Integrated Rotor-Driven Thread Feeder Design
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Solution Overview
Problem
Existing thread feeders for textile machines are not inexpensive to manufacture, are not compact in structure, and are not reliable in operation, often requiring complex components and multiple bearings.
Innovation Solution
A thread feeder with a compact design featuring a delivery roller that doubles as the rotor, enclosed in a fluid-tight plastic stator housing with an electronically commutated DC electric motor, eliminating the need for additional bearings and using integrated permanent magnets, and a simple plastic roller component produced through injection molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional thread feeder designs are used, then the structure is more robust, but the manufacturing cost increases and the device becomes less compact
Solution Approach 1:
The patent merges the rotor and delivery roller into a single integrated component. The rotor serves dual functions as both the rotating element of the electric motor and the delivery roller that conveys the thread. This eliminates the need for separate components and reduces the overall device complexity while maintaining functional integrity.
Solution Approach 2:
The rotor is designed to perform multiple functions: it acts as the rotating component of the electric motor, the delivery roller for thread conveyance, and the bearing support structure. This multi-functionality reduces the number of parts needed and simplifies the overall device structure, making it more compact and cost-effective to manufacture.
2Reliability
If multiple bearings are used for the delivery roller and rotor, then the reliability improves, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the bearing functions into a single integrated bearing that supports both the rotor and delivery roller. Since the rotor and delivery roller are merged into one component, only one bearing is needed to support the combined structure, reducing the number of moving parts while maintaining operational reliability.
3Object-affected harmful factors
If the stator is not enclosed, then the manufacturing process is simpler, but the susceptibility to moisture and dust increases
Solution Approach 1:
The patent uses a plastic housing to enclose the stator, creating a sealed environment that protects against moisture and dust. The plastic material provides effective sealing while the manufacturing process remains relatively simple, achieving protection without excessive complexity.
4Productivity
If additional components are added to improve functionality, then the performance increases, but the manufacturing cost and device complexity increase
Solution Approach 1:
The rotor delivers threads efficiently through its integrated design that combines motor rotation with direct thread conveyance. This eliminates the need for additional transmission components while maintaining high thread delivery efficiency, as the rotor's rotation directly drives the thread forward without intermediate mechanical elements.
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 results in a thread feeder that is inexpensive to produce, reliable in operation, and easy to replace, with reduced susceptibility to moisture, achieving efficient thread delivery with a compact and cost-effective design.
Implementation Method 1
an electric motor (5) with a stator (7) and a rotor (15), by means of a rotational movement of the rotor (15) due to a mechanical connection between the rotor (15) and the delivery roller (2) delivery roller (2) can be made to rotate
Implementation Method 2
the stator (7) being enclosed in a fluid-tight manner by a plastic stator housing (19) and all stator components (36), apart from the electrical contact elements (13), being completely enclosed and fluid-tight in the plastic of the plastic stator housing (19), in particular overmoulded
Implementation Method 3
a bearing (17) for the delivery roller (2) and the rotor (15)
Data Source
AI summary
The device (1) has a delivery roller (2) comprising a radial outer side (3) to support a thread conveyed by the roller. The roller is brought into rotational movement by a mechanical connection between an injection molded rotor of an electric motor i.e. multiphase electronically commutated direct current motor, and the roller. An injection molded stator is arranged in a plastic stator housing (29) in a fluid-tight manner. The rotor is arranged in a plastic roller component (24) in a fluid-tight manner. A bearing i.e. slide bearing, is provided for the roller and the rotor. Independent claims are also included for the following: (1) a method for operating a thread supplier (2) a method for manufacturing a thread supplier.