Separate Warp Yarn Tension Profiles to Reduce Weaving Wear
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Solution Overview
Problem
Existing weaving methods and machines apply uniform yarn tension to warp threads, leading to excessive tension during certain phases, causing increased wear, machine load, and energy consumption without ensuring optimal fabric quality.
Innovation Solution
A method and machine that control yarn tension separately for groups of warp threads, using reference yarn tension profiles tailored to specific conditions and statuses, reducing maximum and average tension levels while maintaining fabric quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If uniform yarn tension is applied to all warp threads, then sufficient tension is guaranteed for all phases of weaving process, but maximum yarn tension becomes excessively high causing increased wear, machine load, and energy consumption
Solution Approach 1:
The patent segments the group of warp threads into multiple part groups, where each part group is controlled by a separate yarn tensioning device. This allows different tension levels to be applied to different part groups based on their specific requirements, rather than applying uniform tension to all warp threads. The segmentation enables the system to maintain sufficient tension for reliable weaving while reducing excessive tension in part groups that don't require high tension.
Solution Approach 2:
The patent implements dynamic control of yarn tension by adjusting the tension in each part group based on the current phase of the weaving process and the specific requirements of that part group. The control system modifies tension levels in real-time, increasing tension only when and where needed for shed formation and weft insertion, and reducing tension during phases where high tension is not required. This dynamic approach maintains reliability while minimizing excessive force.
2Productivity
If high yarn tension is maintained throughout the weaving process, then shed formation and weft insertion are ensured, but energy consumption increases
Solution Approach 1:
The patent applies periodic action by adjusting yarn tension in a cyclical manner that corresponds to the weaving process phases. During phases requiring high tension (shed formation, weft insertion), the tension is increased; during phases where low tension suffices (reed beating, take-up), the tension is reduced. This periodic modulation of tension ensures productive weaving progress while minimizing energy consumption during low-demand phases.
Solution Approach 2:
The patent changes the yarn tension parameter dynamically based on the weaving phase and part group requirements. The control system modifies tension levels from high to low and vice versa, adapting the parameter to match the actual needs of the weaving process at each moment. This prevents sustained high tension and reduces overall energy consumption while maintaining productivity.
3Device complexity
If uniform yarn tension is applied to all warp threads, then simple control is maintained, but fabric quality deteriorates due to excessive tension on certain threads
Solution Approach 1:
The patent divides the warp threads into multiple part groups, each with its own yarn tensioning device and control parameters. This segmentation allows the control system to apply differentiated tension strategies to different part groups based on their specific requirements, improving fabric quality by preventing excessive tension on sensitive threads while maintaining adequate tension on threads that need it. The increased device complexity is justified by the significant improvement in manufacturing precision.
Solution Approach 2:
The patent implements local quality control by applying different tension characteristics to different part groups of warp threads. Each part group receives the specific tension level and control strategy appropriate to its location and function in the fabric structure. This localized approach ensures optimal fabric quality by matching tension characteristics to local requirements, rather than applying a one-size-fits-all uniform tension regime.
Data Source
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AI summary
The invention concerns firstly a weaving method with which the yam tension of several part groups with at least one warp thread per part group is controlled or adjusted separately, in order to follow a respective reference yam tension profile during weaving, wherein for at least one part group, the reference yarn tension profile is changed during weaving, wherein the reference yarn tension profile is determined and changed separately for at least two part groups, and wherein each reference yarn tension profile is selected from a collection of different reference yarn tension profiles; and secondly also a weaving machine provided with yam tensioning elements, a storage unit in which said collection is provided, and a control or steering unit in order, in cooperation with the yarn tensioning elements, to adjust or control the yarn tension in separate warp threads using the indicated weaving method.