Spring Compensator for Constant Tension Thread Feeding

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Solution Overview

Problem

Existing constant tension thread feeders struggle with maintaining consistent tension during discontinuous feeding to textile or winding machines, especially with rigid threads, leading to inefficiencies and potential yarn breaks due to inadequate response to sudden absorption changes and limited dynamic acceleration/deceleration performance.

Innovation Solution

Incorporating a compensator with a spring mechanism inside the tension adjustment ring, coupled with a microprocessor control unit and electric motor, allows for instantaneous adjustment to thread absorption variations, reducing tension peaks and enabling precise control of thread tension, even with rigid threads, by dynamically adjusting the spring force and position.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a motor and electronic control unit are used to control thread tension, then thread tension can be maintained constant during continuous feeding, but the system cannot respond quickly enough to sudden absorption changes in discontinuous feeding

Engineering Contradiction:

Improvethread tension controlVSAvoidresponse speed

Core Design Contradiction:

ReliabilityVSSpeed

Solution Approach 1:

A spring mechanism is introduced as an intermediary element between the thread feeding system and the tension control system. The spring acts as a mechanical mediator that can rapidly respond to sudden absorption changes by physically moving to equalize tension, bypassing the slow electronic control loop while still allowing the motor to maintain overall tension control during continuous feeding phases.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system transitions from a static motor-controlled tension system to a dynamic system where the spring can freely move in response to real-time tension variations. This dynamic element allows the system to adapt instantly to discontinuous feeding conditions while the motor provides dynamic adjustment during continuous operation.

Inventive Principle:

Principle #15Dynamics

2Reliability

If a motor is used to control the mobile arm position, then thread tension can be controlled, but the arm cannot move freely causing defects or yarn breaks

Engineering Contradiction:

Improvethread tension controlVSAvoidyarn breaks and defects

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The motor is extracted from the direct path of thread tension control and relocated to control only the pulley rotation. The mobile arm is completely freed from motor control, allowing it to move freely in response to tension variations without causing yarn breaks, while the motor continues to maintain overall tension control through pulley adjustment.

Inventive Principle:

Principle #2Taking out (Extraction)

3Adaptability or versatility

If yarn storage feeders are used to accumulate thread turns, then discontinuous feeding can be handled, but the device becomes much more bulky and tension control is limited

Engineering Contradiction:

Improvediscontinuous feeding capabilityVSAvoiddevice size

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The spring mechanism serves multiple functions simultaneously: it acts as a tension equalizer during discontinuous feeding, provides mechanical cushioning during acceleration and deceleration phases, and works in conjunction with the motor to maintain tension control during continuous operation. This eliminates the need for separate yarn storage feeders while maintaining discontinuous feeding capability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

This solution enhances the dynamic performance of thread feeding systems, reducing tension peaks, increasing productivity, and ensuring consistent thread quality by anticipating and reacting to sudden absorption changes, effectively managing both elastic and rigid threads with improved precision and repeatability.

Implementation Method 1

Incorporating a compensator with a spring mechanism inside the tension adjustment ring... allows for instantaneous adjustment to thread absorption variations, reducing tension peaks

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentEP2546400B1Device and method for the constant tension feeding of threads or yarns fed in a discontinuous way

Publication Date: 2023.01.18 B T S R INT

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AI summary

A device for the constant tension feeding of threads fed to a textile machine, said machine being apt to produce a manufactured product, said feeding taking place in a discontinuous way that is with phase sequences wherein the thread motion takes place with a first and a second feeding or absorption state, said states following each other in time, comprises tension detecting means (3), thread accumulating means (4) and control means (40) connected to said detecting means (3) and accumulators (4) and apt to intervene on the latter based upon a tension value obtained from said detecting means; compensating means (11) is provided arranged between said accumulating means (4) and said tension detecting means (3) apt to cooperate with such thread (8) so as to compensate a variation of the feeding or absorption state of the latter upon the passage between each first and each second feeding or absorption state following the first one.