Reflection Optical Sensor for Weft Thread Detection in Weaving Feeders
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Solution Overview
Problem
Traditional reflection optical sensors for weaving weft feeders are bulky, require precise geometric alignment, and suffer from low sensitivity due to long optical paths, making them costly and difficult to manufacture, while barrier optical sensors face challenges with power supply and increased complexity.
Innovation Solution
A compact reflection optical sensor design using miniaturized SMD components with parallel optical axes and a shielding plate to focus reflected radiation, reducing the optical path length and enhancing sensitivity, allowing for easy assembly and low-cost production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional reflection optical sensors are used with light emitter and light receiver placed on a support arm, then the sensor can detect weft thread presence, but the sensor becomes bulky and requires precise geometric alignment
Solution Approach 1:
The patent transitions from a traditional support arm configuration to mounting the light emitter and light receiver directly on the drum surface. This dimensional change allows the optical components to be positioned in a planar arrangement rather than extending outward, significantly reducing the sensor's bulk while maintaining detection functionality.
Solution Approach 2:
The patent divides the optical detection function into two separate components: a light emitter and a light receiver, both mounted on the drum. This segmentation allows each component to be positioned independently on the drum surface, eliminating the need for a bulky support arm structure and reducing alignment complexity.
2Device complexity
If the optical path length is increased to accommodate support arm mounting, then the sensor structure is simplified, but the detection sensitivity decreases
Solution Approach 1:
By mounting both the light emitter and light receiver directly on the drum surface, the patent creates a compact optical path that operates in a two-dimensional plane on the drum surface. This eliminates the need for long optical paths while maintaining structural simplicity.
Solution Approach 2:
The patent merges the mounting function with the drum structure itself. The drum serves dual purposes: as the thread-winding component and as the mounting surface for the optical sensors. This integration eliminates the need for separate support arms and long optical paths.
3Measurement precision
If barrier optical sensors are used with light emitter on drum and light receiver on support arm, then detection sensitivity is high, but power supply becomes complex
Solution Approach 1:
The patent makes the drum self-sufficient by mounting both the light emitter and light receiver on it. This self-contained configuration eliminates the need for complex power supply arrangements across rotating interfaces, as all components are positioned on the same rotating element.
Solution Approach 2:
The patent combines the light emitter and light receiver on the same drum, merging their positions to eliminate the need for complex inter-component power and signal connections that would be required in barrier sensor configurations.
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 solution achieves high detection sensitivity comparable to barrier optical sensors, reduces manufacturing complexity and cost, and improves repeatability by using standard components with parallel axes and a cylindrical screening diaphragm to focus reflected light, making it more robust against dust and positioning errors.
Implementation Method 1
both the light emitter and the light receiver are placed on a support arm which projects from the base body of the weft feeder
Implementation Method 2
The optical radiation path between the above said two elements of the optical sensor is achieved by means of a respective reflective surface formed or fixed on the drum lateral surface
Implementation Method 3
A compact reflection optical sensor design using miniaturized SMD components with parallel optical axes and a shielding plate to focus reflected radiation
Data Source
AI summary
A reflection optical sensor (F1-F4) for the detection of a weft thread in a weaving weft feeder (P) comprises a light emitter (1) and a light receiver (2) assembled on a relative supply printed circuit board (3) and housed in an arm (A) of the weft feeder which projects towards the front part of the weft feeder (P) and extends alongside the weft feeder drum (D) whereon the weft thread coils are wound, so as to form a path of direct light radiation, from said light emitter (1) towards a respective reflective surface (R) placed on said drum (D), and of reflected light radiation, from said reflective surface (R) to said light receiver (2), for detecting the presence/absence of a weft thread running through said path. Said light emitter (1) and light receiver (2) are assembled with mutually parallel optical axes on said supply printed circuit board (3). The optical sensor further includes a screening means (8) of the reflected radiation coming from said reflective surface (R) and directed towards said light receiver (2).