Adjustable Reed Weft Insertion for Oblique Fabric Weaving
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Solution Overview
Problem
Existing fabric production methods require right-angle intersections of warp and weft threads, leading to unnecessary process steps like diagonal cutting and joining of fabric layers, which can result in unevenness and require manual intervention.
Innovation Solution
A device that allows for the adjustable insertion and beating of weft threads at angles between 40° and 90° relative to warp threads using a reed, enabled by a variable angle adjustment unit coupled to an electric drive, allowing oblique weaving and automated production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If weft threads are inserted at right angles to warp threads using conventional weaving devices, then the weaving process is simple and straightforward, but additional process steps (diagonal cutting and joining) are required which increase production time and create fabric unevenness
Solution Approach 1:
The patent changes the insertion angle parameter from the conventional 90 degrees to an oblique angle (e.g., 45 degrees) by adjusting the reed's orientation relative to the warp threads. This parameter change eliminates the need for subsequent diagonal cutting and joining operations, thereby improving both productivity and fabric uniformity simultaneously
2Adaptability or versatility
If diagonal cutting and joining of fabric layers is performed to achieve desired fabric geometry, then the fabric can be shaped for specific applications, but seams and abutments are created which reduce fabric quality and require manual intervention
Solution Approach 1:
The patent performs the geometric shaping action during the weaving process itself by inserting weft threads at oblique angles, rather than performing cutting and joining operations after the fabric is woven. This preliminary action creates the desired fabric geometry directly, eliminating seams and abutments that would otherwise require manual intervention
3Ease of manufacture
If the reed is fixed at a constant angle to the warp threads, then the device structure is simple and easy to manufacture, but the weft thread insertion angle cannot be adjusted to optimize fabric reinforcement
Solution Approach 1:
The patent transforms the reed from a fixed-angle component to a dynamically adjustable component. The reed can now be rotated or tilted to different angles relative to the warp threads, allowing optimization of weft thread insertion angles for various fabric reinforcement requirements while maintaining reasonable device complexity through mechanisms like rotary tables or adjustable mounts
Data Source
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AI summary
The invention relates to a device (2) for producing a fabric (3), wherein, in each weaving step, a shed can be formed by means of warp threads (3.2), through which a weft thread (3.1) can be led, and the weft thread (3.1) can be pushed in the direction of a fabric edge by means of a reed (5). Here, a weft thread insertion device (4) is provided, by means of which an angle of insertion of the weft thread (3.1) and/or beating up the same at the edge of the fabric can be adjusted variably in relation to the weft thread (3.2). The invention further relates to such a fabric (3). According to the invention, the weft thread insertion device (4) for adjusting the angle of insertion of the weft thread (3.1) has at least one adjusting unit (1), which is coupled to the reed (5), wherein the adjusting unit (1) comprises two piston-cylinder units (6), which are each coupled to one end (5.1) of the reed (5).