Rotary Creel Sensor for Bobbin Diameter Measurement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sample warping machines rely heavily on operator monitoring to prevent thread spool depletion, leading to inefficiencies and potential disruptions due to inaccurate thread consumption measurement, especially when producing pattern warps with varying thread lengths.
Innovation Solution
A sensor arrangement with a movable sensor parallel to the axis of rotation allows for precise measurement of bobbin diameters along the axis, enabling accurate determination of thread filling levels and automatic monitoring to prevent spool depletion, utilizing a single non-contact laser sensor and minimizing installation space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If operator monitoring is used to track thread spool depletion, then the machine can operate without automatic sensing systems, but the rotation speed must be kept low and operator dependency increases
Solution Approach 1:
The patent replaces manual operator monitoring with an automated optical sensor system. The sensor arrangement uses optical sensors to detect spool diameter and calculate thread consumption, substituting the mechanical/visual monitoring method with an automated sensing system that provides precise measurements without requiring operator intervention.
Solution Approach 2:
The system enables self-service operation by automatically monitoring thread consumption and alerting operators only when thread depletion is imminent. The sensor arrangement continuously measures spool diameter and calculates remaining thread length, allowing the machine to manage its own thread supply without constant operator attention, thereby improving both precision and operational autonomy.
2Device complexity
If a single sensor is used to measure bobbin diameter, then installation space is minimized and device complexity is reduced, but measurement accuracy along the axis may be insufficient
Solution Approach 1:
The patent employs a movable sensor arrangement that can be positioned at different locations along the bobbin axis. Instead of using multiple fixed sensors, a single sensor is dynamically repositioned to measure bobbin diameter at various axial points, achieving comprehensive measurement coverage while maintaining device simplicity and minimizing installation space requirements.
Solution Approach 2:
The measurement process is segmented into multiple discrete measurement points along the bobbin axis. The single sensor takes sequential measurements at different axial positions, and the system processes these segmented measurements to determine overall thread consumption, thereby achieving accurate three-dimensional measurement with a single sensor.
3Productivity
If high-speed rotation of the rotary creel is maintained, then productivity is improved, but accurate thread consumption measurement becomes more difficult
Solution Approach 1:
The sensor arrangement performs periodic measurements of spool diameter during the rotation cycle. By taking measurements at regular intervals and using the known rotational position, the system accurately determines thread consumption even at high rotation speeds. The periodic measurement approach synchronizes with the creel rotation to capture precise diameter data without reducing warping speed.
Solution Approach 2:
The system implements feedback by continuously monitoring spool diameter and calculating remaining thread length in real-time during high-speed operation. The measurement results are fed back to the control system, which can alert operators or automatically adjust operations based on thread consumption data, maintaining both high productivity and measurement accuracy through closed-loop monitoring.
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
This solution enhances measurement accuracy and reliability, allowing for automatic thread supply management, reducing thread waste, and ensuring continuous operation with minimal disruptions by predicting thread availability and enabling knot-free pattern production.
Implementation Method 1
JP 2004185885A describes a method for measuring the degree of filling of coils, in which a laser beam impinges axially on a coil and the amount of light absorbed by the coil is used as a measure for determining the degree of filling of the coil.
Implementation Method 2
DE 35 27 473 A1 describes a method and a device for determining the filling level of feed bobbins on a spinning or twisting machine, with the diameter of the bobbins being repeatedly scanned. The diameter is determined by moving a light barrier perpendicular to the longitudinal axis of the coil and measuring the interruption of the light barrier.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The creel (5) has carriers (9, 10) rotatably supported to a machine frame around a rotation axis, and a set of reel supports arranged on the carriers. A sensor arrangement is provided for determining a filling level of reels (12, 13) arranged in the reel supports. The sensor arrangement exhibits a sensor that is movable parallel to the rotation axis. The sensor is arranged on a sliding rail, which is arranged at the machine frame. The sensor is designed as a contactlessly operating sensor such as laser sensor. An independent claim is also included for a method for measuring a filling level of reels of a sample warping machine.