies have attempted to use superplastic forming techniques to address the groove-forming issue, they still face difficulties in manufacturing molds that can handle the inverted draft of the groove section. This has become a major bottleneck in the localization of automatic winders in China, making it essential to develop an industrialized solution for the "automatic winding method of metal troughs."
Qingdao Tongchun Electromechanical Technology Co., Ltd. has taken a new approach by leveraging its existing silica sol precision casting technology. After five years of research and development, the company introduced an innovative mold design and manufacturing process for the "overall precision casting method" of metal troughs used in automatic winders. This breakthrough provides an effective way to produce complex parts that are difficult to form, offering crucial technical support for the localization of winding machines.
The first innovation involves a mold-opening scheme that combines axial splitting, sand cores, and live blocks. This method successfully addresses the issue of inverted drafts in the vase-shaped grooves of the metal trough, enabling the production of precise and accurate trough shapes suitable for precision casting. The second improvement focuses on optimizing the existing silica sol casting process to address rough casting issues caused by the unique structure of the automatic winder’s metal trough. Finally, the company uses micro-grinding flexible polishing technology, which preserves the original groove shape while achieving a surface finish with a roughness of Ra 0.4, meeting high-quality standards.
This advanced technology offers several advantages. First, it uses precision casting to form complex grooves during the initial casting stage, eliminating the need for costly and time-consuming post-casting machining processes. This significantly improves efficiency and reduces overall costs. Second, the trough shape is formed using a precision grooved cylinder mold, resulting in smooth, round grooves that can be directly polished. Third, the whole-casting method eliminates complicated processing steps, cutting the cost of groove production by over 40% compared to traditional five-axis forming methods—reducing costs to just one-tenth of the previous level.
The metal troughs developed by Qingdao Tongchun have been widely tested in large cotton mills across China. From a performance standpoint, they not only meet but often exceed the quality of Italian-made Savio metal troughs. These products are now being used on Savio automatic winders in companies such as Qingdao Bayi, Dezhou Demian, Binzhou Liumian, and Shandong Beyond. They operate at speeds of 1200–1300 m/min, delivering excellent spindle formation, winding quality, and yarn unwinding that meets installation requirements. According to comprehensive tests conducted by the Wuxi Mashan Textile Machine Testing Center, all performance indicators fully satisfy usage requirements. In addition, comparative tests by the Zhengzhou Zhongyuan Textile Institute showed that the yarn guiding performance of Tongchun’s metal troughs outperformed imported alternatives, with a lower yarn failure rate.
Currently, Qingdao Tongchun has a monthly production capacity of 2,000 to 5,000 metal troughs, supported by mature production technology and consistent product quality. This advancement marks a significant step forward in the localization of automatic winding systems in China, demonstrating both technical innovation and commercial viability.
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