Yarn Feeder Drum Speed Control via Magnetic Lever Sensors
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Solution Overview
Problem
Existing yarn feeders for textile machines are either inexpensive but lack adjustable feeding speed and yarn tension control, or they are expensive and complex, making them unsuitable for basic processes like striper machines.
Innovation Solution
A yarn feeder with a stationary drum, a motor, and a lever system controlled by magnetic sensors and an electronic circuit that adjusts the drum speed and yarn tension based on detected tension changes, allowing for modular connection and cost-effective operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a belt drive system with pulleys is used to connect the drum to the downstream machine, then the feeding speed can be mechanically determined based on pulley diameters, but the adjustment of feeding speed becomes awkward and requires operator intervention for replacing/setting components
Solution Approach 1:
The patent replaces the mechanical belt drive system with an electronic control system. The motor speed is controlled by electronic means rather than mechanical pulley ratios, allowing for easier and more flexible speed adjustment without physical component changes. This substitution eliminates the complexity of belt drives while enabling programmable speed control.
Solution Approach 2:
The patent introduces a dynamic speed control system where the motor speed can be adjusted in real-time based on process requirements. Instead of fixed mechanical ratios, the system allows dynamic modification of feeding speed through electronic control, adapting to different operating conditions without physical reconfiguration.
2Reliability
If a feedback loop with tension sensor and controlled motor is used, then the yarn tension can be maintained substantially constant at a predetermined value, but the cost of the feeder becomes very expensive
Solution Approach 1:
The patent implements a self-regulating tension control mechanism where the lever system automatically adjusts the drum speed in response to yarn tension variations. The system uses the yarn tension itself to control the adjustment mechanism, eliminating the need for expensive external sensors and complex feedback loops while maintaining reliable tension control.
Solution Approach 2:
The patent introduces a lever as an intermediary mechanical element that mediates between the yarn tension and the drum speed control. This simple mechanical intermediary translates tension variations into speed adjustments without requiring electronic sensors or complex control systems, providing cost-effective tension regulation.
3Adaptability or versatility
If multiple drums are provided for yarn selection in striper machines, then the selection of one yarn among multiple yarns is enabled, but the adjustment and calibration of feeding speed becomes awkward requiring operator intervention
Solution Approach 1:
The patent creates a universal feeder design that can handle both basic continuous feeding operations and selective yarn feeding for striper machines. The electronic control system provides multi-functionality, allowing the same device to operate in different modes (continuous feeding or selective feeding) without requiring separate specialized equipment for each function.
Solution Approach 2:
The patent enables dynamic switching between different operating modes for yarn selection and continuous feeding. The electronic control system can dynamically adjust which drum operates and at what speed, providing flexible yarn selection capability while maintaining ease of operation through electronic rather than mechanical adjustment mechanisms.
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
Enables easy adjustment of yarn feeding speed and tension control without expensive sensors, making it suitable for both basic and advanced textile processes, including striper machines, while maintaining cost-effectiveness.
Implementation Method 1
magnetic sensors...detects the tension of the yarn
Data Source
Figure 1~6
Figure 2~3
Figure 4~5
AI summary
A shell (12) has a motor (18) housed therein, which is provided with a driving shaft (20) having a yarn-winding drum (22) mounted thereto. A lever (28) hinged to the shell (12) is slidably engaged by the yarn (F). Return means (42, 44) bias the lever (28) toward a stop position, in which it deviates the yarn coming from the drum (22) with respect to its feeding direction to a downstream machine. The lever (28) is subject to swing in contrast to the return means (42, 44) in relation to the variations of tension of the yarn (F). Sensor means (46, 48) detect the movements of the lever (28) with respect to the stop position and generate a corresponding activation signal. An electronic circuit (50) is operatively connected to the sensor means (46, 48) and is programmed to activate the motor (18) to unwind yarn in response to the activation signal.