Weaving Machine Spacers for Pile Warp Yarn Protection
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Solution Overview
Problem
Existing weaving machines for pile fabrics face issues with pile warp yarns experiencing excessive friction and damage due to knots, particularly when moving through arrays of lancets with uniform profiles, leading to increased wear and rupture.
Innovation Solution
The weaving machine incorporates spacers with projections that gradually overlap in the weft direction, providing a longer initial space before constriction, thereby reducing the impact of collisions and distributing the shock over two points in time, thus minimizing yarn damage and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If lancets with uniform profiles are used in the weaving machine, then the device structure is simplified and manufacturing is easier, but the pile warp yarns experience excessive friction and damage due to knots moving through the uniform array
Solution Approach 1:
The patent applies asymmetry by configuring lancets with different profiles rather than uniform profiles. Specifically, alternating lancets have different shapes - some with sharper edges and others with more gradual transitions - creating an asymmetric array that prevents knots from experiencing concentrated friction at identical positions across all lancets. This asymmetric configuration reduces yarn damage while maintaining manufacturing feasibility.
Solution Approach 2:
The patent implements local quality by giving different sections of the lancet array different characteristics. Lancets positioned at different locations have locally optimized profiles - for example, lancets in high-friction zones have more gradual edges while others have sharper definition. This local differentiation addresses yarn damage issues without requiring complete redesign of all lancets, balancing manufacturing ease with performance.
2Volume of moving object
If lancets are positioned closely together to maintain compact device structure, then the overall device size is reduced, but the pile warp yarns experience increased friction and the shed-forming zone becomes constrained
Solution Approach 1:
The patent resolves the space-friction contradiction by introducing dimensional variation in the lancet profiles. Instead of increasing horizontal spacing between lancets, the invention varies the vertical profiles and angles of different lancets, creating three-dimensional pathways that accommodate yarn movement without increasing the overall device footprint. This dimensional approach allows compact construction while reducing friction.
Solution Approach 2:
The patent applies dynamics by designing lancets with profiles that facilitate yarn movement through varying angles and transitions. The lancets are configured to dynamically guide yarns through the shed-forming zone with optimized contact points, allowing the system to maintain compact dimensions while reducing friction through intelligent geometric design rather than increased spacing.
3Device complexity
If the same shape is used for all lancets to simplify the device, then device complexity is reduced, but knots in pile warp yarns experience concentrated stress at the same position across all lancets leading to rupture
Solution Approach 1:
The patent directly addresses the reliability issue by implementing asymmetry in lancet profiles. Alternating lancets have different shapes - for instance, one lancet may have a sharper leading edge while the adjacent lancet has a more gradual transition. This asymmetric arrangement ensures that knots in pile warp yarns encounter varying stress distributions as they pass through the array, preventing concentrated stress at identical positions and reducing rupture risk, all while maintaining relatively simple device construction.
4Object-affected harmful factors
If spacers are positioned to provide adequate space for yarn movement, then yarn damage is reduced, but the pile height uniformity and loop height determination become less precise
Solution Approach 1:
The patent resolves the contradiction between space and precision by varying geometric parameters of the lancets. Different lancets have different profile angles, edge radii, and positioning offsets - these parameter variations create diverse pathways that reduce yarn stress while the overall array geometry is carefully controlled to maintain precise pile height uniformity and loop height determination. The parameter differentiation occurs within tolerances that preserve manufacturing precision.
Data Source
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AI summary
The invention relates to a weaving machine for weaving pile fabrics, and a set (100) of at least two spacers (1 - 4, 11, 12, 21, 22, 31, 32, 41 and 42), wherein the spacers (1 - 4, 11, 12, 21, 22, 31, 32, 41 and 42) are provided and arranged in the weaving machine in such a manner that the pile warp yarns (18, 18') have more space during their movement in the shed-forming zone towards the fabric line in the warp direction at their entry point in the array of lancets, so that they are hindered to a lesser degree by this array of lancets.