Warp Thread Tension Sensing Bar with Distributed Strain Gauges
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Solution Overview
Problem
Existing technologies fail to accurately monitor and regulate the tension of individual warp threads across the entire width of a warp in a weaving machine, leading to defects in fabric quality due to imprecise tension measurement and uneven dynamic behavior of backrests.
Innovation Solution
A sensing bar equipped with evenly or unevenly distributed strain gauge sensors along its length, connected to a backrest beam, provides accurate tension data for warp threads, allowing for precise regulation of tension across the entire warp width.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensing bar with multiple strain gauge sensors is used to monitor tension across the entire warp width, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The sensing bar is divided into multiple segments with strain gauge sensors positioned at different locations along its length. Each sensor monitors tension in a specific zone of the warp, allowing individual thread tension detection while maintaining an integrated sensing structure. This segmentation enables precise local measurement without requiring a completely separate sensor for each thread.
Solution Approach 2:
The sensing bar acts as an intermediary element that transfers warp thread tension forces to the strain gauge sensors. Instead of directly attaching multiple sensors to individual threads, the sensing bar distributes and concentrates the tension forces from multiple warp threads to specific sensor locations, enabling indirect but accurate tension measurement across the entire warp width.
2Area of stationary object
If strain gauge sensors are distributed along the sensing bar to cover the entire warp width, then monitoring coverage is improved, but manufacturing precision requirements increase
Solution Approach 1:
The sensing bar is designed with varying sensor distribution characteristics along its length, with sensors positioned at specific locations corresponding to different warp zones. Each section of the sensing bar has optimized sensor placement tailored to the local tension characteristics of that warp region, allowing accurate local measurement while maintaining overall system simplicity.
3Reliability
If the sensing bar is mounted on multiple strain gauge sensors to enable individual thread tension sensing, then reliability is improved, but ease of manufacture decreases
Solution Approach 1:
Multiple strain gauge sensors are integrated onto a single sensing bar structure, combining what would otherwise be separate sensing units into one unified component. This merging approach maintains the reliability benefits of multiple sensors for comprehensive warp monitoring while significantly simplifying the manufacturing and assembly process compared to installing individual sensors for each warp thread.
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 accurate monitoring and regulation of warp thread tension along the entire width, preventing defects and ensuring consistent fabric quality by providing detailed tension distribution data.
Implementation Method 1
a sensing bar (5) fixed by means of a clamp mounting (61) of the bar (5) to six strain gauge sensors (6)
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
The present invention relates to a device for sensing the tension of warp threads in a warp in a weaving machine, in which a sensing bar (5) extending across the entire width of the warp is mounted in the path of the warp threads, whereby the sensing bar (5) is fixedly mounted on at least three strain gauge sensors (6) which are distributed along the entire length of the sensing bar (5).