Thread Feeding System with Dual Pulley Speed Control

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Solution Overview

Problem

Existing thread feeding systems for textile machines either require synchronization with the machine, leading to complex programming and potential thread breakage, or fail to maintain a constant drawing ratio, resulting in inconsistent product quality due to uncompensated friction variations.

Innovation Solution

A system comprising two feeders connected through a control unit that maintains constant tension and preset drawing ratio by adjusting the speed of pulleys using algorithms like P, PI, PID, allowing for automatic operation without synchronization with the textile machine, and enabling programming of drawing values based on machine operating steps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If synchronization with the textile machine is implemented to maintain constant thread speed, then the thread feeding speed consistency is improved, but the device complexity and programming difficulty increase significantly

Engineering Contradiction:

Improvethread feeding speed consistencyVSAvoidsynchronization programming complexity

Core Design Contradiction:

SpeedVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical/electrical synchronization system with a tension-based feedback control system. Instead of synchronizing the feeder motor speed with the textile machine speed through complex electrical signals, the system uses tension sensors to detect actual thread tension and adjusts the feeder motor speed automatically based on tension feedback, eliminating the need for synchronization programming

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables the feeder to self-regulate its operation based on real-time tension measurements. The tension sensor continuously monitors thread tension and the control unit automatically adjusts motor speed to maintain constant tension, allowing the system to adapt to varying machine speeds and thread conditions without external synchronization signals

Inventive Principle:

Principle #25Self-service

2Stability of the object's composition

If tension control is implemented during thread feeding, then the thread tension uniformity is improved, but the drawing ratio consistency deteriorates due to uncompensated friction variations

Engineering Contradiction:

Improvethread tension uniformityVSAvoiddrawing ratio consistency

Core Design Contradiction:

Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

The patent implements a feedback control system that measures actual thread tension during feeding and uses this information to adjust motor speed. The tension sensor provides continuous feedback to the control unit, which modifies the feeder speed to compensate for friction variations and maintain both constant tension and consistent drawing ratio

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system dynamically changes the motor speed parameter based on real-time tension measurements. When tension deviates from the setpoint, the control unit adjusts the motor speed to restore proper tension, thereby maintaining consistent drawing ratio despite variations in friction or machine speed

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If automatic start and stop feeding is implemented through tension measurement, then the ease of operation is improved, but the thread breakage risk increases due to speed ratio errors

Engineering Contradiction:

Improveautomatic feeding controlVSAvoidthread breakage resistance

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent replaces the speed-ratio-based automatic control system with a tension-based control system. Instead of relying on pre-programmed speed ratios between feeder and machine, the system uses tension sensors to detect actual thread conditions and adjusts feeding speed automatically, eliminating thread breakage caused by speed ratio errors while maintaining ease of operation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP2914524B1Method and system for feeding a thread to a textile machine, at a constant tension and preset draw, as a function of the operating step of the latter

Publication Date: 2017.02.08 B T S R INT

AI summary

A method and system for feeding a thread (F) at a preset drawing to a textile machine (T) comprising a first feeder (5) which sends the thread to the textile machine (T) and a second feeder (6) arranged spaced from the first feeder and which sends such thread to the latter, each feeder (4, 5) having a rotary member (15) on which there is partly wound the thread (F) before the feeding thereof and speed sensor means adapted to detect the rotational speed of such rotary member and tension sensor means adapted to detect the tension of the thread (F) exiting from each feeder (4,5). There is provided for controlling the drawing of the thread sent to the textile machine (T) by controlling and adjusting the ratio between the rotational speed (V1) of the rotary member of the first feeder (5) and the rotational speed (V2) of the rotary member of the second feeder (4).