Non-stop Tying-in Process for Textile Looms
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Solution Overview
Problem
The weaving process in textile production is bottlenecked by frequent stoppages due to yarn breaks and style changes, which significantly reduces efficiency and productivity, as existing methods require stopping the loom for tying-in and replacing warp beams.
Innovation Solution
A non-stop tying-in process utilizing a warp accumulator that maintains warp yarn tension and feed, allowing continuous operation by creating a reservoir of warp yarn sheet, enabling the loom to run without interruption during the tying-in process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the loom is stopped for tying-in when the warp beam runs out, then the tying-in process can be performed to continue the same fabric, but the weaving efficiency and productivity are significantly reduced due to process interruption
Solution Approach 1:
The patent applies preliminary action by creating a warp sheet tail of sufficient length during the warping process, before the actual weaving begins. This pre-prepared tail allows the loom to continue weaving without stopping when the main warp beam is exhausted, as the tail can be tied to a new warp beam and continue feeding the loom. The tail length is specifically calculated to provide enough time for the tying-in operation while maintaining continuous production.
Solution Approach 2:
The warp sheet tail acts as an intermediary element between the exhausted warp beam and the new warp beam. Instead of directly connecting the two beams, the tail serves as a buffer and transition medium that can be gradually consumed during the tying-in process, allowing the loom to operate continuously without interruption.
2Productivity
If the warp beam is replaced when it runs out, then a new warp beam can be supplied to continue production, but the process must be stopped for beam replacement and tying-in operations
Solution Approach 1:
The patent applies preliminary action by preparing the warp sheet tail in advance during warping, and by positioning the new warp beam and tying-in machine before the actual beam replacement is needed. This pre-positioning allows the transition to occur seamlessly without stopping the loom, as all necessary components are ready before the old beam is exhausted.
Solution Approach 2:
The patent maintains continuity of useful action by ensuring the loom never stops during the beam replacement process. The warp sheet tail is designed to bridge the transition period, and the tying-in machine is positioned to operate simultaneously with the loom's continuous operation, eliminating any idle time during beam replacement.
3Reliability
If a long warp sheet tail is created to enable non-stop tying-in, then the loom can run without interruption, but the warping process becomes more complex and time-consuming
Solution Approach 1:
The patent applies parameter changes by optimizing the warp sheet tail length to a specific range (at least 10% of the total warp sheet length, preferably 15-20%). This parameter optimization ensures the tail is long enough to enable non-stop tying-in but not so long as to excessively complicate the warping process. The tension parameters during warping are also adjusted to ensure the tail maintains proper tension without requiring additional complex control mechanisms.
Data Source
AI summary
Various examples are provided for non-stop tying-in process for weaving of textiles. In one example, a method for non-stop tying-in of loom warps during operation of a loom includes providing free ends of a replacement warp sheet and a warp sheet tail to the tying-in machine during the operation of the loom, where the warp sheet tail is provided through a warp accumulator; accumulating the warp sheet tail in the warp accumulator during tying-in of the free ends; supplying at least a portion of the warp sheet tail accumulated by the warp accumulator to the loom after being released from a warp beam; removing the tied-in warp sheet tail and replacement warp sheet from the warp accumulator; and supplying the replacement warp sheet to the loom during its operation.