Whipping Tail Detection in Fiber Winding via Optical Timing
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Solution Overview
Problem
During fiber winding, uncontrolled whipping tails can cause significant damage to the wound fiber and pose safety hazards due to the rapid rotation of the take-up spool, as existing technologies lack effective methods for timely detection and prevention of fiber breaks.
Innovation Solution
A method and apparatus that utilize a light beam to detect whipping tails by converting intensity dips into digital electrical signals, comparing the timing of these signals to the spool's rotational speed to identify and prevent damage, incorporating a whip shield and a controller to manage the detection and potential stop of the spool rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the spool rotates at high speed to maintain productivity, then fiber winding efficiency is improved, but the risk of fiber breakage and whipping tail formation increases
Solution Approach 1:
The optical detection system is set up in advance to monitor the fiber winding process. The light beam is positioned to intersect the fiber path before breaking occurs, and the system continuously scans for disruptions. When a fiber break is detected through light beam interruption, the system immediately triggers a spool stop, preventing whipping tail formation and protecting both the fiber and operators.
2Object-affected harmful factors
If the spool rotation is stopped immediately to prevent whipping tail damage, then fiber safety is improved, but production time is lost
Solution Approach 1:
The optical detection system provides real-time feedback on the fiber's condition during winding. The light beam continuously monitors the fiber path, and any interruption or anomaly is immediately detected and fed back to the control system. This enables the spool to be stopped only when necessary (upon actual fiber break detection), minimizing unnecessary production interruptions while ensuring safety when breaks occur.
3Difficulty of detecting and measuring
If a light beam detection system is implemented to detect whipping tails, then detection capability is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical detection systems with a simple optical detection system. Instead of using mechanical sensors or contact-based detection methods, the invention uses a light beam that passes through or near the fiber path. When the fiber breaks and a whipping tail forms, it interrupts or alters the light beam, providing a clear detection signal. This optical approach is simpler, has no moving parts, and provides reliable detection without adding significant complexity to the winding system.
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
Effectively detects whipping tails, preventing damage to the wound fiber and ensuring safety by comparing the timing of light beam intensity dips to the spool's rotational speed, allowing for immediate action to stop the spool and prevent further damage.
Implementation Method 1
directing a light beam so that the whipping tail at least partially intersects the light beam either periodically or quasi-periodically due to the rotating spool to create intensity dips in the light beam
Data Source
Figure 1A
Figure 1B
Figure 1C~1D
AI summary
The apparatus and methods disclosed herein are directed to detecting the presence of a whipping tail when using a fiber winding system (10) to wind a fiber (70) onto a rotating spool (20). The fiber (70) is guided onto the rotating spool (20) through a containment region (80) between the spool (20) and a whip shield (100) to create the wound fiber. The whipping tail (72W) outwardly extends from the wound fiber (70) and periodically or quasi-periodically passes through a light beam (152) to create a series intensity dips in the light beam, thereby forming a modulated light beam. The modulated light beam (152M) is converted into a digital electrical signal (SD) made up of electrical pulses (PV) having a timing defined by the intensity dips (Dl). The measured timing of the electrical pulses (PV) is compared to an estimated timing based on the rotating spool (20) to ascertain the presence of a whipping tail (72W).