Weaving Device for Filament Count Determination
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Solution Overview
Problem
In the manufacturing of turbomachine components with fibrous reinforcement, accurately determining the number of filaments in strands used for weaving is challenging due to manual and error-prone processes, leading to mechanical deviations and potential scrapage, resulting in significant costs and delivery delays.
Innovation Solution
A weaving installation equipped with a diaphragm device having an iris mechanism that adjusts to enclose the strand, allowing for precise measurement of the strand's diameter and thereby determining the number of filaments, which can be automated for increased efficiency and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual counting of filaments is used to determine strand size, then operators can control thread size, but the process is tedious and error-prone with no automatic traceability
Solution Approach 1:
The patent replaces the manual mechanical counting method with an optical measurement system. A camera captures an image of the strand cross-section, and image processing software automatically counts the filaments, eliminating the need for manual counting while improving accuracy and speed.
Solution Approach 2:
The patent creates a digital copy (image) of the strand cross-section instead of directly counting physical filaments. This optical copy allows for automated analysis through image processing, significantly reducing measurement time and eliminating human error.
2Reliability
If manual control of thread size is used, then operators can place spools in corresponding creels, but errors can be made and no automatic traceability can be carried out
Solution Approach 1:
The patent implements a feedback system where the measured filament count is automatically recorded and can be used to verify correct spool placement. The system provides automatic traceability by storing measurement data, allowing for verification and correction of any placement errors.
Solution Approach 2:
The patent replaces manual verification processes with automated optical measurement and data recording systems, significantly improving reliability and enabling automatic traceability of strand size control.
3Manufacturing precision
If incorrect strand size is used, then mechanical modifications are required, but this results in waivers and potential part scrappage with significant costs and delivery delays
Solution Approach 1:
The patent performs filament count measurement before the weaving process begins, allowing for early detection of incorrect strand sizes. This preliminary measurement prevents costly rework or scrappage by identifying issues before material is committed to production.
Solution Approach 2:
The patent uses automated optical measurement to ensure precise strand size verification, eliminating the need for mechanical modifications and reducing material waste associated with incorrect strand usage.
4Measurement precision
If caliper or thickness gauge is used to measure strand diameter, then measurement attempts can be made, but the filaments move and the section is not constant making measurement impossible
Solution Approach 1:
The patent replaces mechanical measurement tools (calipers, thickness gauges) with an optical imaging system. The camera captures the strand cross-section image, and software processing automatically determines filament count and dimensions, eliminating the problems of filament movement and irregular section shape.
Solution Approach 2:
The patent creates a digital image copy of the strand cross-section, allowing for accurate measurement and filament counting without physically touching or disturbing the strand, thus overcoming the limitations of mechanical measurement tools.
Data Source
Figure 1~2
Figure 3A~3D
AI summary
The invention relates to a weaving installation comprising a loom (10) designed to receive a series of strands (14), and at least one device (32) for measuring the diameter of a strand (14) comprising a defined number of filaments, the device (32) comprising a diaphragm (34) having an external ring (38) forming a support on which a series of strips (36) forming an iris are fixed, the strips (36) being movable and allowing a substantially circular space (40) with variable dimensions to be defined at the center of the iris. The diaphragm (34) being configured to adjust the dimensions of the space (40) so as to allow a strand (14) of the loom to pass through it, and to encircle the profile of the strand (14) so as to allow the number of filaments in the strand (14) to be determined.