Compact Thread Supply Control Device with Integrated Tension and Velocity Sensors
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Solution Overview
Problem
Existing devices for controlling the supply of textile or metal threads to processing machines lack precision in maintaining constant tension and quantity, especially when dealing with multiple threads, leading to potential defects in finished products.
Innovation Solution
A compact device with a plate-like body supporting two rotary members and sensors that measure thread rotation velocity and tension, connected to a control unit for precise control of thread supply, including generation of alarms for deviations, and capable of self-synchronization and remote data transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a device for controlling thread supply is designed to be compact, then it can be easily mounted on processing machines, but it may have limited space for sensors and control components
Solution Approach 1:
The patent combines multiple functions (thread supply control, tension measurement, quantity measurement, and regulation) into a single integrated compact device. The body houses both rotary members for supply control and sensors for measurement, merging what would traditionally be separate components into one unified unit that maintains precision while reducing overall system volume.
Solution Approach 2:
The compact device performs multiple functions simultaneously: it controls thread supply velocity through rotary members, measures tension via sensors, monitors quantity supplied, and provides regulation loops. This multi-functionality allows a single compact unit to replace what would otherwise require multiple separate devices, maintaining comprehensive measurement precision within a reduced volume.
2Length of stationary object
If sensors are placed distant from the processing machine to control thread parameters, then the control range is increased, but the response time and precision are reduced
Solution Approach 1:
The patent introduces a tension sensor as an intermediary element that directly contacts the thread between the rotary members and the processing machine. This intermediary sensor provides real-time, precise measurement of thread tension at the critical point near the machine, while the rotary members maintain control over the supply from a distance, combining both long-range control and near-field precision measurement.
3Productivity
If multiple threads are processed simultaneously, then productivity is increased, but it becomes difficult to monitor and control each thread's tension and quantity individually
Solution Approach 1:
The patent divides the monitoring and control system into separate modular units, each equipped with its own rotary members and sensors. This segmentation allows each thread to be independently monitored and controlled through dedicated components, while the overall system maintains manageable complexity through standardized modular architecture that can be replicated for multiple threads.
Solution Approach 2:
The patent implements feedback loops where sensors continuously monitor thread tension and quantity, and this information is fed back to control mechanisms that adjust supply in real-time. This feedback system enables automatic individual control of each thread's parameters, maintaining precision even when processing multiple threads simultaneously without requiring complex manual intervention.
4Measurement precision
If the device includes comprehensive sensors and control mechanisms for precise thread control, then measurement precision is improved, but the device complexity and cost increase
Solution Approach 1:
The patent merges the tension sensor and velocity detection capabilities into a single integrated device structure. The rotary members serve dual purposes: controlling thread supply velocity while also providing a mounting basis for tension sensors. This merging reduces the number of separate components needed, maintaining measurement precision while lowering device complexity and cost.
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
Ensures precise control of thread tension and quantity, preventing defects by generating alarms for irregularities and allowing for complex regulation loops, enhancing product quality and reducing production errors.
Implementation Method 1
velocity detector means which are connected to a control unit adapted to detect the rotation velocity of the rotary members
Implementation Method 2
means for detecting the tension of the moving thread
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A compact device for controlling the supply of a textile or metal thread to a processing machine, such as a textile machine or a spooling or winding machine, comprises a body (1), at least one rotary member (5, 6) with which the thread cooperates, said member being associated with detector means (12) for detecting the rotation velocity thereof, these detector means (12) being connected to a control unit (13), means (15) being provided for detecting the thread tension that are connected to such unit (13). The rotary member is idle and is placed in rotation by the thread which is moved thereon, in proximity to such member (5, 6) the tension detector means (15) being placed. Also claimed is a method for controlling the supply of thread actuated by such device.