Warp Yarn Breakage Detection Using Gravity Drop Wire
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Solution Overview
Problem
Conventional warp yarn/tape breakage detection systems in circular weaving machines are prone to operator error, require frequent monitoring, and malfunction in dusty environments, leading to fabric wastage and machine downtime.
Innovation Solution
An automated warp breakage detection system using a drop wire with a motion restrictor element and sensing elements that maintain contact or proximity to send a notification signal to the operator, functioning effectively in dusty conditions and reducing false alarms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If automated yarn end detection systems using electric circuits are used, then productivity is improved through automation, but reliability deteriorates due to frequent malfunctioning in dusty environments
Solution Approach 1:
The patent replaces electronic/optical sensing systems with a purely mechanical sensing mechanism. A gravity-controlled drop wire made of metal passes through the yarn, and when the yarn breaks or ends, the drop wire falls down mechanically to trigger a sensor. This mechanical system is resistant to dust interference that causes electronic circuit malfunctioning.
Solution Approach 2:
The drop wire acts as an intermediary mechanical element between the yarn and the detection system. Instead of directly sensing the yarn condition with electronic sensors, the drop wire mechanically transmits the yarn breakage signal to the detection mechanism, providing a dust-resistant interface.
2Measurement precision
If operator monitoring of bobbin exhaustion is implemented, then measurement precision is improved through direct observation, but loss of time increases due to frequent monitoring requirements
Solution Approach 1:
The system makes the yarn end detection self-acting. The drop wire automatically falls and triggers the alarm mechanism when the yarn breaks or ends, without requiring operator intervention for monitoring. The system detects and signals the condition itself, eliminating the need for continuous operator observation.
Solution Approach 2:
The system provides immediate feedback through an alarm notification when the yarn condition changes. The mechanical drop wire movement is directly coupled with an alarm mechanism that instantly notifies the operator of yarn breakage or end, enabling timely response without continuous monitoring.
3Object-affected harmful factors
If machine stoppage is implemented when warp ends are detected, then harmful factors are reduced by preventing fabric damage, but productivity decreases due to machine downtime
Solution Approach 1:
The system takes preliminary action by providing advance warning through the alarm mechanism before the loose yarn can cause fabric damage. The operator is notified in advance and can plan the machine stoppage, minimizing disruption to production while preventing harmful effects.
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 system reliably detects warp yarn/tape breakage, reduces operator dependency, minimizes fabric wastage, and minimizes machine downtime by sending timely notifications, even in dusty environments.
Implementation Method 1
Drop wires (6) are provided on every individual warp yarn/tape which is fed to the central reed ring section. Breakage of the running yarn (1A) causes loss of tension in the yarn (1A), causing the drop wire (6) to lose its elevation rapidly and fall (under its self-weight) from its normal operative position.
Implementation Method 2
causing the drop wire (6) to lose its elevation rapidly and fall (under its self-weight) from its normal operative position
Data Source
AI summary
A warp breakage/end sensing system and device are configured to detect an end of a warp yarn on a circular weaving machine. A mechanism causes a notification signal to be sent to the loom operator in the situation where a yarn breakage is detected. A drop wire loses its elevation and falls from its normal operative position. The drop causes a first element to rotate and come in contact (physical or non-physical) with a second element, thereby completing an electric circuit and sending a yarn breakage signal to the operator. Upon restoration of the yarn, the first element restores to its normal working position. In the case of a non-physical contact, the first sensing element enters the triggering region of the second sensing element thus causing a signal to be sent.