Tension Sensing Unit with Motorized Spacer for Yarn Calibration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current zeroing calibration methods for tension sensors in textile processes are unreliable and inaccurate, requiring manual intervention and causing machine downtime, especially when dealing with numerous tension sensing units.
Innovation Solution
A tension sensing unit with a motorized spacer element that moves between a resting and operative position to disengage yarns from sensors, allowing for automatic and simultaneous zeroing calibration, minimizing interference and downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If yarns are loosened before calibration, then tension on sensors is reduced, but calibration accuracy deteriorates because yarns continue to affect the sensors
Solution Approach 1:
The patent extracts the yarns from the sensing area by moving them to a different spatial location (around the creel) during calibration, completely removing their interfering effect on the tension sensors. This allows the sensors to measure zero tension accurately without any yarn influence.
Solution Approach 2:
The patent introduces dynamic movement of the yarn path through the creel structure, allowing the yarns to be temporarily relocated from the sensor area during calibration and then returned to the normal path for operation. This dynamic reconfiguration enables accurate calibration without permanent system changes.
2Measurement precision
If manual calibration is performed on numerous sensors, then calibration accuracy improves, but time consumption increases significantly
Solution Approach 1:
The patent merges the calibration process for all tension sensors into a single unified operation. By relocating all yarns simultaneously to a common position around the creel, all sensors are calibrated at once rather than individually, dramatically reducing total calibration time while maintaining accuracy.
Solution Approach 2:
The patent performs preliminary relocation of yarns to the creel before calibration begins, preparing the system in advance so that when calibration starts, all sensors are already in the correct state for accurate measurement. This preliminary setup enables rapid simultaneous calibration of all sensors.
3Device complexity
If tension sensors remain in place during calibration, then system complexity is reduced, but calibration reliability deteriorates due to yarn interference
Solution Approach 1:
The patent makes the creel structure multi-functional by using it both for its normal yarn support function and as a temporary relocation position for calibration. This universal use of existing structure achieves calibration reliability without adding separate dedicated calibration equipment, maintaining system simplicity.
Data Source
Figure 1
Figure 1a
Figure 2
AI summary
A tension sensing unit configured to sense the tension of a group of yarns involved in a textile process, comprising a series (S) of clustered tension sensors (14) each provided with a sensitive element (14a) adapted to be slidingly engaged by a yarn (Y) of a group (A). A spacer element (22), which is shaped according to the mutual arrangement of the sensitive elements (14a) of the tension sensors (14) of the series (S), is movable between a resting position, in which it does not interfere with the path of the yarns (Y) of the group (A), and an operative position, in which it pushes the yarns (Y) of the group (A) away from the respective sensitive elements (14a) to perform a zeroing calibration of the tension sensors (14).