Self-adjusting Thread Tensioner for Textile Winding Pulsations
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Solution Overview
Problem
Existing thread tensioning devices in textile machines struggle to accurately adjust and maintain thread tension during the spooling process, particularly due to pulsations in speed and tension caused by conical package geometry, hairiness, and friction variations, leading to inconsistent yarn density and package shape.
Innovation Solution
A thread tensioning device with a comb-like structure featuring stationary and displaceable deviator elements, actuated by a stepper motor and controlled by a tension sensor, modulates the thread's path tortuousness and spring compression to dynamically adjust tension and dampen vibrations, ensuring consistent tension across varying spool conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conventional thread tensioning device is used, then the device structure is simple, but the tension control precision is insufficient due to pulsations from conical package geometry and friction variations
Solution Approach 1:
The patent implements a dynamic tensioning system where the guide element can change its position along the thread path in real-time. The guide element is movable along the curved path, allowing the system to adapt to varying tension conditions caused by conical package geometry and friction variations. This dynamic adjustment capability enables precise tension control throughout the winding process, resolving the contradiction between simple structure and precise control.
Solution Approach 2:
The patent introduces a curved guide element as an intermediary component between the thread source and the winding device. This guide element creates a defined curved path that the thread must follow, and by positioning the guide element at different locations along this path, the system can modulate the thread tension. The guide element acts as a mediator that translates positional changes into tension adjustments, enabling precise control without requiring complex active actuation mechanisms.
2Productivity
If the winding speed is increased to improve productivity, then the production efficiency increases, but the tension pulsations become more severe leading to inconsistent yarn density
Solution Approach 1:
The movable guide element provides dynamic tension compensation that becomes increasingly important at higher winding speeds. As the winding speed increases, the system can rapidly reposition the guide element along the curved path to counteract the amplified tension pulsations. This dynamic response capability allows the system to maintain stable thread tension even during high-speed operation, enabling increased productivity without sacrificing yarn density consistency.
Solution Approach 2:
The curved guide path is designed to preemptively counteract the tension pulsations that arise during conical winding. By forcing the thread to follow a predetermined curved trajectory, the system creates a geometric constraint that opposes the natural tension variations caused by the conical package geometry. This preliminary anti-action mechanism works continuously to stabilize tension before the pulsations can significantly affect yarn density, even at high winding speeds.
3Adaptability or versatility
If a fixed tensioning mechanism is used, then the device is easy to operate, but it cannot compensate for friction variations and hairiness effects throughout the winding process
Solution Approach 1:
The system implements self-service tension control through the movable guide element that automatically adjusts its position based on the thread tension requirements. As the winding progresses and friction conditions change, the guide element's position along the curved path can be modified to compensate for these variations. This self-adjusting mechanism provides adaptability to different winding conditions without requiring complex manual intervention or sophisticated control systems, maintaining ease of operation while enhancing tension control adaptability.
Solution Approach 2:
The patent utilizes parameter changes by varying the guide element's position along the curved path as a control parameter. By changing this geometric parameter (the position of the guide element), the system can adjust the effective tension on the thread to compensate for friction variations and hairiness effects. This simple parameter change approach provides versatile tension adjustment capability without introducing complex operational procedures, balancing adaptability with ease of use.
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 device effectively amplifies entry tension exponentially, adjusts tension based on detected values, and dampens vibrations, resulting in a more consistent and stable thread tension, improving yarn density and package shape quality by compensating for speed and tension pulsations.
Implementation Method 1
an elastic abutment with springs, reacting to the pulsations in tension
Implementation Method 2
an elastic abutment with springs, reacting to the pulsations in tension
Implementation Method 3
the tension is amplified exponentially by the successive deviations, producing a tension dependent on the deviation of the thread and on the friction
Data Source
Figure 1
Figure 2A~2B
Figure 2C
AI summary
Device for tensioning a winding thread (2) in textile machines comprising a plurality of stationary deviator elements (22, 54) and a plurality of displaceable deviator elements (27, 47) arranged like a comb facing one another in a staggered and opposed manner so as to form a tortuous path for the thread that passes through the device, in which such deviator elements are provided with sliding elements (38) elastically contrasted to move forth and back against the thread, each sliding element (38) being capable of moving independently from each other, in which the tortuousness of the path is adjusted with a mobile device (26) that modulates the load of the elastic elements (39, 49) working in contact with the thread, to obtain the desired tension in the thread in outlet from the thread tensioning device.