Optical Yarn Tension Sensor with Motion Analysis
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Solution Overview
Problem
Current textile machine monitoring systems for yarn tension and breakage are often mechanical and prone to errors, with optical sensors being less accurate and sensitive to environmental conditions, making it difficult to accurately monitor tension without mechanical members which can break.
Innovation Solution
A sensing system using optical sensors integrated into a sensor bar with multiple eyelets, connected to a microprocessor that analyzes yarn motion and tension data in real-time, allowing for precise detection of over-tensioned or broken yarn, and automatically controlling the textile machine to prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical sensors are used to monitor yarn tension and breakage, then the system is simple and reliable, but the mechanical members are prone to error and breakage
Solution Approach 1:
The patent replaces mechanical sensors with optical sensors that use light to detect yarn tension and breakage. The optical sensor system includes a light source, optical fiber, and detector that measure light intensity changes caused by yarn motion, eliminating the need for mechanical contact components that are prone to wear and failure.
2Ease of operation
If optical sensors are used to monitor yarn breakage, then the system avoids mechanical contact, but the sensors are less accurate and more sensitive to environmental conditions
Solution Approach 1:
The patent introduces yarn motion as an intermediary parameter that correlates with tension. Instead of directly measuring tension with optical sensors, the system detects yarn motion (vibration frequency and amplitude) which is influenced by tension forces, providing indirect but accurate tension monitoring without mechanical contact.
Solution Approach 2:
The system monitors changes in yarn motion parameters (frequency, amplitude, velocity) that occur in response to tension variations. By tracking these dynamic parameter changes rather than static light intensity, the system achieves accurate tension measurement while maintaining non-contact operation.
3Loss of time
If mechanical members are used to detect yarn breakage, then the detection is direct, but the machine stops only after yarn breaks causing production loss
Solution Approach 1:
The patent implements preliminary detection of yarn breakage by monitoring for the complete absence of yarn motion signals. When the optical sensor detects no yarn movement over a predetermined time period, the system immediately triggers an alarm and stops the machine, preventing yarn breakage and associated production losses before they occur.
Solution Approach 2:
The system continuously monitors yarn motion parameters and provides real-time feedback to the control system. When abnormal patterns indicating potential breakage are detected (such as cessation of motion or unusual vibration patterns), the feedback loop immediately triggers corrective action, enabling proactive prevention of yarn failure.
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, reducing production downtime by immediately detecting and responding to over-tensioned or broken yarn, thereby improving product quality and machine efficiency.
Implementation Method 1
each of the multiple eyelets containing at least one sensor, preferably optical
Data Source
Figure 1
Figure 2
Figure 2A~2B
AI summary
A yarn monitoring system for textile machines uses sensors (50, 60) to indicate yarn over-tensioning and breakage. The sensors (50, 60) within eyelets (32) monitor the passage of the yarn (16) and send raw signals to the controller (70). The eyelets (32), each with a sensor (50, 60), are within a body containing a circuit board (31) which is in constant communication with the sensors (50, 60) and software contained within a controller (70). The controller (70) is in constant communication with the textile machine. The software contains an acceptable operational zone for raw signal data and control limits establishing the lowest raw signal data reading permitted for the yarn. The user establishes set points for the control limits, and reaching these set points is an indication over-tension or yarn breakage. To prevent unnecessary shut down of the machine, the software averages the raw signal data and, when the raw signal average remains out of the established set points, initiates communication to the textile machine.