Thread Tension Control via Magnetic Brake Current Regulation

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Solution Overview

Problem

Existing thread delivery systems face challenges in accurately regulating thread tension due to individual deviations and temporal fluctuations in braking devices, which can lead to inconsistent thread tension values across different manufacturing conditions and temperature changes.

Innovation Solution

A method and device for controlling thread delivery that uses a braking device with magnetic elements, where a working current is adjusted using pulse width modulation to compensate for variations, with a processor unit assigning specific current values to achieve desired thread tension based on measured values and production conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a working coil is used to adjust the brake body position through magnetic field, then the thread tension can be regulated, but individual deviations and temporal fluctuations occur due to manufacturing conditions and heating, leading to inconsistent thread tension values

Engineering Contradiction:

Improvethread tension consistencyVSAvoidthread tension stability

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent implements a feedback control system where a sensor detects the actual thread tension and compares it with the target value. The control unit adjusts the working coil current based on this feedback to compensate for individual deviations and temporal fluctuations, ensuring consistent thread tension across different braking systems and operating conditions.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent changes the control parameter from fixed current values to dynamically adjusted current values based on actual measurements. By monitoring thread tension and adjusting the working coil current in real-time, the system compensates for manufacturing variations and thermal effects, maintaining reliable thread tension control.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If a high working current is continuously applied to the working coil to maintain thread tension, then the thread delivery is controlled, but heat generation in the power supply unit increases

Engineering Contradiction:

Improvethread tension control precisionVSAvoidpower supply unit temperature

Core Design Contradiction:

Manufacturing precisionVSTemperature

Solution Approach 1:

The patent uses periodic pulsed current instead of continuous current to actuate the working coil. The control unit applies current in short pulses sufficient to adjust the brake body position, then interrupts the current. This periodic action maintains thread tension control while significantly reducing heat generation in the power supply unit compared to continuous current application.

Inventive Principle:

Principle #19Periodic action

3Device complexity

If manual adjustment devices are used for the brake body, then the structure is simple, but the thread tension regulation is imprecise and cannot compensate for temporal fluctuations

Engineering Contradiction:

Improveadjusting device structureVSAvoidthread tension regulation precision

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent replaces manual mechanical adjustment devices with an automated electromagnetic system. The working coil generates magnetic field forces to position the brake body, controlled by a microprocessor-based control unit that continuously adjusts parameters based on sensor feedback. This substitution of mechanical manual control with electromagnetic automation achieves precise thread tension regulation while compensating for temporal fluctuations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution ensures precise regulation of thread tension, compensating for individual and temporal deviations, thereby maintaining consistent thread delivery across varying conditions and reducing heat generation in the power supply unit.

Implementation Method 1

one magnetic element acting on the brake body. At least one of the magnetic elements of the adjustment device is designed as a working coil

Methodology Applied

Scientific EffectElectromagnetic force: Lorentz Force

Implementation Method 2

the brake body being pressed against the withdrawal end of the storage body by mutually repelling permanent magnet arrangements on the brake body and in a support

Methodology Applied

Scientific EffectMagnetic repulsion: Magnetism

Data Source

PatentEP2878722B1Method for controlling thread feed, thread feed device and system with thread feed devices

Publication Date: 2017.01.11 MEMMINGER IRO GMBH

AI summary

According to the invention, a loom extracts a thread from a storage body (3) of a thread feeder (1) and the thread tension of the threads (40) in the rear part of the storage body (3) in a thread route is controlled by brake equipment. The thread tension is controlled by a regulating device of the brake equipment. The regulating device is at least provided with a working coil (12) and the working current of the working coil is regulated by a current feeding unit of the regulating device for the adjustment of thread tension. An expect value of the working current is output by a processor unit (P) having a data unit. The expect value is special to the thread feeder (1) and is distributed to the thread tension. The working current is regulated to the expect value through the regulating mechanism of the current feeding unit.