Carbon Thread Positioning and Continuity Control in Looms
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Solution Overview
Problem
The preparation of warp threads in looms, particularly with carbon fibers, is prone to errors due to the high number of threads and small distances between them, leading to incorrect placement and breakage, resulting in suboptimal mechanical characteristics and increased waste.
Innovation Solution
A weaving installation with pairs of electrical contacts along the path of each carbon thread, connected to an open-circuit detection circuit, monitors thread positioning and integrity, allowing for error detection and real-time intervention to prevent waste and ensure correct weaving.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual warp preparation is used to place carbon threads in perforated boards, then the threading operation can be completed, but the high number of threads and small distances between them lead to placement errors and breakage
Solution Approach 1:
The patent replaces manual mechanical threading operations with an automated system that uses electrical contacts to detect thread presence and position. The system automatically monitors each carbon thread through electrical conductivity detection, eliminating manual placement errors while handling the high number of threads efficiently.
Solution Approach 2:
The system enables self-monitoring of thread placement and continuity through automated electrical detection. The loom itself detects thread issues without external intervention, allowing real-time correction of placement errors and prevention of breakage through automatic monitoring of each thread's electrical continuity.
2Reliability
If traditional warp preparation methods are used, then threading can be completed, but thread breakage during weaving is difficult to detect
Solution Approach 1:
The patent replaces visual or manual inspection methods with electrical detection systems that continuously monitor thread continuity through conductivity measurements. This automated electrical monitoring system detects breakages instantly without the difficulties of visual inspection, significantly improving reliability.
Solution Approach 2:
The system implements continuous feedback monitoring through electrical contacts that detect thread breakages in real-time. When a breakage occurs, the system immediately receives feedback signal and can stop the loom or alert operators, preventing defective fabric production and enabling prompt intervention.
3Loss of substance
If manual threading operations are performed without monitoring, then the loom can operate continuously, but incorrect placement or breakage results in waste of raw material
Solution Approach 1:
The system performs preliminary detection of thread placement correctness before weaving begins. Electrical contacts verify thread presence and position in advance, allowing correction of errors before they result in material waste during the weaving process.
Solution Approach 2:
The automated monitoring system provides continuous feedback during weaving operations, detecting breakages and placement errors in real-time. This immediate detection prevents continued production with defective threads, minimizing raw material waste by stopping the process before significant loss occurs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively detects and corrects thread placement errors and breakages in real-time, ensuring the mechanical integrity of the fibrous reinforcement and minimizing material waste by automatically controlling the loom in response to detected issues.
Implementation Method 1
each pair of first and second contacts of a plurality of pairs of first and second electrical contacts being connected to an open-circuit detection circuit
Data Source
AI summary
A weaving installation (400) comprises a loom (100) for making a woven texture by weaving between a plurality of threads, at least part of the plurality of threads being carbon threads (210, 211, 212, 213, 214, 215), the carbon threads each being individually stored on one bobbin of a plurality of carbon thread storage bobbins (220, 221, 222, 223, 224, 225) present upstream of the loom. The installation further comprises a plurality of pairs of first and second electrical contacts (301, 302; 303, 304; 305, 306; 307, 308; 309, 310; 311, 312) present between the storage bobbins (220, 221, 222, 223, 224, 225) and the loom (100). Each pair of first and second electrical contacts is present in the path of a carbon thread, the first and second contacts of each pair being intended to be in electrical contact with a given carbon thread. The contacts of each pair of first and second contacts are further connected to an open-circuit detection circuit (230).