Compact Reflection Optic Sensors for Weft Feeder Thread Detection
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Solution Overview
Problem
Weft feeders of the first category face challenges with complex optic systems requiring precise positioning and protection from dust, leading to installation difficulties and increased bulk, especially when multiple units are used in weaving looms.
Innovation Solution
A compact group of reflection optic sensors using SMT-type devices with horizontal optic axes and a mirror reflection system, allowing for automated mounting and reduced thickness, while being dust- and oil-proof.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If reflection optic sensors are used in weft feeders with support arm configuration, then the construction simplicity is improved, but the optic system complexity increases requiring precise positioning and dust protection
Solution Approach 1:
The patent combines the emitting sensor, receiving sensor, and reflecting surface into a single integrated support arm assembly. This merging eliminates the need for separate precise positioning of multiple components and reduces the overall optic system complexity while maintaining construction simplicity.
Solution Approach 2:
The patent introduces a reflecting surface as an intermediary element that enables the optic sensors to detect thread presence indirectly. This mediator allows the sensors to be positioned on the support arm rather than requiring direct line-of-sight positioning, simplifying the overall construction while maintaining detection accuracy.
2Reliability
If reflection optic sensors are used in weft feeders, then the detection capability is improved, but the bulk and installation complexity increase
Solution Approach 1:
The patent segments the optic sensor system into modular components (emitting sensor, receiving sensor, reflecting surface) that are pre-assembled on the support arm. This segmentation allows for easier installation and replacement while maintaining detection capability, as the modular unit can be installed as a single assembly rather than requiring complex integration of separate components.
3Productivity
If multiple weft feeders are used in weaving looms, then the productivity is improved, but the installation difficulty and space requirements increase
Solution Approach 1:
The patent combines multiple sensor functions into a single support arm assembly, creating a compact unit that can be installed in limited spaces. This merging allows multiple weft feeders to be arranged more closely together in the weaving loom, increasing productivity while reducing installation difficulty and space requirements compared to separate sensor assemblies.
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 more efficient, easy-to-install, and reliable optic sensor system that is less prone to soiling and has reduced bulk, enhancing operational simplicity and reliability in weft feeder applications.
Implementation Method 1
the path of the optic radiation between each pair of sensors is obtained through a respective reflecting surface fastened to the lateral surface of the drum which faces said support arm
Data Source
Figure 1A~1C
Figure 2
Figure 3
AI summary
Group of optic sensors (S) in a weft feeder, in particular for weaving looms, comprising one or more pairs of emitting sensors (E) and receiving sensors (R) arranged on a portion of the weft feeder (C) which extends laterally to the drum (T) of the weft feeder whereon the coils of the weft thread are wound, so as to form optic radiation going-paths from each of said emitting sensors (E) to a reflecting surface (9) provided on said drum (T) and optic radiation back-paths, from said reflecting surface (9) to corresponding receiving sensors (R), for detecting the presence/absence of a thread which crosses said paths. The optic sensors (E, R) are of the SMT type and are wired on a printed-circuit board (8) with an optic axis parallel to the plane of said board (8). A first group of total-reflection mirrors (V), one for each pair of emitting/receiving sensors (E, R), is inclined so as to deviate the optic radiation from the plane of the board (8) to a plane perpendicular to or inclined with respect to the same. A second group of partial-reflection mirrors (H), one for each pair of emitting/receiving sensors (E, R), is inclined so as to deviate the optic radiation in the same plane as board 8.