Optical Yarn Sensor Bar for Tension and Breakage Detection
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Solution Overview
Problem
Existing textile machine monitoring systems struggle to accurately and reliably measure yarn tension and breakage, often relying on mechanical members that are prone to error and breakage, and are influenced by environmental conditions like humidity.
Innovation Solution
A sensing system using a sensor bar with multiple eyelets, each equipped with optical sensors that transmit data to a microprocessor for real-time analysis, allowing for the detection of yarn tension and breakage through continuous monitoring and comparison to predefined control limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical members are used to monitor yarn tension and breakage, then the system can detect yarn conditions, but the mechanical members are prone to error and breakage, reducing reliability
Solution Approach 1:
The patent replaces mechanical monitoring members with optical sensors that use light to detect yarn tension and breakage. The optical sensor system eliminates mechanical contact points that were previously prone to failure, substituting a non-contact optical measurement system instead.
Solution Approach 2:
The patent introduces an optical intermediary (light) as the medium between the yarn and the detection system. Instead of direct mechanical contact, light serves as the intermediary carrier that interacts with the yarn and conveys information about its tension and continuity state to the sensor.
2Measurement precision
If piezoelectric sensors are used to monitor yarn tension, then tension can be detected, but the sensors are less accurate and more prone to environmental effects such as humidity
Solution Approach 1:
The patent substitutes piezoelectric sensors with optical sensors that measure yarn tension through light interaction rather than electrical charge generation. This replacement eliminates the environmental sensitivity of piezoelectric materials to humidity while maintaining measurement capability.
Solution Approach 2:
The patent changes the measurement parameter from electrical (piezoelectric charge) to optical (light transmission or reflection properties). By measuring changes in light characteristics rather than electrical signals, the system achieves greater precision and environmental stability.
3Reliability
If mechanical members are used to indicate breakage, then breakage can be detected, but the mechanical members are prone to error and require frequent maintenance
Solution Approach 1:
The patent replaces mechanical breakage indicators with optical sensors that detect yarn continuity through light transmission. This substitution eliminates mechanical wear and failure modes, significantly improving reliability and reducing maintenance requirements.
Solution Approach 2:
The patent creates an optical copy or representation of the yarn's physical state through light interaction. Instead of relying on mechanical replicas or indicators that can fail, the system uses light to create a faithful representation of the yarn's continuity and tension state.
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 provides accurate and reliable monitoring of yarn tension and breakage, enabling timely intervention to prevent yarn breakage and ensure consistent product quality, while being resistant to environmental influences.
Implementation Method 1
A sensor bar contains multiple eyelets to receive the yarn, each of the multiple eyelets containing at least one sensor, preferably optical. The sensors can be reflective or transmissive with equal accuracy.
Data Source
AI summary
A yarn monitoring system for textile machines uses sensors to indicate yarn over-tensioning and breakage. The sensors within eyelets monitor the passage of the yarn and send new signals to the controller. The eyelets, each with a sensor, are within a body containing a circuit board which is in constant communication with the sensors and software contained within a controller. The controller is in constant communication with the textile machine. The software contains an acceptable operational zone for new signal data and control limits establishing the lowest new signal data reading permitted for the yarn. The user establishes set points for the control limits, and reaching these set points is an indication of over-tension or yarn breakage. To prevent unnecessary shut down of the machine, the software averages the new signal data and, when the new signal average remains out of the established set points, initiates communication to the textile machine.