Yarn Feeder Sensing Apparatus for Precise Tension Control
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Solution Overview
Problem
Conventional yarn feeders struggle to precisely control the rotational speed and tension of yarns due to indirect motor drive through a belt member, which leads to imprecise control and wear, affecting weaving quality and yield.
Innovation Solution
A sensing apparatus with a tension controller featuring an elongated sensing block, impedance sensing piece, and electronic control board that directly measures and adjusts yarn tension and rotational torque, ensuring precise control of yarn feeder operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a belt member is used to connect the driving motor to the winding wheel, then the motor can drive the winding wheel, but the belt member is prone to wear and idling of transmission, leading to imprecise rotational speed control
Solution Approach 1:
The patent removes the belt member from the transmission system entirely, replacing it with a direct drive mechanism where the driving motor connects directly to the winding wheel. This eliminates the intermediate transmission component that caused wear and idling, thereby improving both reliability and rotational speed control precision.
Solution Approach 2:
The patent replaces the mechanical belt transmission system with a direct mechanical coupling system. The driving motor is directly connected to the winding wheel through a simplified transmission structure, eliminating the need for belt members and improving precision control.
2Ease of operation
If multiple pulleys are used to control yarn rotational speed, then the yarns can be driven, but the tension and extraction speed of every yarn cannot be precisely controlled
Solution Approach 1:
The patent incorporates a tension detection device that detects the tension of each yarn in real-time and provides feedback to the control system. The control system then adjusts the rotational speed of each winding wheel individually based on the detected tension, enabling precise tension control for every yarn.
Solution Approach 2:
The patent implements dynamic speed adjustment for each winding wheel based on real-time tension detection. Unlike the static multi-pulley system, each winding wheel can independently adjust its rotational speed to maintain optimal tension, improving precision control.
3Device complexity
If the driving motor indirectly drives the winding wheel through a belt member, then the structure is simpler, but the rotational speed control of the yarn feeder becomes imprecise
Solution Approach 1:
The patent removes the belt member from the transmission system, replacing indirect drive with direct drive. The driving motor is directly connected to the winding wheel, eliminating the intermediate transmission component that compromised precision while maintaining structural simplicity.
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 apparatus automatically maintains optimal yarn tension and rotational speed, enhancing weaving quality and yield by providing precise control and reducing mechanical wear.
Implementation Method 1
At least an impedance sensing piece is attached on a surface of the sensing block... the impedance sensing piece is bent to enable the tension controller to obtain the tension value of the yarn
Data Source
AI summary
A sensing apparatus for yarn feeder may comprise a yarn feeder and a tension controller. The tension controller has an elongated sensing block installed therein, and a horizontal extending board is connected to the sensing block. An operating rod is mounted on a middle upper surface of the extending board at one end and upwardly sticks out of the tension controller to pivotally connect to a tension pulley at the other end. A yarn wound on a winding wheel of the yarn feeder is configured to couple with the tension pulley. At least an impedance sensing piece is attached on a surface of the sensing block, and a deformable hole horizontally penetrates through the sensing block. When the sensing block is pressed or pulled, the tension controller can obtain the tension value of the yarn and further calculate the torsion value of the yarn feeder.