Weaving Device Yarn Separating Rollers for Pile Fabric Tension Control
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Solution Overview
Problem
The existing weaving devices for pile fabrics face issues with warp yarn deformation and irregularities due to high tensions, leading to fabric irregularities and increased risk of warp yarn breakage, especially when weaving widths exceed 3 meters, as the warp beams are split into multiple sections and yarn separating rollers are used to maintain shed formation, causing visual disturbances and increased friction.
Innovation Solution
The introduction of a weaving device with yarn separating rollers connected by supporting devices, eliminating the intermediate frame between them, allows ground warp yarns to pass more directly to the fabric forming zone, reducing tension on the reed dents and minimizing friction, and incorporating a comb with teeth to guide yarns parallel to the warp direction, thereby reducing yarn breakage and wear on the reed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If warp beams are split into multiple sections lying alongside one another to reduce load, then the load on each warp beam is reduced, but a distance gap appears between the warp yarn packages causing yarn irregularities
Solution Approach 1:
Yarn separating rollers are introduced as intermediary elements between the split warp beams to bridge the gap and maintain continuous yarn alignment. These rollers pass through the distance gap between warp yarn packages from adjacent beams, ensuring uniform yarn distribution and preventing irregularities while allowing the beams to be split for load reduction
Solution Approach 2:
The warp beam system is segmented into multiple smaller beams lying alongside one another, with each beam handling a portion of the total warp yarns. This segmentation reduces the load on individual beams while yarn separating rollers ensure the segmented beams work together to maintain overall yarn alignment
2Stability of the object's composition
If yarn separating rollers are used to maintain shed formation, then shed formation stability is improved, but friction on warp yarns increases causing yarn breakage
Solution Approach 1:
The diameter of yarn separating rollers is optimized to a specific range (65-85mm) to balance two competing requirements: sufficient diameter to maintain stable shed formation geometry, but not so large as to create excessive friction. This parameter optimization reduces yarn breakage while preserving shed stability
Solution Approach 2:
Yarn separating rollers are strategically positioned only where needed to maintain shed formation, rather than along the entire yarn path. This localized application provides shed stability precisely where required while minimizing friction exposure of warp yarns to roller surfaces
3Stability of the object's composition
If an intermediate frame is used to support yarn separating rollers, then roller positioning is stabilized, but device complexity and weight increase
Solution Approach 1:
The support function for yarn separating rollers is merged with the existing warp beam structure and weaving machine frame. Rather than adding a separate intermediate frame, the rollers are supported by and integrated into the existing structural elements, reducing overall device complexity while maintaining positioning stability
Solution Approach 2:
Existing structural components of the weaving machine are designed to serve multiple functions: the warp beam structure not only holds the warp yarn packages but also provides support for the yarn separating rollers. This multi-functionality eliminates the need for dedicated intermediate framing while maintaining structural stability
4Stability of the object's composition
If yarn separating rollers with larger diameter are used, then shed formation is more stable, but device weight and cost increase
Solution Approach 1:
The diameter of yarn separating rollers is precisely controlled within the range of 65-85mm to achieve the minimum sufficient diameter for stable shed formation. This optimized parameter selection provides adequate shed stability while minimizing roller weight and associated costs, avoiding unnecessary material usage
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 configuration reduces warp yarn breakage, minimizes visual disturbances, and decreases the diameter of the yarn separating rollers, making the device lighter and less expensive, while ensuring consistent yarn alignment and reduced friction, resulting in improved fabric quality and reduced maintenance needs.
Implementation Method 1
the frictional resistance over the path of the pile-warp yarn between the weaving creel and the fabric forming zone
Implementation Method 2
reduces the contact area between separating roller and ground warp yarns so that the ground warp yarns are subject to less frictional force
Data Source
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AI summary
This invention relates to a weaving device for weaving pile fabrics comprising a weaving machine with at least two yarn separating rollers (3), the weaving device having at least two warp beams (1a;1b) lying alongside one another in weft direction, each of which is provided to guide ground warp yarns (5a;5b) via a yarn separating roller (3) to shed formation means (11,12) of the weaving machine, said yarn separating rollers (3) extending over the whole width of the weaving machine and being connected at their respective ends to the weaving machine, and whereby at least two yarn separating rollers (3) between their ends comprise several supporting devices (9) that link these yarn separating rollers (3) together, and each of these yarn separating rollers (3) has at least one zone between two consecutive supporting devices (9) that is designed for the passage of ground warp yarns (5a;5b) coming from both a first (1a) and a second warp beam (1b).