Roving Breakage Detection Using Merged Photocell Sensors
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Solution Overview
Problem
Existing roving frames face challenges in detecting breakage of roving due to high speed and oscillations, leading to costly sensor solutions that are impractical for large-scale implementation.
Innovation Solution
A roving frame equipped with a digital breakage detection system using photocell sensors and digital processing devices to generate and process signals, reducing interference from oscillations and allowing for economical installation across multiple machining points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If numerous sensor solutions are installed at each machining point to detect roving breakage, then detection reliability is improved, but system cost increases significantly
Solution Approach 1:
The patent combines multiple sensor functions into a single integrated sensor unit that can detect breakages across multiple machining points. This sensor unit includes a housing with multiple openings, a single sensor element that can detect roving presence at different positions, and associated electronics that process signals from multiple locations, thereby reducing the total number of separate sensor installations needed while maintaining comprehensive detection coverage.
Solution Approach 2:
The sensor unit is designed as a universal device that can be installed at multiple different positions along the roving frame to detect breakages at various machining points. The sensor housing can be positioned at different locations, and the same sensor type can serve multiple functions across the entire system, reducing the need for different sensor types for different locations.
2Reliability
If sensors are installed at all machining points to detect breakage, then detection capability is improved, but cost increases due to the large number of sensors required
Solution Approach 1:
The patent merges multiple detection functions into a single sensor unit that can detect roving breakages at multiple positions. The sensor housing includes multiple openings arranged to detect roving at different locations, and a single sensor element processes signals from all these positions, reducing the total number of sensors needed and thereby lowering manufacturing costs while maintaining comprehensive detection capability.
Solution Approach 2:
The patent uses a standardized sensor unit design that can be replicated and installed at multiple locations. Instead of customizing sensors for each machining point, the same sensor unit design is used throughout, simplifying manufacturing and reducing costs while maintaining consistent detection performance across all positions.
3Productivity
If the roving frame operates at high speed with strong drawing forces, then productivity is improved, but roving breakage increases
Solution Approach 1:
The patent implements a feedback system where the sensor unit continuously monitors roving presence at multiple positions and provides real-time signals to the control system. When a breakage is detected, the system immediately responds by stopping the roving frame or alerting operators, enabling rapid intervention to prevent further damage and minimize production loss, thereby maintaining high productivity while improving reliability.
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 system effectively detects roving breakage with high reliability and reduced costs, enabling prompt machine stopping and intervention while minimizing power consumption and physical obstruction.
Implementation Method 1
said sensors being suitable for generating an oscillating signal Sp depending on the presence or absence of the roving in a detection zone of the intermediate region (19)
Data Source
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AI summary
A roving frame (1) of a spinning line, comprises a drawing device (12), a winding device (14) and a system for detecting breakages of the roving (20) comprising a plurality of detection sensors, a processing device (50) associated with each sensor according to a low-pass or timer filter, and a control device (70) connected to the processing devices (50) to stop the drawing device (12) and the winding device (14) in the presence of a breakage of the roving.