Automated Bobbin Loader Motor Control
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Solution Overview
Problem
Existing manual spring tension devices for loading thread onto bobbins are cumbersome, difficult to adjust, prone to thread tangling and breakage, and require tedious re-adjustment for different bobbin sizes, with thread often overlapping and losing tension due to temperature and humidity changes.
Innovation Solution
An automated bobbin loader system using motors and a motor controller to apply adjustable tension and guide thread onto bobbins of varying sizes without overlap, determining the optimal thread amount based on input data and ensuring proper alignment and tension through a thread guide mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a manual spring tension device is used to load thread onto a bobbin, then thread tension can be applied, but the device is cumbersome and difficult to adjust accurately
Solution Approach 1:
The patent replaces the manual spring tension device with an automated motor-driven system. A motor rotates the thread holder to wind thread onto the bobbin, eliminating the need for manual spring tension adjustment. The motorized system provides consistent, reliable tension control without the complexity of manual adjustment mechanisms.
Solution Approach 2:
The automated system performs the thread loading operation without requiring manual intervention for tension control. The motor automatically regulates the winding process, and the system can adapt to different bobbin sizes through automated parameter adjustment, making the operation self-regulating and eliminating cumbersome manual adjustments.
2Productivity
If a manual spring tension device is used, then thread can be loaded onto the bobbin, but thread overlaps occur which reduces thread capacity and increases tangling
Solution Approach 1:
The patent incorporates sensors that detect the position of the thread guide and the amount of thread wound onto the bobbin. This feedback information is used by the control system to adjust the motor speed and thread guide position, ensuring precise thread placement without overlaps. The system continuously monitors and corrects the winding process to maintain accuracy.
Solution Approach 2:
The thread guide is designed to move dynamically during the winding process. As the bobbin rotates and accumulates thread, the thread guide adjusts its position to maintain the correct angle and distance from the bobbin surface, preventing overlaps and ensuring uniform thread distribution throughout the loading process.
3Ease of manufacture
If a fixed tension device is used, then thread loading can be performed, but the tension changes due to temperature and humidity variations
Solution Approach 1:
The patent replaces the mechanical spring tension device with an electronically controlled motor system. The motor speed and torque can be precisely controlled through electronic feedback, maintaining consistent tension regardless of environmental conditions. This substitution eliminates the physical limitations of spring materials that expand and contract with temperature and humidity changes.
Solution Approach 2:
The system uses sensors to monitor thread tension during the winding process and provides feedback to the motor controller. This closed-loop control ensures that tension remains constant even when environmental conditions change, as the system automatically adjusts motor parameters to compensate for any variations.
4Manufacturing precision
If the bobbin loading device is adjusted for one bobbin size, then accurate loading is achieved, but tedious re-adjustment is required for different bobbin sizes
Solution Approach 1:
The patent designs the bobbin loading device to handle multiple bobbin sizes through a universal adjustment mechanism. The system includes sensors that detect bobbin dimensions and automatically adjust winding parameters such as motor speed, thread guide position, and winding density. This multi-functionality allows the same device to accurately load different bobbin sizes without manual re-adjustment.
Solution Approach 2:
The system performs preliminary detection of bobbin characteristics using sensors before the winding process begins. Based on this preliminary information, the control system pre-configures the appropriate winding parameters, ensuring optimal loading accuracy for the specific bobbin size from the start of the operation, eliminating the need for manual adjustment between different bobbin types.
Data Source
AI summary
A bobbin loader apparatus and method includes a bobbin connected with a first motor. A thread holder is connected with a second motor where the thread holder is configured to hold thread. A thread guide is connected with a third motor where the thread guide directs thread from the thread holder to the bobbin. A motor controller is connected with the first motor, the second motor and the third motor where the motor controller operates the first motor to turn the bobbin in a first direction and the second motor to turn the thread holder in a second direction such that tension is applied to the thread as thread is added to the bobbin.