Thread Feeding Device One-Piece Shaft Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing thread feeding devices for knitting machines face challenges in assembly safety and packaging volume, particularly with multi-part shafts leading to concentricity errors that affect thread tension and fabric quality, and require cost-effective and space-efficient solutions for shipping and installation.
Innovation Solution
A thread feeding device with seamless, one-piece cylindrical shafts and a two-shell housing design, featuring pre-assembled bearings and a snap-in coupling system, which simplifies assembly and reduces the risk of damage, along with a flexible plastic cover for space-saving packaging and a drive motor arrangement that minimizes interference with manual access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multi-part shafts are used to hold yarn spools, then assembly flexibility is improved, but concentricity errors occur leading to periodic fluctuations in yarn tension and impaired fabric quality
Solution Approach 1:
The shaft is divided into multiple segments that can be assembled together, allowing flexibility in assembly while maintaining concentricity through precise manufacturing of each segment. The segmentation enables modular construction where each part can be manufactured with high precision independently, then assembled to form the complete shaft system.
Solution Approach 2:
The shaft segments are pre-manufactured with precise dimensions and concentricity before assembly. By performing the precise manufacturing action in advance during production rather than during final assembly, the patent ensures high concentricity is achieved without compromising assembly flexibility. The pre-fabricated segments are designed to fit together in a predetermined manner.
2Volume of moving object
If shafts are disassembled for shipping, then packaging volume is reduced, but assembly complexity increases and risk of incorrect assembly rises
Solution Approach 1:
The device is segmented into modular components including the shaft, housing, and bearing assemblies that can be separately packaged to reduce volume. However, these segments are designed with standardized connection interfaces that simplify reassembly, reducing the complexity increase that would otherwise result from disassembly for shipping.
Solution Approach 2:
The shaft and bearing components are pre-assembled into integrated units before shipping. This preliminary assembly reduces packaging volume compared to shipping individual separate parts, while the pre-assembled nature of these units simplifies the final installation process, avoiding increased assembly complexity.
3Manufacturing precision
If shafts are made as one-piece continuous elements, then concentricity is improved and thread damage is prevented, but manufacturing complexity increases
Solution Approach 1:
The shaft is manufactured as a one-piece continuous element to ensure high concentricity and prevent thread damage. While this increases manufacturing complexity compared to assembling multiple parts, the patent addresses this by integrating the shaft with the bearing seats and housing features in a single monolithic component, eliminating assembly steps while maintaining precision.
Solution Approach 2:
The shaft is merged with the bearing seats and housing features into a single integrated component. This combining of functions into one piece ensures perfect concentricity and eliminates the need for separate assembly operations, offsetting the increased manufacturing complexity by reducing overall assembly complexity.
4Reliability
If bearings are pre-installed on shafts during factory assembly, then assembly safety is improved and damage risk is reduced, but manufacturing time increases
Solution Approach 1:
The bearings are pre-installed on the shafts during factory assembly under controlled conditions. This preliminary action improves assembly safety by eliminating the risk of damage during final installation, while the manufacturing time increase is offset by the standardized, repeatable nature of the pre-assembly process that can be efficiently performed during production.
Solution Approach 2:
The shaft and bearing assembly is created as a pre-assembled unit during manufacturing. This segmentation of the production process into pre-assembly and final installation phases improves safety while the modular nature of the pre-assembled unit allows for efficient manufacturing that minimizes time loss.
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
The solution enhances assembly safety, reduces packaging volume, ensures consistent thread tension, and lowers production costs while maintaining the quality of the knitted fabric by eliminating concentricity errors and simplifying the assembly process.
Implementation Method 1
The bearings, preferably ball bearings, are held on the shafts, preferably by a clamping or press fit
Implementation Method 2
The bearings, preferably ball bearings, are held on the shafts, preferably by a clamping or press fit
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A thread delivery device (1) according to the invention has a flexible hood (16) and/or integrally formed shafts (12, 13) for storing yarn bobbins, and a horizontally divided housing and/or an electric drive motor (50). The device permits reliable and simple production and facilitates handling.