Sample Warper Axial Guide for Uniform Warp Density
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Solution Overview
Problem
Modern sample warping machines face challenges in producing pattern warps with unequal bands, leading to non-uniform density, which requires complex and expensive speed adjustments for transport belts to accommodate varying thread counts, complicating the setup and operation.
Innovation Solution
The warping drum and thread guide carrier are made movable relative to each other in the axial direction, allowing decoupling of movement corrections for different strip widths from the feed movement of transport surfaces, enabling simpler motor control and operation with constant speed drives, and facilitating uniform density patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the speed of transport belts is adjusted to accommodate varying thread counts per band, then uniform density pattern warp can be achieved, but the device complexity and cost increase due to requiring variable speed drives and complex programming
Solution Approach 1:
The invention makes the thread guide carrier movable in the axial direction relative to the warping drum, allowing the system to dynamically adapt to different band widths by adjusting the position of the thread guide carrier rather than adjusting the speed of transport belts. This dynamic positioning capability enables uniform density pattern warp to be achieved with simpler constant speed drives.
Solution Approach 2:
The invention changes the parameter being adjusted from transport belt speed to the axial position of the thread guide carrier. By varying the position parameter of the thread guide carrier instead of the speed parameter of transport belts, the system achieves the same uniform density result with simpler constant speed drives.
2Productivity
If multiple thread counts are wound per belt to increase productivity, then production efficiency improves, but the transport belt speed control becomes more complex to maintain uniform density
Solution Approach 1:
The movable thread guide carrier provides a dynamic solution that works regardless of how many threads are wound per belt. Whether one thread or multiple threads are wound per belt, the thread guide carrier can be positioned axially to ensure proper spacing and uniform density, eliminating the need for complex speed programming that would be required to handle different thread counts per belt.
3Productivity
If the transport surfaces move faster to accommodate wider bands with more threads, then productivity increases, but the density uniformity across different band widths becomes problematic
Solution Approach 1:
Instead of varying the speed of transport surfaces, the invention dynamically positions the thread guide carrier axially according to the width of each band. This allows transport surfaces to maintain constant high speed for productivity while the movable thread guide carrier ensures proper thread distribution and uniform density across bands of varying widths.
Data Source
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AI summary
The warp pattern warping machine, with a warping drum (1) with movable transporting surfaces (2) arranged on the circumference of the drum, thread guides (14) arranged on a thread guide carrier (15), and a creel (7) from which the thread guide draws threads, has the warping drum and the thread guide carrier movable in relation to each other in the axial direction. The thread guide carrier and the creel are interconnected in the axial direction, wherein the warping drum and the creel are movable in relation to each other in the axial direction. An independent claim is included for a method for producing a warp pattern in which the warping drum and the thread guide carrier are moved in the axial direction in relation to each other.