Thread Speed Sensor for In-Line Coating Substance Dispensing Accuracy

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Solution Overview

Problem

Existing thread consuming devices, such as embroidery machines, face challenges in accurately dispensing coating substances like colorants due to uncertainties in thread speed measurement, which are affected by thread elasticity and system heat, leading to inconsistencies in color application.

Innovation Solution

A system with a thread speed sensor measures the thread's speed accurately, allowing precise control of coating substance dispensing through a treatment unit, using a rotational sensor and encoder, and a light detection system to ensure correct color application.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If thread speed is measured using the motor driving the thread, then the measurement is affected by thread elasticity and generated heat, but using a separate thread speed sensor driven by thread motion provides accurate speed measurement without these disturbances

Engineering Contradiction:

Improvethread speed measurement accuracyVSAvoidsystem complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The measurement function is segmented from the driving motor to a separate thread speed sensor. This separates the measurement task from the actuation system, allowing independent optimization of each component and eliminating cross-interference between motor disturbances and measurement accuracy.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A dedicated thread speed sensor acts as an intermediary between the moving thread and the control system. This intermediary component directly contacts only the thread (not the motor), translating thread motion into accurate speed signals without being influenced by motor-generated disturbances.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If multiple pre-coloured threads are used for multi-coloured patterns, then thread complexity increases, but in-line colouring reduces complexity while improving colour quality

Engineering Contradiction:

Improvethread management complexityVSAvoidcolour application accuracy

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The system uses a single white thread that serves as a universal substrate, eliminating the need for multiple pre-coloured threads. The in-line colouring apparatus then applies different colours to this single thread type, achieving multi-colour patterns while simplifying thread management and reducing device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The thread is pre-prepared in a neutral white state before entering the treatment zone, creating a blank canvas that receives colour application. This preliminary preparation ensures consistent baseline properties across all threads, enabling precise colour dispensing and improving manufacturing precision.

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If in-line colouring is implemented without speed compensation, then the system is simpler to operate, but colour application accuracy decreases due to speed variations

Engineering Contradiction:

Improvesystem operation simplicityVSAvoidcoating substance dispensing accuracy

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The thread speed sensor provides continuous feedback about actual thread speed to the control system. This feedback loop enables real-time compensation for speed variations, allowing the coating substance dispensing to be dynamically adjusted to maintain precise colour application even as thread speed changes during operation.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system transitions from static, fixed-parameter dispensing to dynamic, adaptive dispensing. The coating amount and timing are continuously adjusted based on real-time speed measurements, making the system responsive to actual operating conditions while maintaining precision.

Inventive Principle:

Principle #15Dynamics

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 system achieves precise and accurate color application on threads by adjusting the dispensing based on thread speed, reducing errors and enhancing the quality of multi-colored patterns.

Implementation Method 1

The thread speed sensor may comprise a rotational sensor being driven by the motion of at least one thread

Methodology Applied

Scientific EffectRotational sensing:

Implementation Method 2

The thread speed sensor may further comprise an encoder being in operative communication with the pulley

Methodology Applied

Scientific EffectEncoder conversion:

Implementation Method 3

a light detection system for illuminating the at least one thread in order to receive light which is reflected from the at least one thread

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentUS12448713B2Method for in-line treatment of a thread and a system therefore comprising a treatment unit and a thread speed sensor

Publication Date: 2025.10.21 COLOREEL INTERNATIONAL HOLDINGS LTD

AI summary

A system for in-line treatment of thread for use with a thread consuming device is provided. The system comprises at least one treatment unit being configured to dispense one or more coating substances onto the at least one thread when activated and a thread speed sensor being driven by the motion of the at least one thread. A method is further provided.