Thread breakage detection systems amd methods

Abstract

A thread breakage detection apparatus comprises a light source operable to generate a light beam, an emitter in communication with the light source, the emitter operable to emit the light beam, and a receiver in communication with and disposed in facing opposition to the emitter, the receiver operable to receive the light beam emitted from the emitter and to communicate the light beam to a sensor. The emitter comprises an emitter lens and a first fiber optic cable comprising proximate and distal ends. The proximate end of the first cable in communication with the light source and the distal end of the first cable in communication with the emitter lens. The receiver comprises a receiving lens and a second fiber optic cable comprising proximate and distal ends, the proximate end of the second cable in communication with the receiving lens and the distal end of the second cable in communication with the sensor.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application is a continuation of and claims priority to U.S. patent application Ser. No. 10 / 644,485, filed Aug. 20, 2003, entitled “Thread Breakage Detection Systems and Methods,” the entirety of which is hereby incorporated by reference.FIELD OF INVENTION [0002] This invention relates to products and processes for detecting thread breakage in a sewing apparatus. BACKGROUND [0003] A sewing apparatus operates by piercing fibers or threads into a base fabric with needles. A sewing apparatus typically includes a needle which receives thread through its eye from a source of thread which may be mounted on the body of the sewing machine or remotely therefrom. The thread generally follows a path through various thread guides or guide plates on the machine, through a thread tensioning device, a thread take-up device, and then through other guide means mounted above the needle. The thread is then directed through the eye of the needle. The ...

AI Technical Summary

Benefits of technology

"The present invention provides a thread breakage detection apparatus for textile sewing machines. The apparatus includes a light source, an emitter, and a receiver. The emitter is a device that emits a light beam, while the receiver is a device that receives the light beam and communicates it to a sensor. The apparatus is designed to be placed close to the thread in the sewing machine, less susceptible to misalignment caused by machine vibration. It can detect thread breakage spanning a distance of up to 4 meters. The technical effects of the invention include improved accuracy in detecting thread breakage and improved efficiency in identifying the location of the breakage."

Problems solved by technology

A common problem associated with any sewing apparatus is the detection of thread breakage during operation before the broken thread is sewn or inserted into the base fabric.

For example, during the carpet tufting process, when one of the multitude of yarns breaks while the carpet tufting apparatus is in operation, the eventual absence of thread in the corresponding needle creates a gap defect, or “mend,” in the carpet.

A relatively short mend, such as less than 0.5 meters, in a carpet sample can be corrected using a hand-held device, but longer mends are much more difficult—or even impracticable—to fix.

Thus, yarn breakage often results in carpet waste, which increases the ultimate cost of production.

The closer the light beam is positioned to a thread, the greater the likelihood a broken thread will interrupt or fall through the light beam.

Further reducing the accuracy and consistency of thread breakage detection is the vibration typical of sewing apparatuses.

Such vibration often jars the light emitter and / or receiver of the optical thread breakage detection device out of alignment.

Not only does such misalignment interrupt the production process, but misalignment can often be difficult to detect, resulting in mend defects.

Machine vibration further reduces the accuracy and consistency of such systems.

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