2D Sensor Grid for Homogeneous Thread Tension Control
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Solution Overview
Problem
Current sensor arrangements for detecting thread tension in textile production are costly, space-intensive, and inefficient, often requiring multiple sensors that can lead to inhomogeneous thread tensions and manufacturing errors due to incomplete measurement coverage.
Innovation Solution
A sensor arrangement featuring a two-dimensional grid of sensors on a printed circuit board with thread bushings, allowing for simultaneous measurement of multiple threads with reduced complexity and wiring, using movable elements and diverse sensor types to detect various physical parameters like tension, yarn count, and material properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple individual sensors are used to measure all warp threads, then measurement precision is improved, but device complexity and installation space increase disproportionately
Solution Approach 1:
The sensor plate is divided into multiple sensor regions, each responsible for detecting specific threads. This segmentation allows comprehensive measurement of all warp threads while organizing the sensor system into manageable units, reducing overall complexity through modular structure
Solution Approach 2:
The patent transitions from linear sensor arrangements to a two-dimensional sensor plate with grid-pattern thread passages. This dimensional change enables simultaneous measurement of multiple threads in parallel rows, dramatically increasing measurement capacity without proportionally increasing system complexity
2Measurement precision
If three-point sensors are used for individual thread measurement, then measurement precision is improved, but installation space and wiring requirements increase
Solution Approach 1:
Multiple sensor functions are merged into a single integrated sensor plate assembly. The plate combines thread guidance features, sensor mounting structures, and detection elements into one compact unit, eliminating the need for separate three-point sensor assemblies for each thread and significantly reducing installation space
Solution Approach 2:
The sensor plate serves multiple functions simultaneously: it guides threads through precisely positioned passages, provides mounting structures for sensors, and enables detection of multiple threads in parallel. This multi-functionality consolidates what would otherwise require multiple separate devices into a single space-efficient unit
3Device complexity
If sensors are used on collective groups of threads, then device complexity is reduced, but measurement precision for individual threads is lost
Solution Approach 1:
The sensor plate is divided into multiple sensor regions, each responsible for detecting specific threads. This segmentation allows comprehensive measurement of all warp threads while organizing the sensor system into manageable units, reducing overall complexity through modular structure
Solution Approach 2:
The patent transitions from linear sensor arrangements to a two-dimensional sensor plate with grid-pattern thread passages. This dimensional change enables simultaneous measurement of multiple threads in parallel rows, dramatically increasing measurement capacity without proportionally increasing system complexity
4Measurement precision
If multiple sensor devices are aligned parallel and offset to measure all threads, then measurement precision is improved, but installation space and technical effort increase
Solution Approach 1:
Multiple sensor functions are merged into a single integrated sensor plate assembly. The plate combines thread guidance features, sensor mounting structures, and detection elements into one compact unit, eliminating the need for separate three-point sensor assemblies for each thread and significantly reducing installation space
Solution Approach 2:
The sensor plate serves multiple functions simultaneously: it guides threads through precisely positioned passages, provides mounting structures for sensors, and enables detection of multiple threads in parallel. This multi-functionality consolidates what would otherwise require multiple separate devices into a single space-efficient unit
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables precise, cost-effective, and flexible measurement of thread parameters, ensuring homogeneous thread tension and quality control, reducing errors and operational complexity while allowing for real-time data processing and storage.
Implementation Method 1
the sensor being a strain gauge
Implementation Method 2
the sensor being a capacitive sensor
Implementation Method 3
the sensor being an optical sensor
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a sensor arrangement for detecting at least one physical characteristic of a plurality of threads (10, 20, 30, 40) comprising a sensor plate (100) with a plurality of thread passages (110) arranged in a two-dimensional grid, wherein each thread passage (110) is assigned at least one sensor (11, 21, 31, 41) designed to detect the at least one physical characteristic of a thread (10, 20, 30, 40) passing through the thread passage (110). The invention further relates to a device with such a sensor arrangement and a method for detecting at least one physical characteristic of a plurality of threads (10, 20, 30, 40) using such a device.