Modular Weaving Machine Drive with Servo Segmentation
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Solution Overview
Problem
Existing weaving machines have complex drive systems with heavy components, requiring significant adjustments and limiting flexibility, accessibility, and efficiency, especially in achieving high pick speeds and precise control.
Innovation Solution
The drive system uses two AC servo motors for synchronized rotary motion, driving a short and lightweight crankshaft, allowing for intermittent operation and minimizing large, heavy components, with modular sections that can be easily adjusted and serviced.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a thick and heavy main shaft with couplings is used to couple all intermediate sections, then mechanical coupling and synchronized rotary motion are achieved, but the machine becomes complex, heavy, and difficult to assemble
Solution Approach 1:
The patent divides the weaving machine into multiple independent intermediate sections (2-25 sections), each with its own localized drive system comprising AC servo motors and reduction gears. This segmentation eliminates the need for a single heavy main shaft spanning the entire machine width, reducing overall complexity while maintaining synchronized motion through electronic control of individual section drives.
Solution Approach 2:
The patent replaces the traditional mechanical coupling system (heavy main shaft with couplings) with an electronically controlled drive system. AC servo motors with electronic synchronization control substitute for the mechanical synchronization achieved through the main shaft, significantly reducing mechanical complexity and component weight.
2Device complexity
If AC servo motors with reduction gears are used for each intermediate section, then component weight and complexity are reduced, but precise control and synchronization become more challenging
Solution Approach 1:
The patent employs AC servo motors which inherently provide feedback control mechanisms. The servo motors include encoders or other position sensing devices that continuously monitor the rotational position and speed of each intermediate section, feeding this information back to the control system to maintain precise synchronization across all sections despite the distributed drive architecture.
Solution Approach 2:
The patent uses identical AC servo motor and reduction gear assemblies in each intermediate section, creating universal, standardized drive units. This standardization simplifies control programming and synchronization, as each section responds to the same control signals in the same manner, making precise coordination easier to achieve and maintain.
3Ease of operation
If modular sections with localized drives are used, then ease of assembly and accessibility are improved, but the number of separate components increases
Solution Approach 1:
The patent segments the weaving machine into modular intermediate sections that can be independently assembled and serviced. Each section contains its own drive components, allowing for localized maintenance and replacement without affecting the entire machine, thereby improving ease of assembly and operation despite the increased number of discrete components.
Solution Approach 2:
The modular design allows individual intermediate sections or drive components to be easily removed, serviced, or replaced independently. If a specific section becomes worn or damaged, it can be discarded or recovered without needing to service the entire machine, improving maintenance efficiency despite the increased component count.
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 solution simplifies the construction and operation of weaving machines, reduces component count, enhances accessibility, and enables higher pick speeds while maintaining precise control, making it easier to standardize and integrate with existing machines.
Implementation Method 1
Each intermediate section is provided with two AC servo motors, which, via their respective reduction gears, jointly drive the crankshaft in said stand in a synchronized rotary motion
Data Source
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AI summary
A weaving machine 1 comprises a lay beam 29 which by means of drive elements is movable between a rear position 29a, in which the introduction of the weft thread into a warp arrangement can be realized, and a front position 29b, in which a beat-up against a beating-up edge 32 of the respective introduced weft thread can be effected. The drive elements comprise two or more crankshaft parts rotatable along the width direction of the weaving machine and according to a common rotational center line 77. These are situated in stands comprising intermediate sections 59, 60, 61 and 62, which respectively also comprise a lay sword 24 which is mounted rotatably on a lay sword shaft 25 and is connected to a connecting rod belonging to the intermediate section. The intermediate section comprises at least one individual motor 66 turning the crankshaft part thereof. The weaving machine 1 comprises or is connected to a control system 64 provided with a rotary motion control unit 65 and arranged to control, via amplifying elements 67, the motors 66 of the intermediate sections for mutual synchronous rotary motion of the crankshaft parts of the various intermediate sections. The control system can comprise a computerized main control system 64 connected to a master motion control unit 65, which in turn is connected to servo amplifiers 67 forming part of the intermediate sections and connected to motors 66 in the form of servo motors provided with reduction gears. Should one wish to increase the synchronization or the coordination of the actions of the modules or intermediate sections upon the lay beam, one or more mechanical shafts 81'-83' with lighter weight and small dimensions can be used. The invention enables substantial weight and space reductions to be made, inter alia by virtue of the fact that a large and heavy shaft with mountings and gearboxes can be avoided.