Sample Warper Thread Speed Sensor for Deposition Detection
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Solution Overview
Problem
Existing sample warping machines face issues in ensuring the accurate deposition of threads on either the warping drum or auxiliary transport device, leading to errors that result in a deterioration of the pattern warp, particularly due to the inability to reliably distinguish between threads being wound on the drum or the auxiliary device.
Innovation Solution
The integration of a yarn speed sensor that generates distinct signals based on thread speed ranges, allowing for the determination of whether the thread is being deposited on the warping drum or the auxiliary transport device, thereby preventing errors and ensuring accurate winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a normal thread tension sensor is used to detect thread deposition location, then the thread tension can be monitored, but the sensor cannot distinguish whether the thread is laid on the circumference of the warping drum or on the auxiliary transport device because the thread is tensioned in both cases
Solution Approach 1:
The patent changes the detection parameter from thread tension to thread speed. Since the warping drum and auxiliary transport device have different circumferences, they rotate at different speeds to achieve the same linear thread speed. By measuring thread speed directly, the system can determine which device is currently winding the thread, resolving the ambiguity that plagues tension-based detection methods.
2Adaptability or versatility
If frequent changeover between warping drum and auxiliary transport device is performed to expand patterning options, then the patterning capability is improved, but the probability of errors increases
Solution Approach 1:
The patent implements a feedback mechanism where the thread speed sensor continuously monitors thread speed and provides real-time information to the control system. The control system compares the measured speed with expected speeds for each device and automatically detects when a thread is being deposited on the wrong device, enabling immediate correction and preventing pattern deterioration.
3Adaptability or versatility
If thread guides are moved frequently to change deposition location, then the patterning options are expanded, but the complexity of the system increases
Solution Approach 1:
The patent replaces complex mechanical tracking systems with a simpler electronic sensing and control system. Instead of relying on complex mechanical mechanisms to ensure precise thread guide positioning, the system uses thread speed sensors to detect deposition location and electronically controls thread guides to correct any errors, reducing mechanical complexity while maintaining or improving precision.
Data Source
Figure 1~2
AI summary
The sample chain wrapping machine (1) has a warping drum (2) which comprises an axis (4) and movable transport surfaces at its circumference. The transport surfaces are parallel to the axis. An auxiliary transport unit (7) has a receiving area in front of a front side of the warping drum. A gate (3) is provided, in which a coil is arranged. Thread guides (10a-10c) are arranged between the gate and the warping drum. A thread is guided from the coil to the warping drum. Thread-speed sensors (12a-12c) are arranged between the coil and the warping drum.