Sewing Machine Thread Tensioner with Spring Length Sensor
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Solution Overview
Problem
Users of traditional sewing machine thread tensioners face difficulties in achieving optimal thread tension due to the lack of precision in adjusting the tension settings, particularly when switching between different types of threads, leading to cumbersome and error-prone processes.
Innovation Solution
A thread tensioner system that includes a knob, first and second disks, a spring, and a sensor, where the sensor tracks the current length of the spring to determine the tension applied to the thread, allowing for real-time display and precise adjustment of the tension setting, enabling users to achieve optimal tension for specific types of threads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a traditional knob-based thread tensioner is used, then the device structure is simple, but the measurement precision of tension setting is insufficient
Solution Approach 1:
The patent replaces the traditional mechanical knob-based tension adjustment system with an automated sensor-based system. The sensor detects the position of the tensioning element and provides feedback to control the motor-driven adjustment mechanism, enabling precise tension measurement and control without requiring manual tracking of knob rotations.
Solution Approach 2:
The patent incorporates a sensor that provides real-time feedback on the tension setting to the control system. This feedback loop allows the system to automatically adjust the tension to the optimal setting and maintain it consistently, eliminating the need for users to manually track and remember adjustment positions.
2Ease of operation
If manual tracking of knob rotations is required, then no additional sensors or systems are needed, but the ease of operation deteriorates
Solution Approach 1:
The patent implements a self-service system where the tensioner automatically adjusts and maintains optimal tension settings without requiring user intervention to track or remember adjustment positions. The sensor-based system autonomously performs the tensioning function, freeing the user from the cumbersome task of manual tracking.
Solution Approach 2:
The patent replaces the manual mechanical tracking system with an automated sensor-based control system that electronically tracks and controls the tension adjustment process, eliminating the need for users to physically track and remember knob rotation positions.
3Productivity
If the tensioner requires re-adjustment when switching thread types, then the basic tensioning function is maintained, but the loss of time increases
Solution Approach 1:
The patent stores optimal tension settings for different thread types in memory. When a user switches thread types, the system can automatically retrieve and apply the pre-stored optimal setting, eliminating the need for manual re-adjustment and time-consuming tracking of previous settings.
Solution Approach 2:
The sensor-based feedback system enables the tensioner to automatically detect and adjust to optimal settings for different thread types, providing rapid adaptation without requiring manual intervention or time-consuming tracking of adjustment positions.
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
Enables users to rotate the knob to the precise rotational position for optimal thread tension, improving consistency and reducing errors in achieving uniform stitches across fabric layers.
Implementation Method 1
a spring configured to exert a force against the second disk
Implementation Method 2
As the knob is rotated, causing the length of the spring to be shortened or lengthened, the sensor may be configured to track a current length of the spring
Data Source
AI summary
Thread tensioner for a sewing machine. In one example embodiment, a thread tensioner for a sewing machine includes a first disk, a second disk, a spring, a knob, and a sensor. The second disk is positioned next to the first disk. The spring is configured to apply tension to a thread positioned between the first disk and the second disk by exerting a force against the second disk. The spring defines a length between a first end and a second end. The knob is configured, when rotated in one direction, to travel along a threaded shaft toward the spring and thereby cause the length of the spring to shorten. The knob is configured, when rotated in another direction, to travel along the threaded shaft away from the spring and thereby allow the length of the spring to lengthen. The sensor is configured to track a current length of the spring.