Electromagnetic Weft Brake Lever Mechanism for High-Speed Looms
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Solution Overview
Problem
Existing controlled thread brakes in weaving machines have slow reaction times and high manufacturing costs, making them unsuitable for high-speed weaving machines and difficult to control with high shot numbers.
Innovation Solution
A thread brake design featuring a flexible brake band, a stationary brake body, an electromagnet, and a rotatable lever that allows for quick braking and adjustable force, with optional additional electromagnets and spring elements for enhanced control and low production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a servomotor is used to control the brake body lifting movement, then the braking force and timing can be controlled, but the reaction time becomes slow (30 ms or more) and manufacturing cost increases
Solution Approach 1:
The patent replaces the servomotor (electromechanical system) with an electromagnet (electromagnetic system) that directly actuates the brake band. This substitution eliminates the mechanical conversion steps and reduces reaction time to under 10 ms while maintaining braking force control through electromagnetic force adjustment.
Solution Approach 2:
The patent extracts and eliminates the servomotor component from the brake system, retaining only the essential electromagnetic actuation mechanism. This simplification removes the source of delay while preserving the controlled braking function through direct electromagnetic actuation of the brake band.
2Ease of operation
If a servomotor is used to control the brake body lifting movement, then the braking force and timing can be controlled, but the manufacturing cost becomes high
Solution Approach 1:
The patent replaces the expensive servomotor with a cost-effective electromagnet system. The electromagnet uses simple electromagnetic components and standard mechanical parts, significantly reducing manufacturing cost while providing the required controlled braking function through electromagnetic force adjustment.
Solution Approach 2:
The patent substitutes the complex servomotor mechanism with a simpler electromagnetic actuation system. This replacement maintains braking force control capability while using cheaper, more straightforward components that are easier to manufacture and assemble.
3Object-generated harmful factors
If the brake band is lifted 1 to 2 mm during braking, then a self-cleaning effect is achieved, but the braking force must be precisely controlled
Solution Approach 1:
The patent employs dynamic control of the electromagnet to lift the brake band by 1 to 2 mm during braking, creating a self-cleaning effect that removes brake bath contamination. The electromagnetic force is dynamically adjusted to maintain this lifting distance while providing sufficient braking force, achieving both cleaning and braking functions simultaneously.
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 provides a fast-reacting thread brake with response times under 10 ms, enabling precise control over braking force and suitability for high-speed weaving machines, along with reduced production costs and a wide range of yarn compatibility.
Implementation Method 1
an electromagnet and a rotatable or tiltable lever which can be moved by means of the electromagnet and which is operatively connected to the brake band in order to exert a pull in the longitudinal direction of the brake band
Implementation Method 2
the thread brake includes a spring element for releasing the thread brake, for example a tension or compression spring that acts on the lever and/or a torsion spring at the pivot point of the lever
Implementation Method 3
apply or press the same to brake the weft thread on the brake body
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
The controlled thread brake has a brake band (3) and a brake body (2). The thread brake (1) has an electromagnet (6, 6') and a rotatable or rocking lever (4) which can be moved by the electromagnet and which is operationally connected to the brake band in order to exert a pulling force in the longitudinal direction of the brake band and to place it against the brake body for braking a weft thread. An independent claim is included for a weaving machine.