Rotary Drum Yarn Feeder with Optical Loop Sensor
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing storage yarn feeders with rotary drums lack the capability to provide accurate, reliable absolute information about the amount of yarn unwound, relying on relative measurements which can lead to inconsistent yarn tension and defects in textile products.
Innovation Solution
A yarn feeder with a rotary drum and a yarn-unwinding sensor system that uses infrared light-emitting and receiving diodes, combined with an annular light guide and optical fiber, to detect and count the unwinding yarn loops, providing absolute information about the yarn unwound, regardless of the drum's rotation speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a storage yarn feeder uses relative measurement methods (photoelectric cells detecting unwinding yarn sequence) to control drum rotation, then the system can maintain yarn stock at a predetermined level, but the sensor cannot provide absolute information about the amount of yarn unwound, leading to potential tension instability
Solution Approach 1:
The patent replaces the mechanical/relative measurement system (photoelectric cells detecting yarn sequence) with an optical absolute measurement system (infrared LED and photodetector measuring yarn loop diameter). This substitution enables direct measurement of the actual yarn stock level on the drum, providing absolute information about yarn unwound rather than relative changes, thereby resolving the measurement precision and reliability contradiction.
2Productivity
If the drum rotates faster to increase productivity, then more yarn can be processed per unit time, but the existing sensor system cannot accurately measure unwound yarn at varying speeds, compromising measurement reliability
Solution Approach 1:
The patent replaces speed-dependent mechanical measurement methods with an optical measurement system that measures the physical dimension (diameter) of yarn loops directly. This optical system is inherently independent of drum rotation speed, allowing accurate measurement of yarn stock level whether the drum rotates slowly or quickly, thus maintaining measurement reliability while enabling high productivity.
3Stability of the object's composition
If the yarn stock on the drum is maintained at a constant optimal level, then yarn tension remains stable, but the existing relative measurement system requires complex control mechanisms to achieve and maintain this balance
Solution Approach 1:
The patent implements a feedback control system where the optical sensor continuously measures the actual yarn stock level (loop diameter) on the drum and provides this information to a control unit. The control unit compares the measured value with the optimal level and automatically adjusts the drum rotation speed to maintain the optimal yarn stock, thereby stabilizing yarn tension. This direct feedback mechanism simplifies control compared to relative measurement systems that require complex indirect control strategies.
Solution Approach 2:
The patent replaces complex mechanical control mechanisms with an optical measurement and electronic control system. By using infrared LED and photodetector to directly measure yarn loop diameter, the system obtains accurate real-time data on yarn stock level, enabling simple and effective electronic feedback control to maintain optimal tension without complex mechanical adjustments.
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
Ensures stable yarn tension by accurately monitoring and maintaining the optimal yarn stock level on the drum, preventing excessive tension or accumulation, thus reducing defects in the textile production process.
Implementation Method 1
a first light-emitting means, in particular an infrared light-emitting diode (46), and a first light-receiving means, in particular an infrared light-receiving diode (72)
Implementation Method 2
a first light-emitting means, in particular an infrared light-emitting diode (46), and a first light-receiving means, in particular an infrared light-receiving diode (72)
Implementation Method 3
an annular light guide (50) arranged between drum (12) and emitting diode (46) and adapted to direct a light beam generated by emitting diode (46) towards cylindrical surface (30a) of cover (30)
Implementation Method 4
The light-guiding means further comprise an optical device (62), which is incorporated in cover (30) and is adapted to focus the light from annular light-guide (50) towards an inlet end (64) of an optical fiber cable (66)
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
A motorized, yarn-winding rotary drum (12) rotatably supported with respect to a motor-housing (16) is adapted to have a plurality of yarn loops (Y) wound on itself, which are adapted to be unwound upon request from a downstream machine. A yarn-unwinding sensor counts the yarn loops unwinding from the rotary drum (12) and comprises light-emitting means (42) and light-receiving means (44), both integral with the motor-housing (16), one of which has an annular configuration operatively facing an annular surface (30a) of the rotary drum (12) from which the yarn is unwound. Light-guiding means (66) integral with the rotary drum (12) guide the light from the light-emitting means (42) to the light-receiving means (44) through a light passage (30c) defined on the annular surface (30a). The unwinding of yarn from the rotary drum (12) is determined on the basis of the light dimming resulting from the yarn transiting on the light passage (30c).