Weft Feeder Optical Module for Entanglement-Resistant Maintenance
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Solution Overview
Problem
Existing weft feeders face challenges in maintaining the integrity of the weft thread and fabric quality due to tension peaks during insertion, while existing optical units either require bulky components that increase entanglement risks or are permanently integrated with the electromagnet group, making maintenance costly and complex.
Innovation Solution
A weft feeder with an independent optical unit housed in a sealed protection box using a rigid-flex PCB, allowing easy installation, testing, and replacement, with a single wiring connection to the main board, and featuring removable fixing means for quick maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the optical unit is permanently integrated with the electromagnet group, then the device structure is simplified, but maintenance becomes costly and complex
Solution Approach 1:
The optical unit is segmented from the electromagnet group into an independent module. This segmentation allows the optical unit to be maintained or replaced separately without affecting the electromagnet group, resolving the contradiction by reducing maintenance complexity while keeping the overall device structure relatively simple through modular integration.
2Ease of manufacture
If bulky optical components are used, then the optical unit is easier to manufacture, but the risk of thread entanglement increases
Solution Approach 1:
The optical components are nested within a compact protection box that integrates multiple functions. This nesting approach allows standard manufactured components to be housed in a space-efficient configuration that reduces protruding elements and minimizes the risk of thread entanglement while maintaining ease of manufacture through standardized component integration.
3Ease of repair
If the optical unit is made autonomous and removable, then maintenance becomes easier, but the device complexity increases
Solution Approach 1:
The optical unit is designed with dynamic characteristics - it can be selectively integrated or separated from the electromagnet group based on maintenance needs. The removable fixing means enable the optical unit to transition between integrated and separated states, providing ease of maintenance while maintaining a relatively simple device structure when assembled.
Data Source
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AI summary
Weft feeder for weaving looms including a winding group (W) to wind a weft thread on a weft feeder drum (D), an optical unit (P) provided with one or more optical sensors (T, R, S, Z) to monitor the weft thread winding on the drum (D) and its release from said drum, an electromagnet group (E) to control the movement of a stop pin (15) which prevents the weft thread from being released from said drum (D), wherein said electromagnet group (E) is enclosed within a cup-shaped shell (11) from which said stop pin (15) protrudes to interfere with said drum (D), and a weft feeder processing board which controls the logical functions of the weft feeder. The optical group (P) is contained in a protection box (1) and it is electrically connected to said weft feeder processing board by direct wiring (6), and said protection box (1) is housed and removably fixed inside said cup-shaped shell (11).