Variable-Diameter Circular Looms for Continuous Hollow Textile Weaving
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Solution Overview
Problem
Current circular looms are limited to weaving at a fixed diameter, requiring re-threading and component replacement for different diameters, leading to inefficiencies and waste in producing garments with varying sizes and shapes.
Innovation Solution
A loom with a variable diameter weaving ring, independently actuated heddle units, and a weft insertion arm system that adjusts position to continuously weave fabrics with varying diameters, allowing for seamless garment production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If current circular looms are designed to weave at a fixed output size, then the loom structure is simple and reliable, but the adaptability to produce garments with varying diameters is limited
Solution Approach 1:
The patent applies the dynamics principle by making the weaving ring diameter adjustable during operation. The support arms are configured to move radially, allowing the weaving ring to change diameter dynamically while weaving, enabling the loom to produce garments with varying diameters without requiring complete structural redesign or re-threading for each size.
Solution Approach 2:
The patent segments the loom structure into modular components, particularly the support arms that can be independently positioned and adjusted. This segmentation allows each support arm to be moved to different radial positions to accommodate varying diameters, providing adaptability while maintaining a relatively simple overall structure that doesn't require complete disassembly or reconfiguration.
2Adaptability or versatility
If circular looms are re-configured to weave at different diameters by replacing components, then different garment sizes can be produced, but the production time and labor costs increase
Solution Approach 1:
The dynamic adjustment mechanism allows the loom to change diameter during the weaving process without stopping or requiring re-threading. The support arms can be moved to different radial positions while the loom operates, enabling size variations to be achieved in real-time during production, thereby eliminating the time loss associated with component replacement and re-threading for different garment sizes.
3Productivity
If fixed diameter circular looms are used, then the manufacturing process is efficient and consistent, but material waste increases when producing garments with varying sizes
Solution Approach 1:
By enabling dynamic diameter adjustment during weaving, the loom can efficiently produce garments with varying sizes directly from the weaving process. This eliminates the need to produce fixed-size garments that may not match customer requirements, thereby reducing material waste from size mismatches while maintaining high weaving efficiency and consistency through continuous operation without interruption for size changes.
4Adaptability or versatility
If variable diameter weaving is implemented, then on-demand garment production is enabled, but the device complexity and control system requirements increase
Solution Approach 1:
The dynamic adjustment mechanism uses mechanical linkages and actuators that, while adding some complexity, enable on-demand production by allowing real-time diameter changes during weaving. The control system manages the coordination between support arm movement and weaving operations, providing on-demand garment production capability through automated control that offsets the increased device complexity.
Data Source
AI summary
A circular loom for continuously weaving fabric with a varying diameter includes a variable diameter weaving ring, independently actuated heddles, and at least one shuttle including a weft insertion arm attached to a linear rail system configured to adjust the position of weft insertion arm based on a diameter of weaving ring. An associated method includes varying the diameter of weaving ring, independently actuating heddles and adjusting the position of weft insertion arm along linear rail system to continuously produce hollow textile products having variable diameters.