Sample Warper Thread Application Control
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Solution Overview
Problem
The existing methods for producing pattern warps face challenges in ensuring that threads are wound onto a warping drum without slipping, leading to uneven tensions and difficulties during unwinding, particularly when multiple threads are wound simultaneously, resulting in a warp that is hard to process in weaving or knitting.
Innovation Solution
The method involves determining at least one parameter of the thread application, such as the parallelism of the surface or the gradient of the free end face, and controlling the relative movement between the thread guides and conveyor belts to achieve the desired structure, ensuring that the threads are wound with a cone-shaped end face and a peripheral surface parallel to the warping drum axis, thereby preventing slipping and ensuring even tension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If threads are wound onto the warping drum without relative movement between thread guides and transport surfaces, then the winding process is simple, but the threads cannot form a cone-shaped end face and may slip off causing uneven tension
Solution Approach 1:
The patent applies dynamics by making the thread guides and transport surfaces movable relative to each other during the winding process. This relative movement enables the formation of a cone-shaped end face on the thread application, preventing thread slippage and ensuring uniform tension distribution across all threads.
Solution Approach 2:
The patent changes the geometric parameters of the thread application by controlling the relative movement between thread guides and transport surfaces. This creates a cone-shaped end face with specific slope characteristics, transforming the thread application from a simple cylindrical winding to a precisely controlled conical structure that eliminates threading problems.
2Productivity
If multiple threads are wound simultaneously to increase productivity, then production efficiency improves, but the threads may have very different tensions making the warp difficult to process
Solution Approach 1:
The patent uses dynamic relative movement between multiple thread guides and transport surfaces to ensure that all simultaneously wound threads form a uniform cone-shaped structure. This dynamic control maintains equal tension across all threads even when multiple threads are wound at high speed, preserving both productivity and tension uniformity.
Solution Approach 2:
The patent controls the geometric parameters of the thread application for multiple threads simultaneously by coordinating the relative movement of thread guides and transport surfaces. This ensures that all threads achieve the same cone-shaped end face geometry, guaranteeing uniform tension distribution across the entire multi-thread warp.
3Reliability
If the thread application surface is not parallel to the warping drum axis, then the winding process is simpler, but the threads may slip off the free end face causing difficulties during beam changing
Solution Approach 1:
The patent applies dynamic relative movement between thread guides and transport surfaces to create a cone-shaped end face where the surface is precisely parallel to the warping drum axis. This dynamic control prevents thread slippage by ensuring the correct geometric relationship between the thread application surface and the drum axis throughout the winding process.
Data Source
Figure 1
AI summary
The method involves placing threads (11) on transport surfaces (5) by a thread eyelet (15), where the transport surfaces are arranged at a periphery of a warping drum (2) and are movable axially parallel to the warping drum. The thread eyelet and the transport surfaces are moved relative to each other during placing of the threads. A parameter of a thread application (17) on the transport surfaces is determined. Relative movement between the thread eyelet and the transport surfaces is controlled based on the determined parameter. An independent claim is also included for a sample warpper comprising a measurement device.