Weaving Machine Sensor System for Vibration-Resistant Weft Detection
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Solution Overview
Problem
Existing sensor systems for detecting weft threads in weaving machines are complex to integrate and have limited accuracy, especially due to vibrations of the weaving machine and reed, which affects the reliability of weft thread detection.
Innovation Solution
A compact sensor system using multiple light emitters and receivers arranged symmetrically to detect light reflected by the weft thread, allowing for improved accuracy and independence from machine vibrations, with a modular design for easy integration and adjustable configuration based on detection zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a light emitter and light receiver are used to detect reflected light from a weft thread, then weft thread sensing is achieved, but the system becomes complex to integrate and accuracy is limited due to machine vibrations
Solution Approach 1:
The patent combines multiple light emitters (first and second light emitters) and multiple light receivers (first and second light receivers) into a single integrated sensor system. This merging of components allows the system to achieve improved detection accuracy through multiple measurement channels while maintaining compact integration on the weaving machine, resolving the contradiction between reliability and device complexity
Solution Approach 2:
The patent uses the reflected light signals from the weft thread to generate detection signals that are processed to determine weft thread presence and position. The system incorporates feedback mechanisms where the light receivers detect reflected light and the control unit processes these signals to compensate for vibrations and improve detection accuracy, addressing the reliability issue while maintaining system integration
2Measurement precision
If a reflector is added to return light in the same direction, then light detection is improved, but the system becomes more difficult to integrate in a weaving machine
Solution Approach 1:
Instead of using a reflector to return light in the same direction as emission, the patent inverts the approach by positioning light receivers to detect light at angles different from the emission direction. The first and second light receivers are positioned to receive reflected light from the weft thread without requiring a separate reflector component, thereby improving measurement precision while maintaining ease of integration in the weaving machine structure
3Measurement precision
If multiple light emitters and receivers are arranged symmetrically, then detection accuracy is improved and independence from vibrations is achieved, but device complexity increases
Solution Approach 1:
The patent employs asymmetric positioning of light emitters and receivers relative to each other, with the first and second light receivers positioned at different locations to receive light from the first and second light emitters respectively. This asymmetric arrangement, combined with symmetric functional pairing, improves measurement precision and vibration independence while keeping the configuration manageable through modular design
Solution Approach 2:
The patent divides the sensor system into separate functional modules with distinct light emitters and light receivers positioned at different locations. This segmentation allows each component to be optimized for its specific function while the overall system achieves improved accuracy through the combined measurements, balancing measurement precision with manageable device complexity
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 sensor system provides accurate and reliable detection of weft thread position and movement, enhancing the monitoring of the stretching process and reducing errors due to machine vibrations, with a modular design that can be easily adapted to various weaving machine configurations.
Implementation Method 1
The one or more light receivers comprise at least a first light receiver. The first light receiver is configured for receiving light from the first and the second light emitter which has been reflected by a weft thread in the first zone.
Data Source
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AI summary
Sensor system for sensing a weft thread (4,5) that is being inserted in the weft insertion direction (D), in at least a first zone (Z1); the sensor system comprising: a plurality of light emitters comprising at least a first and a second light emitter (110,120) configured for emitting light (L1,L2) in the first zone (Z1) where the weft thread (4,5) needs to be detected; wherein the first light emitter (110) and the second light emitter (120) are located at a distance from each other, seen in the weft insertion direction (D); one or more light receivers comprising a first light receiver (210) configured for receiving light from the first and the second light emitter (110,120) which has been reflected by the weft thread in the first zone (Z1); wherein the first light receiver (210) is located, seen in the weft insertion direction (D), between the first light emitter (110) and the second light emitter (120).