Yarn Planning Software for Tufting Machine Waste Reduction

Solution Overview

Problem

In the manufacturing of tufted textiles, the uneven yarn consumption across needles of a tufting machine leads to inefficiencies such as yarn waste and increased labor costs, especially when multiple colors are used in patterns.

Innovation Solution

The development of advanced yarn planning software that computes needle-by-needle yarn consumption and optimizes yarn lengths for cones in the creel, minimizing waste and labor by balancing yarn usage across needles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple colors of yarn are used in patterns with individual control needle machines, then design versatility and pattern complexity are improved, but yarn consumption becomes uneven across needles leading to waste and increased labor costs

Engineering Contradiction:

Improvepattern design capabilityVSAvoidyarn waste

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The system performs preliminary calculation of yarn consumption for each needle before the tufting process begins. The controller computes the exact amount of yarn each needle will consume based on the pattern design, then uses this information to optimize yarn cone allocation and minimize waste before production starts.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system changes the parameter of yarn cone configuration based on calculated consumption data. By adjusting which yarn cones are assigned to which needles according to their specific consumption needs, the system optimizes yarn usage and reduces waste while maintaining pattern versatility.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If yarn consumption is not balanced across needles, then production speed is maintained, but labor costs increase due to frequent rewinds and yarn cone changes

Engineering Contradiction:

Improveproduction speedVSAvoidlabor time for rewinds

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The system performs preliminary calculation of yarn consumption for each needle before the tufting process begins. The controller computes the exact amount of yarn each needle will consume based on the pattern design, then uses this information to optimize yarn cone allocation and minimize waste before production starts.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system uses feedback from the calculated consumption data to continuously optimize yarn cone assignment. The controller monitors and adjusts yarn distribution based on actual usage patterns, ensuring that yarn cones are replaced or redistributed at optimal moments to minimize production interruptions.

Inventive Principle:

Principle #23Feedback

3Reliability

If yarn cones are overfilled to accommodate high consumption needles, then yarn availability is improved, but yarn waste increases for low consumption needles

Engineering Contradiction:

Improveyarn supply reliabilityVSAvoidexcess yarn waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The system applies local quality by assigning different yarn cone sizes or quantities to different needles based on their specific consumption requirements. Each needle receives the appropriate amount of yarn for its needs, rather than using a uniform allocation strategy, thereby minimizing waste while ensuring sufficient supply for high-consumption needles.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The system performs preliminary calculation of yarn consumption for each needle before the tufting process begins. The controller computes the exact amount of yarn each needle will consume based on the pattern design, then uses this information to optimize yarn cone allocation and minimize waste before production starts.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12254248B2Yarn planner for tufted patterns and creeling

Publication Date: 2025.03.18 TUFTCO CORP

AI summary

A tufting machine interface or simulator is provided with yarn planning software enabling the optimization of winding yarn cones for particular patterns and production runs to minimize waste yarn and labor attendant to rewinds.