Sample Warper Auxiliary Transport Device for Thread Tension Control
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Solution Overview
Problem
Existing sample warping machines face challenges in achieving high productivity due to thread consumption and space constraints when handling multiple threads, often resulting in thread accumulation and breakages, especially when threads are temporarily removed from the patterning process.
Innovation Solution
A sample warping machine design where the yarn guide device is non-rotatable, the warping drum has a warping drive for rotation, and the auxiliary transport device has a rotary drive synchronized with the warping drive, allowing the auxiliary transport device to move in two directions and maintain tension on threads not wound onto the drum, preventing accumulation and breakages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If threads are removed from the patterning process and wound onto an auxiliary winding body, then thread accumulation is avoided, but the auxiliary winding body requires large space and consumes excessive thread
Solution Approach 1:
The auxiliary transport device is configured to move in two directions: axially parallel to the warping drum axis and rotationally around the drum axis. This two-dimensional movement allows threads to be distributed along the axial direction rather than accumulating radially, minimizing the space required and reducing thread consumption while effectively managing thread accumulation.
2Loss of substance
If the auxiliary transport device moves faster than conveyor belts, then thread accumulation is prevented, but thread tension becomes excessive causing breakages
Solution Approach 1:
The auxiliary transport device employs dynamic speed control where its movement speed is synchronized with the warping drum rotation speed. The device can adjust its axial and rotational speeds independently to match process requirements, maintaining optimal thread tension that prevents both accumulation and breakage through real-time speed adaptation.
Solution Approach 2:
The system changes the movement parameters of the auxiliary transport device based on process conditions. By adjusting the axial speed and rotational speed as independent variables, the thread tension can be optimized to prevent accumulation while avoiding excessive tension that causes breakages.
3Reliability
If the auxiliary transport device is rotated to maintain thread tension, then thread breakages are prevented, but device complexity increases
Solution Approach 1:
The auxiliary transport device combines axial movement and rotational movement into a single integrated mechanism. By merging these two movement functions into one device that operates in coordination with the warping drum, the system maintains thread tension through rotation while avoiding the need for separate tensioning mechanisms, thus reducing overall device complexity.
4Volume of moving object
If multiple threads are wound on top of one another to increase diameter, then space efficiency improves, but thread tension distribution becomes uneven causing deformation
Solution Approach 1:
Instead of winding multiple threads radially on top of one another, the auxiliary transport device distributes threads along the axial direction of the warping drum. This dimensional redistribution prevents uneven radial tension and deformation while maintaining space efficiency by utilizing the axial space along the drum length.
Data Source
Figure 1
Figure 2
AI summary
The sample warper (1) has a thread guiding device comprising a thread guide that is displaceable between a position in front of an end face of a warping drum (2) in an axial direction and another position behind the end face of the warping drum. The thread guiding device is non-rotatable with respect to an axis of the warping drum. The warping drum comprises a warp drive (7) operated in a rotation direction (8). An auxiliary transport device (13) comprises rotary drives (19, 21) that are operated simultaneously with the warp drive. An independent claim is also included for a method for producing a sample warp.