Yarn Tension Sensor with Averaging Logic
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Solution Overview
Problem
Existing textile machine monitoring systems face challenges in accurately detecting yarn tension and breakage, with mechanical methods being more prevalent and optical sensors struggling to effectively monitor tension.
Innovation Solution
A yarn monitoring system utilizing photoelectric sensors within eyelets to detect yarn speed and tension, with a microprocessor-controlled software that averages signals to prevent unnecessary machine shutdowns and identifies sensor issues, allowing for precise tension and breakage detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical monitoring devices are used to detect yarn tension and breakage, then reliability of detection is improved, but device complexity increases and ease of operation deteriorates
Solution Approach 1:
The patent replaces mechanical monitoring devices with an optical sensing system. Photoelectric sensors detect yarn presence and tension status through optical means rather than mechanical contact, thereby maintaining detection reliability while reducing mechanical complexity and improving ease of operation.
Solution Approach 2:
The patent introduces an optical intermediary (photoelectric sensor) between the yarn and the detection system. The sensor uses light to detect yarn status without direct mechanical contact, serving as a mediator that preserves detection accuracy while eliminating complex mechanical linkages.
2Ease of operation
If optical sensors are used to monitor yarn breakage, then ease of operation is improved, but measurement precision deteriorates for tension detection
Solution Approach 1:
The patent uses photoelectric sensors that operate optically rather than mechanically. The sensors detect yarn tension status by monitoring light transmission or reflection properties, providing precise measurement without mechanical contact, thus maintaining both ease of operation and measurement precision.
Solution Approach 2:
The patent changes the detection parameter from mechanical force to optical properties. By measuring light transmission or reflection changes as the yarn passes through the sensor, the system achieves precise tension detection through optical parameter changes rather than mechanical measurement.
3Measurement precision
If mechanical sensors are used for yarn monitoring, then measurement precision is improved, but ease of operation deteriorates
Solution Approach 1:
The patent replaces mechanical sensors with photoelectric sensors that use optical fields for detection. This substitution maintains measurement precision through optical measurement while significantly improving ease of operation by eliminating complex mechanical adjustments and alignments.
4Ease of operation
If photoelectric sensors are used to monitor yarn speed and tension, then ease of operation is improved, but reliability deteriorates without signal averaging
Solution Approach 1:
The patent implements preliminary signal processing through averaging multiple sensor readings before making detection decisions. This preliminary action filters out noise and transient variations, ensuring reliable detection while maintaining the ease of operation provided by the optical sensor system.
Solution Approach 2:
The patent incorporates feedback mechanisms where sensor signals are continuously monitored, averaged, and compared against thresholds. The system provides feedback control by adjusting detection based on accumulated signal data, thereby improving reliability while maintaining operational 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 system ensures accurate monitoring of yarn tension and breakage, preventing machine damage by initiating shutdowns only when necessary, thus maintaining machine efficiency and product quality.
Implementation Method 1
uses sensors, preferably photoelectric, are contained within, or adjacent to, eyelets dimensioned to receive a strand of yard. The sensors preferably monitor, sending signals to the controller, the speed of the yarn passing through the eyelet and past the sensors.
Data Source
AI summary
A yarn monitoring system for textile machine uses sensors to indicate yarn over tensioning and breakage. The sensors are contained within, or adjacent to, eyelets and monitor, sending signals to the controller, the speed of the yarn. The eyelets, each with a sensor, are within a body that also contains a circuit board which is in constant communication with the eyelets and software contained within a controller. The controller, in turn, is in constant communication with the textile machine. The software is preprogrammed by a user with an acceptable signal range for passage of the yarn past the sensors and a predetermined time period for the signal to remain outside the acceptable signal range. To prevent unnecessary shut down of the textile machine, the software averages the signal and, when the averaged signal remains out of the acceptable signal range for the preprogrammed time initiates communication to the textile machine.