Programmable Weft Needle Drive for Ribbon Looms

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Solution Overview

Problem

Ribbon needle weaving looms face challenges in maintaining uniform weft thread tension and precise weft insertion, particularly during transitions in ribbon width and when handling different types of threads, due to the rigid crescent motion of the weft needle driven by the main shaft, leading to unappealing weave regions and potential weaving faults.

Innovation Solution

A ribbon needle weaving loom with a programmable control unit for the weft insertion needle, allowing for variable path and starting time adjustments, using either rotary or linear drives, such as servo motors or stepper motors, to optimize weft thread insertion paths and tensions, and incorporating adjustable reeds and spring/mass systems for enhanced flexibility and precision.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the weft needle is driven by the main shaft with rigid crescent motion, then the weaving cycle is synchronized, but the weft thread tension cannot be kept constant during width transitions

Engineering Contradiction:

Improvesynchronization of weaving cycleVSAvoiduniformity of weft thread tension

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent applies dynamics by making the weft needle drive independent and programmable, allowing the insertion path and timing to be dynamically adjusted based on ribbon width and thread type, rather than being rigidly coupled to the main shaft. This enables constant weft thread tension maintenance during width transitions.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The control unit changes parameters such as insertion path, starting time, and insertion speed programmatically to maintain uniform weft thread tension. The system adapts these parameters according to the current ribbon width and thread characteristics, resolving the tension uniformity issue during width transitions.

Inventive Principle:

Principle #35Parameter changes

2Device complexity

If the weft needle follows a fixed insertion path, then the mechanical drive is simple, but unappealing weave regions appear during width transitions

Engineering Contradiction:

Improvesimplicity of mechanical driveVSAvoidquality of weave region

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent replaces the mechanical coupling between the main shaft and weft needle drive with a programmable control system. The control unit independently programs the weft needle insertion path and timing, eliminating the need for complex mechanical transmissions while enabling adaptive path adjustment for different ribbon widths.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If the weft insertion is hard synchronized with the main shaft, then the timing is precise, but the starting time cannot be optimized for different thread types

Engineering Contradiction:

Improveprecision of weft insertion timingVSAvoidadaptability to different thread types

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The control unit programmatically adjusts the starting time parameter of weft needle insertion based on thread type and ribbon width requirements. This allows optimization of insertion timing for different threads (e.g., antenna threads, effect threads) while maintaining precise timing control through digital programming rather than mechanical synchronization.

Inventive Principle:

Principle #35Parameter changes

4Productivity

If the shedding speed is increased to improve productivity, then more threads can be woven per hour, but the warp threads cannot be separated quickly enough causing insertion faults

Engineering Contradiction:

Improveweaving speedVSAvoidaccuracy of weft insertion

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The control unit is configured to account for the finite shedding speed by programmatically adjusting the weft needle insertion timing. The system performs preliminary calculation of the optimal insertion moment, ensuring the weft needle enters the shed only after the warp threads have sufficiently separated, even at high weaving speeds.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11242626B2Narrow fabric needle loom and corresponding weaving method

Publication Date: 2022.02.08 TEXTILMA AG

AI summary

A ribbon needle weaving loom including an electromechanic actuator for driving the weft thread insertion needle. A control device is provided and the actuator is configured—in co-operation with the control unit—in such manner as to allow preselection of the end position of the weft thread insertion needle at weft-insertion and of the position with retracted weft-insertion needle, and/or the starting time point of the motion of the weft-insertion needle and/or—the instantaneous speed of the motion of the weft-insertion needle, at least within a certain range. The electromechanic actuator is configured as rotary actuator or a linear actuator.