Motor-Driven Thread Tension Apparatus for Sewing Machines
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Solution Overview
Problem
Existing thread tension systems for sewing machines are difficult to operate and adjust, leading to inconsistent thread delivery, tangling, and irregular stitches due to varying machine speeds and thread angles.
Innovation Solution
A thread tension apparatus with a motor-connected thread cone holder and guide, featuring adjustable components and a motor controller to apply tension in a controlled direction, aligning thread with an 'S' pattern and using vertical and horizontal channels to manage thread movement and reduce angular stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a mechanical thread tension device is used, then thread tension can be applied, but the device becomes difficult to operate and adjust
Solution Approach 1:
The patent replaces complex mechanical tensioning devices with a motor-driven system. The motor (28) rotates the thread cone holder (12) to unwind thread, eliminating the need for mechanical tension devices. The motor controller (26) electronically adjusts tension parameters, making the system easier to operate and adjust while maintaining controlled thread tension.
Solution Approach 2:
The patent introduces a motor as an intermediary between the thread cone holder and the sewing machine. Instead of direct mechanical contact between the thread cone and tension devices, the motor mediates the thread delivery process by controlling rotation and tension through electronic signals from the motor controller.
2Device complexity
If thread is simply placed on a spindle and pulled by the sewing machine, then the system is simple, but thread hunches and tangles due to varying speeds
Solution Approach 1:
The patent implements feedback control through the motor controller (26) which receives signals from the sewing machine's speed sensor (38). The controller adjusts the motor's rotation speed to match the sewing machine's varying speeds, preventing thread hunching and tangling while maintaining system simplicity.
Solution Approach 2:
The patent makes the thread delivery system dynamic by enabling the motor speed to vary in real-time according to the sewing machine's operational speed. This dynamic adjustment ensures consistent thread delivery without tangling while keeping the overall system structure simple.
3Device complexity
If thread leaves the cone at varying angles as it unwraps, then thread delivery is simple, but stitches vary in unacceptable ways
Solution Approach 1:
The patent uses a conical thread holder geometry where thread unwinds from the cone surface. The conical shape naturally guides thread at a consistent angle as it unwraps, improving stitch consistency. The thread guide (22) with its curved channel further maintains proper thread alignment and angle throughout the delivery process.
Solution Approach 2:
The patent pre-configures the thread guide (22) and thread holder (12) geometry to establish the correct thread angle before thread delivery begins. This preliminary geometric arrangement ensures consistent thread orientation and angle throughout the unwinding process, eliminating stitch variation.
4Reliability
If the thread cone holder is rotated to apply tension in the opposite direction, then controlled thread delivery is achieved, but the system complexity increases
Solution Approach 1:
The patent replaces complex mechanical tensioning mechanisms with an electric motor system. The motor controller (26) electronically manages the motor (28) to rotate the thread cone holder (12) in the opposite direction to apply controlled tension, achieving reliable thread delivery without the complexity of mechanical tension devices.
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 system ensures predictable and adjustable thread delivery, reducing tangling and variability in stitches, making it easier to use and adaptable to different machines and thread types.
Implementation Method 1
a motor controller operably connected with the motor, wherein the motor controller operates the motor to turn the thread cone holder such that thread is drawn in a second direction opposite from the machine first direction such that tension is applied to the thread
Data Source
AI summary
A thread tension apparatus and method consists of a thread cone holder configured to hold thread where the thread cone holder is connected to a motor. A thread guide is provided where the thread guide includes a thread channel such that the thread guide directs thread to a machine where the machine draws thread in first direction. A motor controller is connected with the motor, where the motor controller operates the motor to turn the thread cone holder such that thread is drawn in a second direction opposite from the machine first direction such that tension is applied to the thread as thread is drawn to the machine.