Thread Tension Control via Braking Variance Switching
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Solution Overview
Problem
Existing methods for controlling thread tension in textile machines are complex and inefficient, particularly during startup or when the thread is not moving, leading to inconsistent tension and potential disruptions in the weaving process.
Innovation Solution
A method that utilizes a braking device with a brake body that can be adjusted by an actuating element, controlled by a brake signal, to regulate thread tension by setting a reference value and adjusting an auxiliary value based on variance in measured tension values, allowing for two operating states to optimize tension control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a braking device with continuous tension regulation is used, then thread tension control is improved, but device complexity and control inefficiency increase during startup or stationary periods
Solution Approach 1:
The control system dynamically switches between two operating modes based on real-time conditions: continuous tension regulation during active weaving, and auxiliary value mode during startup or stationary periods. This dynamic adaptation resolves the contradiction by activating complex control only when necessary, simplifying the system during idle periods while maintaining reliability during operation.
Solution Approach 2:
The system changes the control parameter from continuous tension regulation to auxiliary value setting based on the operational state. During startup or when the thread is stationary, the system uses pre-set auxiliary values instead of continuous regulation, reducing control complexity while maintaining adequate tension control for reliable operation.
2Stability of the object's composition
If continuous tension regulation is applied, then thread tension stability is improved, but control efficiency decreases during startup or stationary periods
Solution Approach 1:
The control system applies periodic assessment of the operational state (weaving active vs. stationary) and switches regulation modes accordingly. During active weaving, continuous regulation maintains tension stability; during startup or idle periods, the system transitions to auxiliary value mode, improving control efficiency by avoiding unnecessary continuous regulation while maintaining adequate stability when needed.
3Ease of operation
If auxiliary values are used for tension control, then control simplicity is improved, but tension regulation precision deteriorates
Solution Approach 1:
The control system segments the operational periods into distinct phases: startup/stationary periods using auxiliary values for simple control, and active weaving periods using continuous regulation for precise tension control. This segmentation allows each mode to be optimized for its specific function, achieving both simplicity when appropriate and precision when required.
Solution Approach 2:
Auxiliary values are pre-determined for startup and stationary conditions, allowing simple control during these phases. When active weaving begins, the system transitions to continuous regulation with real-time precision control, ensuring that precision is applied only when necessary while maintaining operational simplicity during transition phases.
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
This approach simplifies thread tension control by using variance in tension measurements to determine operating states, enabling efficient regulation of thread tension and minimizing disruptions, thus improving the reliability and efficiency of the thread delivery process.
Implementation Method 1
The thread tension is adjusted by a brake element of the braking device acting on the thread path downstream of the storage body in a braking interval. This is achieved by pressing the brake element against a clamping surface, for example, at the take-off end of the storage body
Data Source
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AI summary
In a method according to the invention for controlling the yarn supply from a yarn supply device (1) to a textile machine, the yarn is drawn from a storage body (3) of the yarn supply device (1) by the textile machine. The yarn tension (40) is set by a braking device with at least one brake element (8) in the yarn path after the storage body (3) and by an adjusting device. At least one actuating element of the adjusting device of the braking device acts on the brake element(s) (8), wherein the actuating element(s) are controlled by a braking signal.In a first operating state (B1), the thread tension is regulated to a reference value (Mrerf) by adjusting the brake signal via a thread tension unit. Measured values (Mi) of the thread tension are determined by a tension measuring unit, and the difference (Mdiff) between the measured value (MI) and the reference value (Mref) is minimized by a tension control unit (80). In a second operating state (B2a, B2b), an auxiliary value (Ihc, Iho) of the brake signal is set. The operating state is determined by a test variable relative to a threshold. A test unit (85) determines a measure of fluctuations in the measured values (Mi) of the thread tension as the test variable.