Automatic Thread Tensioning in Quilting Machines
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Solution Overview
Problem
Sewing and quilting machines require an automatic thread tensioner that can adjust thread tension based on the translation of the sewing head relative to the workpiece, as existing technologies do not effectively manage tension changes during sewing and non-sewing translations.
Innovation Solution
A controller-actuated thread tensioner system that moves between two positions to adjust thread tension, with a rotary tension assembly featuring a cylindrical housing, tension disk, and actuator to reduce or maintain tension based on the sewing or non-sewing translation of the sewing head, ensuring optimal thread engagement and release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a traditional thread tensioner is used in sewing machines, then the structure remains simple and compact, but the thread tension cannot be automatically adjusted during sewing and non-sewing translations
Solution Approach 1:
The patent applies the dynamics principle by making the thread tensioner adjustable between different tension states. The tensioner includes a movable component that can change its position to provide different levels of thread resistance, allowing it to adapt dynamically between sewing and non-sewing translations rather than maintaining a fixed tension setting.
Solution Approach 2:
The patent implements self-service through the actuator system that automatically adjusts the tensioner based on detected translation types. The controller receives signals about whether the machine is in sewing or non-sewing mode and autonomously actuates the tensioner to the appropriate tension level without requiring manual intervention from the operator.
2Ease of operation
If thread tension is maintained high during non-sewing translation, then thread control is good, but thread engagement with workpiece is compromised
Solution Approach 1:
The tensioner dynamically changes its tension level based on the operational mode. During non-sewing translation, the tensioner reduces thread tension to allow proper thread engagement with the workpiece, while during sewing translation, it increases tension to maintain control over the thread path and ensure consistent stitching quality.
3Manufacturing precision
If thread tension is reduced during sewing translation, then thread engagement is improved, but stitching consistency deteriorates
Solution Approach 1:
The system dynamically adjusts tension based on the phase of operation. During sewing translation, the tensioner maintains high thread tension to ensure consistent stitching and proper thread control through the needle and fabric layers, while during non-sewing translation, it reduces tension to facilitate smooth thread engagement without resistance.
4Productivity
If an automatic tension adjustment system is added, then threading efficiency improves, but the form factor constraints are violated
Solution Approach 1:
The patent applies the nesting principle by integrating the actuator and tension adjustment mechanism within the existing tensioner housing. The movable tension component is positioned inside the compact tensioner assembly, allowing the automatic adjustment functionality to be embedded within the original form factor without requiring additional external space.
Data Source
AI summary
A system and method are provided for selectively controlling a thread tension in a quilting machine. The thread tensioner is moveable to a reduced tension configuration in response to an actuator, wherein the actuator is sized to be located within an existing form factor. A controller can be connected to the actuator to regulate the thread tension in response to a sewing translation and a non-sewing translation of the sewing head relative to a workpiece.