Distance Fabric Weaving via Electromagnetic Manipulating Bar
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Solution Overview
Problem
Existing methods for forming distance fabrics with inter-yarns are inefficient, requiring manual intervention and resulting in low productivity, with issues such as loose inter-yarn loops and relative movement of outer fabrics during winding, due to the complexity of releasing warp threads and maintaining tension during the weaving process.
Innovation Solution
A method using two warp systems where one forms binding threads by pulling binding warp threads into the gap between outer fabrics using a manipulating bar with electromagnets, synchronized with the weaving machine's motion, to create loops of binding threads with selvedges that close the hollow part, ensuring stability and efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a movable back rest is used to release the warp for pulling the inter-yarns, then the desired length of the warp yarns can be released, but the device complexity increases and it is difficult to implement on the weaving machine
Solution Approach 1:
The patent extracts the back rest mechanism from the weaving machine by using a separate manipulating bar that is inserted into the shed from outside. This allows the warp release function to be performed without integrating a complex movable back rest into the machine structure, thereby reducing device complexity while maintaining operational capability.
Solution Approach 2:
The patent introduces a manipulating bar as an intermediary tool that performs the warp release function. Instead of using a complex movable back rest integrated into the machine, the manipulating bar serves as a simple external mediator that can be inserted into the shed to release the binding warp threads, simplifying the overall system.
2Ease of operation
If the raising means moves from the shed forward between the two outer fabrics to pull the inter-yarns, then the inter-yarns can be formed, but the productivity decreases due to frequent interruptions of the weaving process
Solution Approach 1:
The patent applies preliminary action by crossing the binding warp threads in the shed area before the actual pulling operation. This preparation step is performed while the weaving process is still running, and only when the crossed threads are ready does the manipulating bar insert to pull them, minimizing interruptions and maintaining higher productivity.
Solution Approach 2:
The patent maintains continuity of useful action by allowing the ground warp threads to continue weaving outer fabrics while the binding warp threads are being prepared and pulled. The two warp systems operate semi-independently, with the binding warp pulling operations integrated into the continuous weaving process rather than completely interrupting it.
3Ease of operation
If manual intervention is used to insert and pull the inter-yarns raising means, then the process can be performed, but the productivity is low and service personnel are required
Solution Approach 1:
The patent implements self-service by designing the manipulating bar with electromagnets that can automatically grasp and pull the binding warp threads without manual intervention. The bar is inserted into the shed, the electromagnets activate to capture the crossed binding warp threads, and the bar automatically pulls them through to form loops, eliminating the need for service personnel and enabling automatic production.
Solution Approach 2:
The patent replaces manual mechanical operations with an electromechanical system. The manipulating bar equipped with electromagnets substitutes for manual hands and tools, using electromagnetic force to grasp and pull the binding warp threads automatically, thereby increasing productivity and eliminating the need for service personnel.
4Strength
If the outer fabrics are thick, then the distance fabric has good cushioning properties, but the outer fabrics may move relative to each other during winding
Solution Approach 1:
The patent applies preliminary action by forming selvedges at the edges of the hollow part during the weaving process. These selvedges are created in advance to close the hollow part and prevent the outer fabrics from moving relative to each other during subsequent winding operations, while still allowing the thick fabrics to provide cushioning properties.
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 approach enables automatic formation of distance fabrics with improved productivity, maintaining warp tension and preventing loose inter-yarns, allowing for efficient winding and reducing the need for manual intervention, resulting in a more stable and efficient weaving process.
Implementation Method 1
a manipulating bar (71) of the means (7) for pulling the binding warp threads (2) into the gap (T0) between the outer fabrics (T1, T2) is provided with at least two electromagnets (72)
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The present invention relates to a distance fabric including two outer fabrics (T1, T2) and a plurality of binding threads (200) connected to the outer fabrics (T1, T2) and arranged between the outer fabrics (T1, T2), wherein the outer fabrics (T1, T2) constitute a hollow part (TA) of the distance fabric filled with loops of binding threads (200) and are on both sides terminated by selvedges (TB), which are at the edges mutually connected by the outer selvedges (TC) closing the cavity of the distance fabric (T). The invention further relates to a method of forming a distance fabric, in which during the interruption of weaving after the crossing of binding warp threads (2) in a shed (P), a pulling means of the binding warp threads (2) is inserted into the shed (P) and, after the formation of the loops of binding threads (200), is displaced into a gap (TO) between the upper outer fabric (T1) and the lower outer fabric (T2) by one half of the length of the binding threads (200) in the fabric take-up motion direction and the weaving cycle is started and after a pre-set number of picked and woven wefts (5) the weaving cycle is interrupted and the pulling means of the binding warp threads (2) returns into the shed (P), moving against the fabric take-up motion, whereupon the pulling means of the binding warp threads (2) is taken out from the shed (P) on one side and after the crossing of the binding warp threads (2) in the shed (P), manipulating bar (71) of the means (7) for pulling out the binding warp threads (2) is reinserted into the shed (P). In addition, the present invention relates to a weaving machine for performing this method.