Rotating Creel Sensor Arrangement for Bobbin Monitoring
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Solution Overview
Problem
The operation of sample warping machines is highly dependent on operator intervention to prevent thread breakage due to empty spools, leading to inefficiencies and potential disruptions, as existing technologies lack effective monitoring of bobbin filling levels.
Innovation Solution
A sensor arrangement is implemented to determine the filling level of bobbins in the rotary creel, allowing for automatic detection of low thread supply and enabling timely replacement, thereby reducing the risk of malfunctions and optimizing productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the rotational speed of the rotary creel is increased to improve productivity, then production efficiency improves, but the ability to visually monitor bobbin filling levels deteriorates
Solution Approach 1:
The patent replaces the manual visual monitoring system with an automated optical sensor system. Sensors detect the diameter of bobbins to determine filling levels, eliminating the need for operator visual inspection and enabling high-speed operation without compromising monitoring capability.
Solution Approach 2:
The sensor system enables the machine to self-monitor bobbin filling levels automatically. The control unit receives sensor signals and can trigger automatic bobbin changes or warnings, allowing the system to manage its own thread supply without continuous human intervention.
2Reliability
If operator intervention is increased to monitor and replace bobbins manually, then thread breakage due to empty spools is prevented, but operational efficiency and productivity deteriorate
Solution Approach 1:
The patent implements a feedback system where sensors continuously monitor bobbin filling levels and transmit information to a control unit. This feedback loop enables timely detection of low thread supply conditions, allowing for proactive bobbin replacement before thread exhaustion occurs, thus maintaining reliability without manual intervention.
Solution Approach 2:
The manual monitoring and decision-making process is replaced by an automated sensor and control system. The sensors detect filling levels, the control unit processes the information, and the system can automatically trigger bobbin changes or warnings, eliminating the need for continuous operator attention while maintaining thread supply reliability.
3Reliability
If the warping process is interrupted frequently to replace empty bobbins, then continuous thread supply is maintained, but production time and productivity deteriorate
Solution Approach 1:
The sensor system detects bobbin filling levels in advance and provides warnings or triggers automatic replacement before the bobbin becomes completely empty. This preliminary action allows for planned, minimal-interruption bobbin changes rather than emergency stops caused by thread exhaustion, reducing production downtime while maintaining thread supply continuity.
4Reliability
If early interruption of warping to replace bobbins is performed, then thread breakage is prevented, but thread material is wasted
Solution Approach 1:
The sensor system provides precise feedback on actual bobbin filling levels, allowing the control unit to determine the optimal replacement timing. This enables interruption only when truly necessary, avoiding premature stops that would waste thread material while still preventing thread breakage from complete exhaustion.
Data Source
Figure 1
Figure 2~3
AI summary
The rotating creel (5) has a carrier rotatable around a rotation axis (4), where reel mounts are arranged on the carrier. A sensor arrangement is provided for determining a filling degree of reels arranged in the reel mounts. The sensor arrangement comprises a sensor e.g. laser sensor, for each reel mount. The sensor is arranged at a machine frame, where the carrier is rotatably supported at the machine frame. The reel mounts are consecutively arranged in two groups along the rotation axis. The sensor arrangement determines a reel diameter. An independent claim is also included for a sample warper comprising a warping drum and a rotating creel.