Automated Cross-Cord Joining for Continuous Warping
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Solution Overview
Problem
The existing warping process requires manual intervention to connect cross cords, leading to interruptions and inefficiencies, as the warping drum must be stopped to create crosshairs, resulting in lost time and reduced productivity.
Innovation Solution
A warping device with a second cross-cord joining device on the opposite side of the thread path allows for automated connection of cross cords, eliminating the need for manual operation and enabling continuous warping by synchronizing the cross-cord insertion with the warping drum's position to avoid cord accumulations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual intervention is used to connect cross cords, then the joining operation can be performed, but the warping drum must be stopped and operator availability is required, leading to time loss and reduced productivity
Solution Approach 1:
The cross cord joining device is designed to automatically perform the joining operation without requiring manual intervention. The device self-activates when detecting the appropriate position, grabs the cross cords, and completes the joining process autonomously, eliminating the need for operator involvement and continuous drum stopping.
Solution Approach 2:
The manual mechanical operation of stopping the drum and manually joining cross cords is replaced by an automated mechanical system with sensors and actuators. The system uses optical or positional sensors to detect when cross cords are in position, then automatically activates the joining mechanism, replacing the manual mechanical process with an automated control system.
2Manufacturing precision
If the warping drum is stopped to create crosshairs, then the cross cords can be inserted and joined, but time is lost and the warping process is interrupted
Solution Approach 1:
The system performs preliminary detection and positioning actions while the drum is still rotating. Sensors detect the position of cross cords and prepare the joining mechanism in advance, so that when the optimal position is reached, the joining operation can be executed immediately without stopping the drum, thereby maintaining continuous operation while ensuring precise positioning.
Solution Approach 2:
The warping drum continues to rotate continuously throughout the cross cord insertion and joining process. The automated joining device operates synchronously with the drum rotation, performing the joining action at the correct moment without interrupting the rotational motion, thus maintaining the continuity of the warping process.
3Ease of manufacture
If operator intervention is required for cross cord joining, then the operation can be completed, but operator qualification requirements increase and availability is not always guaranteed
Solution Approach 1:
The joining device is designed to autonomously perform the entire cross cord joining operation without human intervention. It automatically detects cross cord positions, activates at the appropriate moment, grabs the cords, and completes the joining process, making the system self-sufficient and eliminating dependency on operator availability or skill level.
Solution Approach 2:
The system incorporates sensors that continuously monitor the position of cross cords and the state of the joining mechanism. This feedback allows the control system to determine when cross cords are in the correct position for joining and when the joining operation has been successfully completed, enabling automatic control without operator involvement.
Data Source
Figure 1a~1d
Figure 2~3
Figure 4~7
AI summary
A warping device comprising a warping drum, a yarn feed path, and a cross-laying device (1) is described, wherein the cross-laying device (1) has a compartment forming device in the yarn feed path and a cross-cord insertion device (8) with which a cross-cord (5, 10) can be inserted into a compartment (4, 9) formed by a divided yarn feed (2, 3). The aim is to enable high productivity of the warping machine. For this purpose, a cross-cord joining device (12, 13) is arranged laterally next to the yarn feed path.