Yarn Tension Detection via Torque Difference on Godet Roller
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing textile machines face challenges in accurately and efficiently measuring yarn tension without deteriorating the quality of the yarn, particularly due to the need for multiple manual measurements and the potential quality issues caused by contact-type tension sensors.
Innovation Solution
A textile machine system that calculates yarn tension by measuring rotational torque differences using a motor with a rotational angle detection unit and torque current calculation, eliminating the need for contact-type tension sensors and allowing for continuous, accurate tension monitoring without damaging the yarn.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a contact-type tension sensor is provided at each management point to measure yarn tension, then the tension measurement can always be done, but the quality of the yarns may be deteriorated due to friction between the running yarns and the tension sensor
Solution Approach 1:
The patent introduces a roller as an intermediary element between the yarn and the torque sensor. The yarn is wound around the roller, and the torque required to rotate the roller against the yarn tension is measured. This intermediary approach allows tension measurement without direct contact between the sensor and yarn, eliminating friction-induced quality deterioration while maintaining measurement capability
Solution Approach 2:
The patent replaces the traditional contact-type mechanical tension sensor with a torque measurement system. Instead of directly measuring yarn tension through contact, the system measures the rotational torque of a roller that the yarn is wound around, converting a direct mechanical contact measurement into a rotational mechanics-based indirect measurement
2Measurement precision
If an operator manually measures yarn tension using a tensiometer at each management point, then the tension can be measured, but it is quite troublesome and cannot always be done
Solution Approach 1:
The system enables automatic tension measurement through the roller-torque mechanism. The roller naturally interacts with the passing yarn, and the torque is automatically measured and converted to tension values by the control unit, eliminating the need for manual operator intervention at each measurement point and enabling continuous automated monitoring
Solution Approach 2:
The patent implements continuous tension measurement by positioning rollers at multiple management points along the yarn path. As yarn continuously passes through the system, each roller continuously measures the local tension, providing uninterrupted real-time data throughout the entire yarn processing line rather than intermittent manual measurements
3Measurement precision
If a tension sensor is provided at each management point to always measure yarn tension, then continuous measurement is achieved, but the device complexity increases
Solution Approach 1:
The roller serves multiple functions: it guides the yarn through the system, maintains yarn tension for proper processing, and acts as the measurement element for torque-based tension detection. This multi-functionality eliminates the need for separate dedicated tension sensors at each location, reducing overall system complexity while achieving continuous measurement
Solution Approach 2:
The patent merges the yarn guidance function with the tension measurement function by using the same roller for both purposes. The roller that naturally guides and supports the yarn during processing is also the element whose torque is measured to determine yarn tension, combining structural and measurement functions into a single component
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 and continuous yarn tension detection without degrading yarn quality, allowing for prompt failure detection and adjustment to maintain optimal tension, ensuring consistent yarn quality.
Implementation Method 1
the quality of the yarns may be deteriorated due to the friction between the running yarns and the tension sensor
Implementation Method 2
a rotational driving unit generating a rotational torque in the roller; a torque information acquisition unit acquiring a value corresponding to the rotational torque
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The tension of yarns is always detected with ease in a textile machine, without deteriorating the quality of the yarns. The textile machine (3) of the present invention includes a godet roller (20), a motor (30) configured to generate a rotational torque in the godet roller (20), a torque information acquisition unit configured to acquire a value corresponding to the rotational torque, and a control unit (60). The control unit (60) executes: a first rotational torque information acquisition process of acquiring a first predetermined value corresponding to a first rotational torque when no yarn (Y) is wound onto the godet roller (20) while the rotation speed of the godet roller (20) is arranged to be constant at a predetermined speed; a second rotational torque information acquisition process of acquiring a second predetermined value corresponding to a second rotational torque when the yarn (Y) is wound onto the godet roller (20) while the rotation speed of the godet roller (20) is arranged to be constant at the predetermined speed; and a yarn tension calculation process of calculating a tension-related value related to the tension of the yarn (Y) wound onto the godet roller (20) based on a difference between the first predetermined value and the second predetermined value.