Weaving Machine Weft Thread Arrival Monitoring
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Solution Overview
Problem
Existing weaving machines require operator input to recognize different weft thread properties, leading to potential weaving errors due to incorrect signal strength recognition during weft insertion, as the system lacks the ability to automatically adapt to various weft thread types.
Innovation Solution
The method employs at least one opto-electronic sensor to generate distinct electrical signal curves based on weft thread properties, with an electronic control unit calculating and storing a reference signal for each weft thread type, allowing for automatic recognition and adaptation during the weaving process, eliminating the need for operator input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If operator input is used to specify weft thread properties, then the system can recognize different weft thread types, but the complexity of operation increases and potential for errors increases
Solution Approach 1:
The system automatically detects and identifies different weft thread types through sensor signals generated during weft insertion, eliminating the need for operator input. The electronic control unit autonomously processes sensor data to recognize thread properties and adapt monitoring parameters accordingly.
Solution Approach 2:
The manual operator input process is replaced with an automated sensor-based detection system. Opto-electronic sensors generate electrical signals that are processed by the electronic control unit to automatically identify weft thread properties, substituting human operation with electronic detection and control.
2Reliability
If fixed monitoring parameters are used, then the device complexity is reduced, but the reliability of monitoring decreases when dealing with different weft thread types
Solution Approach 1:
The monitoring parameters are made dynamic rather than fixed. The electronic control unit automatically adjusts monitoring parameters based on the detected weft thread type, allowing the system to adapt its behavior to different thread properties while maintaining a unified device structure.
Solution Approach 2:
The system changes monitoring parameters automatically based on the detected weft thread characteristics. Different electrical signal thresholds and evaluation criteria are applied depending on the thread type identified, optimizing monitoring accuracy for each specific thread without requiring physical device modifications.
3Measurement precision
If signal amplification is adjusted for different weft threads, then measurement precision improves, but the device complexity increases due to additional control requirements
Solution Approach 1:
The system uses feedback from sensor signals to automatically adjust amplification and evaluation parameters. The electronic control unit receives sensor output signals, analyzes their characteristics, and adapts the monitoring parameters including signal amplification factors based on the detected weft thread type, creating a closed-loop adaptive system.
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 approach enables optimal monitoring and adaptation to different weft threads, reducing weaving errors and incorrect stops by automatically recognizing thread arrival and properties, ensuring accurate weft insertion without operator intervention.
Implementation Method 1
at least one opto-electronic sensor is used to generate different electrical signal curves depending on different properties of the weft thread when different weft threads pass through the sensor
Data Source
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Figure 2
AI summary
On a weaving machine, the arrival of the weft thread (1) during insertion into a shed is monitored by means of a sensor (4) at the end of the insertion path (5). The sensor (4) produces different signal profiles (6) upon the passage of different weft threads (1,2,3...n). A control unit (7) determines the respective reference signal from several signal profiles (6) of the sensor (4) for each weft thread (1,2,3...n) to be inserted depending on the weaving pattern, the reference signal being compared with the actual signal profile (6) in the weaving process. The operator no longer has to make any entries into the controller (7) regarding the type of weft threads (1) to be monitored during weft insertion.