Sample Warper Linear Drive Arrangement for Thread Guide Spacing
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Solution Overview
Problem
Conventional pattern warping machines are limited in productivity due to the restricted number of threads that can be wound simultaneously, primarily because each thread guide requires a significant amount of space for its drive, which limits the overall capacity and efficiency of the machine.
Innovation Solution
The drives are distributed on both sides of a surface formed by a projection of a line parallel to the axis, divided into two groups, and arranged at different distances and positions, allowing for a more efficient use of space and minimizing interference between drives, enabling a larger number of thread guides to be accommodated without compromising their operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If each thread guide is equipped with a drive, then the thread guide can be positioned accurately, but the space required for each drive limits the number of threads that can be warped simultaneously
Solution Approach 1:
The patent transitions from a two-dimensional arrangement (single side of the warping drum) to a three-dimensional arrangement (both sides of the warping drum). By distributing drives on both sides of the drum's axial midplane, the system effectively doubles the available space for accommodating drives, thereby increasing the number of thread guides that can be equipped with drives simultaneously.
Solution Approach 2:
The patent divides the drives into two distinct groups: first drives arranged on one side of the axial midplane and second drives arranged on the other side. This segmentation allows independent positioning and operation of drives on each side, optimizing space utilization and enabling a greater total number of driven thread guides.
2Productivity
If drives are arranged close together to maximize space utilization, then more drives can be accommodated, but mutual interference between drive magnets occurs
Solution Approach 1:
By utilizing the third dimension (radial distance from the axial midplane), the patent increases the separation between drives. Drives are positioned at different radial distances, which provides sufficient spacing to prevent magnetic interference while still accommodating a large number of drives on both sides of the drum.
Solution Approach 2:
Different drives are positioned at different radial distances from the axial midplane, creating local variations in positioning. This allows each drive to have an optimized position that avoids magnetic interference from adjacent drives while maintaining effective control of its associated thread guide.
3Ease of operation
If a rotary creel is used to hold bobbins, then thread winding can be achieved, but the number of bobbins is limited
Solution Approach 1:
The patent moves from a rotary creel configuration (circular arrangement) to a linear arrangement of thread guides along a line extending axially from the warping drum. This dimensional change allows thread guides to be positioned along the axial direction, significantly increasing the number of bobbins that can be accommodated in a gate.
Solution Approach 2:
The thread guides are made movable along the axial direction, allowing dynamic adjustment of thread guide positions. This enables flexible configuration of the number of active thread guides and allows for easy loading and unloading of bobbins, enhancing operational efficiency.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The warper has a warping drum rotated around an axle, and thread guides (6) moved parallel to the axle between rest position and winding region by linear drives (14, 18, 20) i.e. linear motors (19). The rest position is set along a line, and the linear drives are arranged on sides of a surface in distributed manner, where the surface is formed by a projection of the line parallel to the axle. The linear drives are provided with a stator and a movable element, which is connected with the thread guides at two positions by an extension. The drives are combined to modules (13).