Waveguide Illumination Projector for Textile Yarn Shadow Detection
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Solution Overview
Problem
Existing clearer systems for textile machines have complex and difficult-to-handle optical setups, along with complex housings that limit their optical capabilities and are tedious to assemble, leading to high resource costs and susceptibility to disturbances.
Innovation Solution
An illumination projector system that includes a light source, such as an LED, and a waveguide configured to project a shadow or reflect light from an object, such as a yarn, with an improved illumination profile that is symmetrical and free of internal patterns, using a waveguide with a diffusive inner surface and a simple, cost-effective design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a complex optical setup with multiple transmitting elements (diffusing foil, aperture, lens) is used, then the illumination capability is improved, but the device complexity and assembly difficulty increase
Solution Approach 1:
The patent combines multiple optical functions (diffusion, aperture control, and focusing) into a single integrated waveguide component. The waveguide features a diffusive inner surface that performs both light distribution and pattern elimination, while the exit aperture provides controlled light projection, eliminating the need for separate diffusing foils, apertures, and lenses used in prior art
Solution Approach 2:
The waveguide serves multiple functions simultaneously: it guides light from the LED source, diffuses the light through its internal reflective surface to eliminate patterns, controls the light output through its exit aperture, and projects the illumination onto the target object. This multi-functional design replaces several specialized components with one universal element
2Illumination intensity
If a complex housing structure is used to support the optical setup, then the optical capabilities are maintained, but the assembly process becomes tedious and resource costs increase
Solution Approach 1:
The invention separates the optical functionality from the housing structure. The waveguide is designed as a standalone component that encapsulates all necessary optical features, allowing it to be manufactured and tested independently before final assembly. This segmentation simplifies the housing design to merely providing mounting support, rather than integrating complex optical mechanisms
Solution Approach 2:
The waveguide can be manufactured using cost-effective methods such as injection molding with integrated diffusive surfaces or internal coatings. This approach replaces expensive, precision-machined optical assemblies with more economical plastic components that achieve the same optical performance through molded-in features rather than assembled parts
3Illumination intensity
If multiple optical components are assembled, then the illumination system is complete, but the system becomes susceptible to disturbances and alignment issues
Solution Approach 1:
By merging the diffusive surface, light guiding path, and exit aperture into a single waveguide component, the invention eliminates multiple interfaces and alignment points that would otherwise exist between separate components. This reduces the number of potential failure points and minimizes sensitivity to assembly variations and environmental disturbances
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 solution reduces resource costs, enhances system capabilities, and makes the system more resilient to disturbances by simplifying the optical setup and assembly process while maintaining effective light projection and detection capabilities.
Implementation Method 1
The waveguide may be at least one of a tube with a non-specular internal surface made out of a highly reflective material
Implementation Method 2
a waveguide with a diffusive inner surface
Implementation Method 3
particularly a light source might be a light emitting diode, in short LED
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to an illumination projector for a shadow projection from an object, particularly a yarn in a textile machine. The illumination projector may comprise at least one light source, particularly a light emitting diode (LED). To reduce the resource costs, to improve the system capabilities and to render the system more inert to disturbances it is provided that the illumination projector comprises at least one waveguide and that the light source is placed such that the emitted light enters the waveguide and that the waveguide is configured to be placed relative to the object such that the light exiting the waveguide on its exit side is to be projecting a shadow from the object to a receiving side or such that light is to be reflected from the object to a receiving side..