Circular Loom Partial Heald Ceramic Inserts
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Solution Overview
Problem
Conventional circular looms face issues with high friction between heald elements and warp threads at high operating speeds, leading to complex thread movements and require structural reinforcement for minimal maintenance, especially in producing doup fabrics with lateral displacement systems.
Innovation Solution
The invention employs a circular loom with a partial heald assembly featuring ceramic inserts in thread eyes and a metallic swivel bush to reduce friction, along with a swing control cam system for high-speed operation, using a combination of metallic and plastic components for durability and reduced maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional healds with lateral displacement mechanisms are used, then doup fabric can be produced, but friction between heald elements and warp threads increases at high operating speeds
Solution Approach 1:
The patent changes the material parameter of the thread eyes from conventional materials to ceramic material, which has superior friction-reducing properties. This parameter change allows the loom to operate at high speeds without the friction problems that plague conventional healds, directly resolving the contradiction between speed and friction.
Solution Approach 2:
The patent employs composite construction by inserting ceramic material into the thread eyes of the heald assembly. This composite approach combines the structural integrity of the heald framework with the low-friction properties of ceramic, enabling high-speed operation while minimizing friction between the heald elements and warp threads.
2Strength
If lateral displacement system is reinforced for high speed operation, then structural strength improves, but maintenance requirements increase
Solution Approach 1:
The patent segments the heald assembly into modular components, particularly making the ceramic inserts removable and replaceable. This segmentation allows the structural framework to remain strong and reinforced for high-speed operation, while the wear-prone ceramic inserts can be easily replaced without dismantling the entire structure, thereby reducing maintenance complexity.
Solution Approach 2:
The patent applies the principle of replaceable wear components by designing the ceramic inserts as removable elements that can be replaced when worn. This allows the expensive and complex reinforced structural framework to remain in place, while only the relatively simple and inexpensive ceramic inserts need periodic replacement, significantly easing maintenance requirements.
3Object-affected harmful factors
If ceramic inserts are provided in thread eyes, then friction is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent segments the thread eye into two parts: the base structure (which can be conventionally manufactured) and the ceramic insert (which provides friction reduction). This segmentation allows each component to be manufactured using appropriate processes, then assembled together, avoiding the need for complex ceramic manufacturing while still achieving the friction-reduction benefit.
Solution Approach 2:
The patent introduces the ceramic insert as an intermediary component between the heald framework and the warp threads. This intermediary serves the dual purpose of reducing friction (solving the harmful factor) while being a discrete, replaceable component that simplifies the overall manufacturing process compared to integrating ceramic directly into the heald structure.
4Productivity
If high-speed operation is achieved, then productivity increases, but component lifespan decreases
Solution Approach 1:
The patent changes the material parameter of the thread eyes to ceramic, which has superior wear resistance and friction-reducing properties. This allows the loom to operate at high speeds (increasing productivity) without the accelerated wear that would normally decrease component lifespan, thus resolving the contradiction between productivity and durability.
Solution Approach 2:
The patent designs the ceramic inserts as replaceable components that can withstand high-speed operation for extended periods. When they do wear out, they can be easily replaced without replacing the entire heald assembly, allowing sustained high-productivity operation while managing component lifespan through economical replacement rather than replacement of entire systems.
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 enables high-speed production of doup fabric with reduced maintenance, increasing production rates by 15-40% and component lifespan by 10-18 times compared to conventional methods.
Implementation Method 1
the eyes (3) are provided with a ceramic insert (3A)... to cope with the high operating speeds and which involve complex movements of the threads, and the friction generated therefrom
Implementation Method 2
The lateral movement needed to create the doup fabric (F) facilitated by a swing control cam (6B) that pushes the swing control cam roller (6A) against the torsion spring (13) mounted with swivel bush (12) resulting in the swinging motion of swivel arm (11)
Implementation Method 3
a torsion spring (13) mounted with swivel bush (12) resulting in the swinging motion of swivel arm (11)
Implementation Method 4
the swivel bush (12) is made of metallic material... the lateral displacement system for the partial heald that is able to operate at a high speed of the modern doup looms with minimal maintenance
Data Source
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AI summary
A circular loom to manufacture doup fabric (F) operating at achieve high speed weaving is disclosed. Conventional looms are faced with problems of undesirable friction at such speeds. The loom comprises a partial healds belt assembly which facilitates displacement of the interacting warp threads is provided on the loom. The warp threads of at least one of the pair of partial healds (4, 5), which are provided with thread eyes (3) through which the threads pass, are guided freely by thread guide means to bring about the shedding, and, on the other partial heald, to bring about a side change. In one aspect of the invention, the eyes (3) are provided with a ceramic insert (3A). The lateral movement needed to create the doup fabric (F) is facilitated by a swing control cam (6B) uses a swivel bush (12) to aid the swinging motion of swivel arm (11). As an aspect of the invention, the swivel bush (12) is made of metallic material.