Warping Machine Image-Based Winding Control
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Solution Overview
Problem
Existing warping machines face limitations in productivity due to the reliance on cam followers or touch sensors for controlling thread movement, and laser sensors are not universally applicable for determining the diameter and inclination of the forming roll, leading to inefficiencies in maintaining a parallel surface during the winding process.
Innovation Solution
An image pickup device, such as a camera arrangement, with an image capture area wider than the thread width, captures successive images of the winding process to detect the winding surface and its tilt, replacing the need for contact-based sensors by providing continuous monitoring and evaluation of the winding structure, allowing for adjustments in thread movement speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cam followers or touch sensors are used to control thread movement, then the winding process can be monitored, but productivity is limited due to the need for contact-based sensing
Solution Approach 1:
The patent replaces mechanical contact-based sensors (cam followers, touch sensors) with an optical measurement system using image pickup devices. This substitution eliminates the need for physical contact between the sensing mechanism and the forming roll, allowing for non-contact measurement that does not interfere with the winding process and enables higher machine speeds while maintaining monitoring reliability
Solution Approach 2:
The patent creates an optical copy (image) of the forming roll surface using image pickup devices. By capturing images of the winding process and evaluating them to detect surface inclination, the system obtains measurement information without physical contact, thereby maintaining reliability while enabling higher productivity through non-contact sensing
2Measurement precision
If laser sensors are used to determine the diameter and inclination of the forming roll, then measurement capability is improved, but the solution is not universally applicable and has limitations
Solution Approach 1:
The patent employs image pickup devices that can capture two-dimensional images of the forming roll, enabling multiple measurement functions (diameter determination, surface inclination detection, winding quality assessment) with a single system. This multi-functional approach provides universal applicability across different winding configurations and positions, overcoming the limitations of specialized laser sensors
Solution Approach 2:
The patent transitions from one-dimensional point measurements (laser sensors measuring at single locations) to two-dimensional area imaging. The image pickup devices capture the entire forming roll surface or relevant portions, providing comprehensive measurement data that is more versatile and applicable to various winding scenarios while maintaining high measurement precision
3Productivity
If the ribbon is moved quickly up the cone, then productivity increases, but the surface of the forming roll becomes inclined and parallelism is lost
Solution Approach 1:
The patent implements a feedback control system where image pickup devices continuously monitor the surface inclination of the forming roll. The image evaluation device processes these images to detect inclination, and this information feeds back to the control device, which adjusts the relative movement between the yarn sheet guide and warping drum to maintain parallelism. This closed-loop control enables high ribbon feed speeds while preserving surface parallelism
Solution Approach 2:
The patent employs dynamic adjustment of the yarn sheet guide position based on real-time image evaluation. Rather than using fixed mechanical positioning, the system continuously adapts the guide position to maintain optimal parallelism during high-speed winding, enabling productivity improvement without sacrificing manufacturing precision
4Measurement precision
If contact-based sensors are used for monitoring, then measurement is possible, but the speed and productivity of the warping machine are limited
Solution Approach 1:
The patent replaces mechanical contact-based measurement systems with optical imaging. Image pickup devices capture images of the forming roll without physical contact, eliminating the speed limitations inherent in mechanical sensing systems. This enables the warping machine to operate at higher speeds while maintaining accurate measurement of forming roll diameter and surface characteristics
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
This solution enhances productivity by enabling continuous monitoring and control of the winding process over the entire width of the ribbon, detecting surface inclination, and adjusting the relative movement between the yarn sheet guide and the warping drum, ensuring a parallel surface and maintaining high-quality winding without the need for contact sensors or laser technology.
Implementation Method 1
an image pickup device which is directed at least to a part of the winding portion
Data Source
Figure 1~2
Figure 3~5
AI summary
A warping machine (1) is described, comprising a warping drum (2) with a winding area, a yarn guide (7), and a control device (11) that controls the movement of the warping drum (2) and the yarn guide (7) relative to each other. The aim is to provide a generally applicable warping machine with high productivity. For this purpose, an image acquisition device (12), directed at least towards a portion of the winding area on which a winding forms during operation of the warping machine, is connected to the control device (11).