Electromagnetic Manipulating Bar for Distance Fabric Weaving
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Solution Overview
Problem
Manual operation is inefficient and labor-intensive for pulling binding warp yarns out of a shed into a gap between upper and lower outer fabrics during the formation of loops in distance fabric weaving, as it requires multiple operators to manage the pulling bar.
Innovation Solution
A weaving machine system with a manipulating bar coupled to reversible electromagnets and permanent magnets arranged in a Halbach array, made from lightweight high-stiffness materials like carbon composite or titanium, which is overlapped with high-strength stainless steel for enhanced durability and equipped with sensors for reliable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual operation with multiple operators is used to pull binding warp yarns, then the manipulating bar can be controlled, but the process becomes labor-intensive and inefficient
Solution Approach 1:
The patent replaces the manual mechanical system of multiple operators physically pulling the manipulating bar with an automated electromagnet-based system. The electromagnets grasp the manipulating bar and pull it automatically, eliminating the need for human physical effort and manual coordination while significantly improving production efficiency.
Solution Approach 2:
The system achieves self-service automation where the electromagnets and manipulating bar work together as an integrated automated unit. The manipulating bar is equipped with permanent magnets that interact with the electromagnets, creating a self-contained automated pulling mechanism that operates without continuous human intervention.
2Weight of moving object
If a lightweight manipulating bar is used for automated operation, then the electromagnets can easily move it, but the bar may lack sufficient strength and durability
Solution Approach 1:
The patent employs composite construction for the manipulating bar, combining lightweight materials with high-strength materials. The bar consists of a lightweight core (such as aluminum or plastic) overlapped and reinforced with high-strength stainless steel plates, achieving optimal balance between low weight for easy electromagnetic manipulation and high strength for durability and wear resistance.
Solution Approach 2:
The manipulating bar features local quality differentiation where different sections have different properties. The central portion has a lightweight core for ease of movement, while the overlapping high-strength stainless steel plates are positioned at critical areas subject to wear and stress, providing localized reinforcement where needed most.
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
Automates the process of pulling binding warp yarns into the gap between outer fabrics, improving efficiency and reducing operator intervention by using electromagnets to hold and move the manipulating bar, ensuring precise and reliable yarn handling during the weaving process.
Implementation Method 1
a manipulating bar (4) coupleable to at least two electromagnets (5) arranged reversibly displaceably above the upper outer fabric (T1) in the direction of the distance fabric (T) take-up motion and back
Implementation Method 2
the manipulating bar (4) is in places in which it is coupleable to electromagnets provided with permanent magnets arranged in a Halbach array
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a weaving machine system for pulling binding warp yarns (2) out of a shed into a gap (TO) between an upper outer fabric (T1) and a lower outer fabric (T2) of a distance fabric during formation of loops of binding yarns by means of a manipulating bar (4) which is coupleable to at least two electromagnets (5) arranged reversibly displaceably above the upper outer fabric (T1) in the direction of the take-up motion of the distance fabric (T) and back. The manipulating bar (4) is provided with permanent magnets (44) at the points at which it is coupleable to the electromagnets (5), the permanent magnets being arranged in Halbach arrays (440), whereby the electromagnets (5) are in the lower part provided with a sliding part (55) made of non-magnetic material, in which the pole pieces (53 a 54) of the respective electromagnet (5) are terminated.