A novel capstan-based method for evaluating yarn tension during reciprocating sliding on the cylindrical pulley

Yarn tension measurement plays a crucial role in the fabric forming process. Despite previous research on load and wrap angle, the effects of sliding direction, sliding speed, and pulley material on tension require further research. A reciprocating yarn sliding apparatus was employed, enabling the measurement and analysis of yarn tension in both ascending and descending sliding stages under four influencing factors. Based on the capstan theory, during the ascending stage, yarn tension exhibited a linear dependence on load, an exponential dependence on wrap angle, a slowing growth trend with sliding speed, and a pronounced increase associated with the pulley material’s coefficient of friction (COF); in contrast, during the descending stage, the study found that parameters that caused higher tension in the ascending stage often resulted in lower tension in the descending stage, resulting in a larger tension spike when the yarn reversed its sliding direction. By capturing the sudden tension surges that occur during directional reversal of yarn sliding, the present study reveals the potential importance of analyzing such surges to ensure safe and reliable production.