Sample Warping Machine Dual-End Thread Guide and Segmented Transport
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Solution Overview
Problem
Existing sample warping machines have limitations in productivity due to long set-up times and inefficient thread winding processes, as they typically require waiting for the warp to be fully wound and unwound before preparing the next pattern or order.
Innovation Solution
A sample warping machine with a warping drum featuring two thread guide devices, one on each end face, and transport surfaces divided into sections that can move in opposite directions, allowing simultaneous winding and unwinding from both ends, reducing set-up times and increasing productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If threads are wound onto the warping drum from a single end face, then the structure remains simple, but the production time increases due to sequential operation requirements
Solution Approach 1:
The warping drum is divided into two end faces, each equipped with its own thread guide device and transport surface. This segmentation allows independent operation at each end, enabling simultaneous winding operations that double productivity without requiring complex coordination mechanisms.
Solution Approach 2:
The patent transitions from single-end (one-dimensional operation) to dual-end (two-dimensional operation) threading. By utilizing both end faces of the warping drum for simultaneous thread winding, the system effectively adds a spatial dimension to the winding operation, thereby doubling output capacity.
2Loss of time
If the transport surface is used as a single continuous section, then the structure is simple, but the set-up time cannot be reduced
Solution Approach 1:
The transport surface is divided into multiple sections that can be independently controlled. This allows one section to be prepared for the next pattern while another section continues winding the current pattern, enabling overlapping operations that reduce set-up time without requiring complete system shutdown.
Solution Approach 2:
The divided transport surface sections enable preliminary preparation of the next pattern on one section while the current pattern is being wound on another section. This preliminary action on parallel paths eliminates idle set-up time by preparing future work during current production.
3Productivity
If threads are wound from both end faces simultaneously, then productivity doubles, but the risk of thread tension imbalance increases
Solution Approach 1:
Each end face is equipped with its own independent thread guide device and transport surface section, allowing localized control of thread tension and winding parameters. This local quality control ensures that tension imbalances at one end do not affect the other, maintaining reliability while doubling productivity.
Data Source
Figure 1~4
AI summary
The machine (1) has conveyor belts (8, 9) moved parallel to an axis of a warping drum (2) and arranged at a circumference of the warping drum. A thread guiding device (17) is provided with a thread guide (18) at a front side of the warping drum. A drive device produces relative motion between the thread guide and the warping drum in circumferential direction. Another thread guiding device (19) is provided with a thread guide (20) at another front side of the warping drum. The conveyor belts are divided into two sections. An independent claim is also included for a method for operating a sample warping machine.