Optical Thread Sensor with Transparent Guide for Contactless Monitoring
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Solution Overview
Problem
Existing thread or yarn monitoring technologies face challenges such as the need for physical contact, sensitivity to vibrations and noise, inability to monitor conductive threads, and sensitivity to dirt and electrical fields, which limit their applicability and accuracy.
Innovation Solution
An optical sensor device using infrared light transmitters and receivers, combined with a light-transparent guide that prevents dirt accumulation and ensures continuous monitoring without contact, offering a large sensitive area for two-dimensional analysis and flexibility in thread guidance, capable of operating under severe conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If piezoelectric sensor devices are used to monitor thread or yarn, then the device is insensitive to dirt and yarn residues, but physical contact is required which can tear the thread or modify tension characteristics
Solution Approach 1:
The patent replaces mechanical contact-based piezoelectric sensing with an optical sensing system using light transmitters and receivers. The optical beam passes through the thread without physical contact, eliminating mechanical damage while maintaining monitoring capability through detection of light intensity variations caused by thread properties
Solution Approach 2:
The patent introduces an optical beam as an intermediary between the monitoring system and the thread. The light acts as a non-contact mediator that interacts with the thread's optical properties (absorption, transmission) to provide monitoring information without requiring direct physical contact that could damage the thread
2Ease of operation
If capacitive sensor devices are used to monitor thread or yarn, then contactless monitoring is achieved, but conductive threads and moist yarns cannot be monitored due to short-circuiting the dielectric
Solution Approach 1:
The patent replaces electrical capacitive sensing with optical sensing, substituting electromagnetic field-based measurement with light-based measurement. This allows monitoring of conductive and moist threads that would short-circuit electrical fields, while maintaining contactless operation through optical transmission and absorption measurements
Solution Approach 2:
The patent changes the measurement parameter from electrical capacitance (sensitive to conductivity) to optical transmission/absorption characteristics. By measuring how the thread interacts with light rather than electrical fields, the system can monitor conductive and moist threads that would otherwise short-circuit the dielectric
3Adaptability or versatility
If optical sensor devices are used to monitor thread or yarn, then any type of thread can be monitored without contact, but the device is sensitive to dirt and residues on the receiver and transmitter
Solution Approach 1:
The patent applies different functional properties to different parts of the optical system. The transmitter and receiver are positioned and oriented specifically to create a measurement beam path that is less susceptible to dirt accumulation, with components arranged to minimize surface area exposed to contaminant deposition while maintaining optical functionality
4Measurement precision
If piezoelectric ceramic is used for vibration detection, then thread sliding state can be detected, but intense vibrations or noises can simulate thread conditions and prevent accurate breakage detection
Solution Approach 1:
The patent replaces mechanical vibration-based detection with optical detection methods. By measuring light transmission and absorption characteristics rather than mechanical vibrations, the system avoids false signals from intense vibrations and noises while maintaining ability to detect thread conditions through optical property changes
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 device effectively monitors any type of thread or yarn, including conductive ones, without contact, while being insensitive to dirt, vibrations, and electrical fields, providing reliable and flexible monitoring with enhanced durability and accuracy.
Implementation Method 1
two infrared light transmitters and a receiver
Implementation Method 2
a receiver element which can be a photodiode, phototransistor, a PSD
Data Source
AI summary
A device for the optical analysis, including two-dimensional, of a thread or yarn (F) fed to a textile machine, said device comprising at least one light emitter element (3, 4) and at least one receiver element (5), said emitter element (3, 4) generating a light signal which strikes said thread (F) before being sensed by the receiver element (5) which, based on this sensing, defines a characteristic of the thread (F) such as its movement or its stoppage, a dimensional defect or another dimensional characteristic, between said light emitter element (3, 4) and said receiver element (5), there being interposed light transparent means (6) which are encountered by the light signal after it has interacted with the thread (F), and which act as a thread guide.