Pile Loom Start Restriction via Reverse-Rotation Number System
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Solution Overview
Problem
Existing pile loom technologies struggle to prevent pile fabric defects when restarting after a weft-insertion failure, especially when weaving complex pile patterns involving three or more loom cycles, as they require extensive setup and are limited to specific pile patterns, leading to potential operational errors and incomplete weft removal.
Innovation Solution
A start restriction method and device for the pile loom that uses a start reverse-rotation number system, where the same numerical value is assigned to loose and first fast picks, and updated based on rotational angles, to inhibit loom startup until all necessary wefts are removed, ensuring proper alignment for restart within a predetermined angular range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the loom is restarted after a weft-insertion failure during loose picks or first fast pick, then the loom can resume production quickly, but pile fabric defects occur due to insufficient weft removal
Solution Approach 1:
The control device performs preliminary identification of the pile pick type (loose pick or fast pick) and calculates the required number of weft removals before allowing restart. This preliminary action ensures that the correct number of wefts are removed in advance, preventing pile fabric defects while enabling quick restart.
Solution Approach 2:
The control device provides feedback by displaying the identified pile pick type and the required number of weft removals to the operator. This feedback mechanism ensures that the operator understands what actions to take before restart, maintaining fabric quality while enabling efficient production resumption.
2Device complexity
If the control device handles only specific pile patterns (2L-1F or 2L-2F), then the setup is simple, but the device cannot handle complex pile patterns with three or more loose picks
Solution Approach 1:
The control device is designed with universal functionality to handle any pile pattern regardless of the number of loose picks or fast picks. It automatically identifies the current pile pick type and calculates the appropriate number of weft removals, making it adaptable to complex pile patterns while maintaining simple operation.
Solution Approach 2:
The control device dynamically adjusts its behavior based on the detected pile pattern parameters. By changing the operational parameters (number of weft removals required) based on the identified pile pick type, the device can handle diverse pile patterns without requiring complex setup for each pattern.
3Reliability
If extensive setup is required to handle complex pile patterns, then the device can be configured for specific patterns, but the setup time and effort increase significantly
Solution Approach 1:
The control device performs self-configuration by automatically identifying the current pile pick type and determining the required number of weft removals. This self-service capability eliminates the need for extensive manual setup, reducing setup time while ensuring accurate handling of any pile pattern.
Solution Approach 2:
The control device performs preliminary identification and calculation of weft removal requirements automatically when a weft-insertion failure occurs. This preliminary action eliminates the need for time-consuming manual setup, as the device is already prepared to guide the operator through the correct recovery procedure.
4Ease of operation
If the operator manually removes wefts without automated guidance, then the operation is simple, but operational errors occur leading to incomplete weft removal
Solution Approach 1:
The control device provides clear feedback to the operator by displaying the identified pile pick type and the exact number of wefts that need to be removed. This feedback ensures that the operator performs the correct number of removals, preventing operational errors while keeping the manual removal process simple.
Solution Approach 2:
The control device acts as an intermediary between the weft-insertion failure detection and the operator's removal action. It translates the complex pile pattern information into simple, actionable guidance for the operator, ensuring complete weft removal while maintaining ease of operation.
Data Source
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AI summary
A start restriction method of a pile loom (1) from which an operator removes a defective yarn when a weft-insertion failure occurs includes previously storing a start reverse-rotation number set so that a same numerical value as a pile step is assigned to a loose pick and a first fast pick included in pile picks, and 1 is assigned to second and later fast picks; when a weft-insertion failure occurs, reading from the start reverse-rotation number and storing as a current value, a numerical value corresponding to the pile pick with the failure; updating the current value by adding 1 (subtracting 1) every time when a rotational angle of a main shaft (24) passes 0° by forward (reverse) rotation of the main shaft through a subsequent motion of the loom; and inhibiting start of the loom by an operation on an operation button (26) until the current value becomes 0.