Title:
MONITOR AND MALFUNCTION PREDICTOR FOR TEXTILE MACHINES
Document Type and Number:
WIPO Patent Application WO/2000/060506
Kind Code:
A1
Abstract:
A moving material, thread, yarn, fabric or wire (1), is directed to pass over a vibrating arm (2). The vibrating arm (2) is induced to vibrate due to contact with moving material (1). The Vibration information, amplitude and frequency, is conversion to an electrical analog of the mechanical vibration. In a preferred embodiment of this device, converted to electrical analog is produced by a hall effect sensor (3) due to changes in the magnetic field caused by vibrations of the steel vibrating arm (2) in proximity ofa magnet. The magnet is positioned below the hall effect sensor (3).
Inventors:
RUBEL LAURENCE P (US)
Application Number:
PCT/US2000/007048
Publication Date:
October 12, 2000
Filing Date:
March 16, 2000
Export Citation:
Assignee:
RUBEL LAURENCE P (US)
International Classes:
B65H63/00; B65H63/06; D03D47/34; D03D51/34; D03D51/44; D03J1/04; D04B35/12; D05B51/00; D05B63/04; D05C11/14; D05C13/02; (IPC1-7): G06F17/40
Foreign References:
| US4031924A | 1977-06-28 | |||
| US5323324A | 1994-06-21 | |||
| US4584833A | 1986-04-29 | |||
| US5838570A | 1998-11-17 | |||
| US5184305A | 1993-02-02 | |||
| US4817381A | 1989-04-04 | |||
| US4429651A | 1984-02-07 | |||
| US5237944A | 1993-08-24 | |||
| US4628847A | 1986-12-16 | |||
| US4763588A | 1988-08-16 | |||
| US4110654A | 1978-08-29 | |||
| US4381803A | 1983-05-03 | |||
| US4619213A | 1986-10-28 | |||
| US3058343A | 1962-10-16 | |||
| US2881833A | 1959-04-14 | |||
| US5388618A | 1995-02-14 | |||
| US3177749A | 1965-04-13 |
Other References:
See also references of EP 1208483A4
Attorney, Agent or Firm:
Woodbridge, Richard C. (P.C. P.O. Box 592 Princeton, NJ, US)
Download PDF:
Claims:
WHAT IS CLAIMED IS:
| 1. | l. |
| 2. | An apparatus for detecting inconsistencies in filaments and snags to filaments, consumed by a textile machine, said apparatus comprising: a vibrating means mounted to a stationary base; an aperture in said vibrating means for receiving said filament, said aperture having a predetermined width; a sensor for sensing the vibration of said vibrating means and giving off an electrical signal in proportion thereto; and, an electronic means for receiving said electrical signal and determining maximum magnitude and the rate of change thereof, wherein said apparatus detects inconsistencies and snags in said filament. |
| 3. | The apparatus of claim 1 wherein said inconsistencies include knots havinga diameter of less than said predetermined width of said aperture and wherein said filament has a diameter less than said predetermined width. |
| 4. | The apparatus of claim 1 wherein said aperture comprises a notch. |
| 5. | An apparatus for detecting changes to the pull or high speed and release or low speed filament speed pattern generated by movement of filament threaded through take up type elements and by stitch formation of a textile machine, said apparatus comprising: a vibrating means mounted to a stationary base, a sensor for sensing the vibration of said vibrating means and giving off an electrical signal in proportion thereto; and, electronic means for receiving said electrical signal wherein electronic means separately detects the high speed and low speed characteristics of filament movement during filament take up type movement cycle, wherein said apparatus detects changes to the filament speed cycle parameters generated by a stitch formation cycle. |
| 6. | The apparatus of claim 4 wherein said electronic means further includes pattern recognition for detecting speed change characteristics of filament consumed by a textile machine. |
| 7. | An apparatus for detecting changes to average speed for a multiplicity of stitch duty cycles of a filament or fabric consumed by a textile machine, said apparatus comprising: a vibrating means mounted to a stationary base; a sensor for sensing the vibration of said vibration means and giving off an electrical signal in proportion thereto; and, electronic means for receiving said electrical signal and determining average signal level, wherein said apparatus detects changes to average speed. |
| 8. | The apparatus of claim 6 wherein the time interval utilized to determine average speed is increased with time following adjustment or start up of textile machine. |
| 9. | The apparatus of claim 6 wherein the detected average signal maximum and minimum levels are compared to converging maximum and minimum reference levels following adjustment or start up of machine. |
| 10. | A monitor for use with textile type machines functioning during a combination of partial, singular or multiplicity of machine duty cycles, including a means to sense speed, tension and material condition of thread, yarn or fabric feeding along a path and means to process sensed information to determine and predict the following conditions: thread breaks and material exhaustion; material inconsistency; knots and snags; machine duty cycle pattern failures; take up failure and threading errors; draw per unit time failures; skipped stitch; feed and tension malfunction; machine mechanical diagnosis; and, stitch count determination, which consists of : a speed and tension sensor which can be mounted anywhere along said path, having a means for sensing a combination of speed and tension of material moving through the textile machine and converting the combination of speed and tension of the material into a corresponding electrical signal; an electronic signal processor which processes speed and tension sensor electrical signal output, said processor output being a prediction or determination of operational status of the machine being monitored; an electrical connection between the speed, tension and material condition sensor and the electronic signal processor; and, indicator means electrically connected to the signal processor. |
| 11. | The monitor in claim 9 wherein the speed and tension sensor consists of a vibrating means, said vibrating means induced to vibration or deflection by contact with the moving material, wherein the resonant frequency of the vibrating means exceeds the duty cycle frequency of the machine being monitored, and a means to convert said vibrations or deflections to analogous electrical signals. |
| 12. | The monitor of claim 9 wherein the speed and tension sensor includes means for sensing material inconsistencies including knots and converting them into a corresponding electrical signal. |
| 13. | The monitor of claim 9 wherein the electronic signal processor consists of : signal manipulation means, said signal manipulation means output being an analog or digital function of the sensor signal parameters; setting adjustment means, used to preset signal levels to a required range or to establish preset, programmed or archived parameters; and, comparison means that compares the sensor or manipulation means output signal parameters to setting adjustment level means levels, wherein an indicator means is electrically connected to the electronic signal processor such that said indicator means indicates operational status or origin of failure of the machine being monitored. |
| 14. | The monitor in claim 9 wherein the electronic signal processor consists of an output means, said output means being electrically connected to the machine being monitored and said output means acting to control operation of the monitored device or to signal an operator. |
| 15. | The monitor in claim 9 wherein said indicator means indicates a diagnosis of the machine being monitored, based on a comparison of the sensor signal output amplitude and time parameters to programmed or archived parameter pattern. |
| 16. | The monitor in claim 9 wherein said indicator means indicates a status and diagnosis of the machine being monitored based on a comparison, of the time domain or frequency domain of sensor signal. |
| 17. | The monitor in claim 9 wherein the electronic signal processor consists of : a means of filtering extraneous signals which are outside the resonant frequency of the vibrating means; a means of controlling amplification of signals through circuit elements; a means to block indicating of failures occurring after first failure, such that only the initial cause of failure is indicated; and, a means to reset signal processor circuits after a failure has been detected. |
| 18. | The monitor in claim 12 wherein the electronic signal processor includes: a knot or material inconsistency determination means wherein the manipulation output generated is a function of speed and tension sensor signal amplitude and the comparison means compares signal amplitude to a predetermined level. |
| 19. | The monitor in claim 12 wherein the electronic signal processor, includes: a knot or material inconsistency determination, wherein the manipulation output generated is a function of rate of change of the sensor signal value and the comparison means, compares the signal increase to a predetermined value. |
| 20. | The monitor of claim 12 wherein the electronic signal processor includes: a means to recognize a duty cycle pattern failure, wherein the electronic signal processor output is generated for a single or limited number of duty cycles, and wherein the electronic signal processor includes manipulation means which generate an analog or digital value that is a combined function of the speed and tension sensor signal amplitude and duty cycle time parameters; and, a comparison means wherein the generated analog or digital value is compared to preset or programmed values. |
| 21. | The monitor of claim 12 which includes a draw failure determination, wherein the electronic signal processor output is generated for a multiplicity of duty cycles, wherein the electronic signal processor consists of : the manipulation means which averages sensor signal for a multiplicity of duty cycles; and, the comparison means wherein average signal value is compared to the preset or programmed values. |
| 22. | The monitor in claim 9 wherein circuit elements of the electronic signal processor includes a combination of : an averaging time interval reduction means, a comparison means wherein the maximum and minimum averaged signal levels are compared to converging maximum and minimum reference levels following adjustment; and, a means to set the initial average value to a level within the comparison window level, following start up. |
| 23. | The monitor of claim 9 having an output port consisting of an interface means to feed the signal output into additional devices. |
| 24. | The monitor of claim 9 wherein the electronic signal processor is electrically connected to a multiplicity of feed speed, tension, and material consistency sensors. |
| 25. | The monitor of claim 9 wherein stitch count is derived from thread sensor output and having a counter to count duty cycles. |
| 26. | The monitor in claim 24 wherein the counter has a means to count oscillator cycles or duty cycles and having a means to compare cycles to a predetermined value to indicate bobbin runout. |
| 27. | The monitor in claim 9 wherein the electronic signal processor output is inputted to an indicator means which indicates material movement speed and length drawn in conjunction with the electronic signal processor. |
| 28. | The vibrating means in claim 10 wherein the vibrating means consists of a spring, an edge of which contains a notch or an aperture within the spring, such that the notch or aperture guides the movement of thread, said notch or aperture dimension and shape being proportioned to react to passage of material inconsistencies such that vibration or deflection of vibrating and deflecting means rises significantly when dimensions of moving material inconsistency exceed acceptable limits, such limits being a function of textile machine needle or looper eye aperture dimensions. |
| 29. | The speed and tension sensor in claim 10 which consists of : a mounting means being isolated from vibration, isolation means consisting of said mounting means supported by resilient material and said resilient material being contained by an enclosure; a vibrating means rigidly affixed to one end, in a cantilever manner, to said mounting means; and, a limitation means affixed to mounting means such that movement of the free end of the cantilevered vibrating means is limited, said limitation means being fixed to assure that the vibrating means remains within its elastic limits. |
| 30. | The monitor of claim 28 wherein the limitation means contains an aperture, said aperture having sharp edges sloped away from the free end of a vibrating means, such that vibrating means vibration and slope of aperture act to direct dust away from the aperture opening. |
| 31. | A monitor of claim 10 wherein the speed and tension sensor includes thread guides mounted upstream and downstream of the vibrating means in the path of moving material, said thread guides having a resonant frequency substantially different from the resonant frequency of the vibrating means frequency, said thread guides being isolated from vibration. |
| 32. | The speed and tension sensor of claim 10 wherein the vibrating means contains a notch at the edge of the vibrating means adjacent to a limitation means, such that the thread is pulled against said limitation means and will be aligned and directed into said notch. |
| 33. | The speed and tension sensor of claim 28 the mounting means assembly comprise surfaces which are adjacent to the vibrating means and sloped downward and away from the vibrating means, whereby said sloped surfaces direct dust away from the vibrating means, such that accumulation of dust is precluded. |
| 34. | The apparatus of claim 32 wherein said aperture comprises a notch. |
| 35. | The monitor of claim 9 further comprising a length counter, wherein units of length of fabric being produced or processed by the machine being monitored is determined from the filament speed and tension sensor signal. |
| 36. | The length counter of claim 34 comprising a speed and tension sensor signal which activates an oscillator means wherein said oscillator means comprises: a frequency that is calibrated to fabric speed of the machine being monitored, and output that is counted by a counter means wherein said oscillator means is activated at the start of machine operation and continues after the machine stops for a time period required to correct for truncation error wherein said truncation error time period is approximately equal to the time required to process one half of the unit length counted by said counting means and wherein a signal to said counting means is maintained on at each cycle by a one shot like means for an interval required to operate counter means. |
| 37. | The monitor of claim 9 wherein the sensor means and the electronic signal processor further comprise a burred needle detection means, wherein the sensor outputs include a combination of sensor signals which are functions of vibration on the needle and increases in thread tension, speed and vibrations carried on the thread such that: sensor signal increase is generated by filament snagging on a needle burr; the electronic signal processor includes frequency filter means; the electronic signal processor uses a combination of signal magnitude, signal rate of change and pattern recognition compared to predetermined values to determined burred needle condition; and, the electronic signal processor uses machine position input to synchronize signal processing to release of looper or fabric thread from the needle. |
Description:
INTERNATIONALSEARCHREPORTInternationalapplicationNo. PCT/US00/07048 C(Continuation).DOCUMENTSCONSIDEREDTOBERELEVANT Category*Citationofdocument,withindication,whereappropriate,
oftherelevantpassagesRelevanttoclaimNo. AUS4,817,381A(MEISSNER)4April1989(04.04.89),Whole6-8 Document INTERNATIONALSEARCHREPORTInternationalapplicationNo. PCT/US00/07048 BoxIObservationswherecertainclaimswerefoundunsearchable(Cont
inuationofitem1offirstsheet) Thisinternationalreporthasnotbeenestablishedinrespectofcerta
inclaimsunderArticle17(2)(a)forthefollowingreasons: 1. 2ClaimsNos.: becausetheyrelatetosubjectmatternotrequiredtobesearchedbythi
sAuthority,namely: 2. rizClaimsNos.: because theyrelatetopartsoftheinternationalapplicationthatdonotcompl
ywiththeprescribedrequirementstosuch anextentthatnomeaningfulinternationalsearchcanbecarriedout,s
pecifically: 3.FClaimsNos.: becausetheyaredependentclaimsandarenotdraftedinaccordancewit
hthesecondandthirdsentencesofRule6.4(a). BoxIIObservationswhereunityofinventionislacking(Continuation
ofitem2offirstsheet) ThisInternationalSearchingAuthorityfoundmultipleinventionsin
thisinternationalapplication,asfollows: PleaseSeeExtraSheet. 1.FXAsallrequiredadditionalsearchfeesweretimelypaidbytheappl
icant,thisinternationalsearchreportcoversallsearchable claims. 2.FAsallsearchableclaimscouldbesearchedwithouteffortjustifyi
nganadditionalfee,thisAuthoritydidnotinvitepayment ofanyadditionalfee. 3.FAsonlysomeoftherequiredadditionalsearchfeesweretimelypaid
bytheapplicant,thisinternationalsearchreportcovers onlythoseclaimsforwhichfeeswerepaid,specificallyclaimsNos.: 4.1 Norequiredadditionalsearchfeesweretimelypaidbytheapplicant.C
onsequently,thisinternationalsearchreportis restrictedtotheinventionfirstmentionedintheclaims; itiscoveredbyclaimsNos.: RemarkonProtestTheadditionalsearchfeeswereaccompaniedbytheap
plicant'sprotest. Noprotestaccompaniedthepaymentofadditionalsearchfees. INTERNATIONALSEARCHREPORTInternationalapplicationNo. PCT/US00/07048 BOX 11. OBSERVATIONS WHERE UNITY OF INVENTION WAS LACKING This ISA found multiple inventions as follows: Group I, claims 1-3, drawn to an apparatus for detecting inconsistencies in filaments using a vibrating means and a sensor.
Group II, claims 4 and 5, drawn to an apparatus for detecting changes to a filament pattern generated by movement of the filament threaded through a textile knitting machine.
Group 111, claims 6-39, drawn to an apparatus for detecting changes to the speed of a filament or fabric by the a textile machine due to tension or tautness of the fabric.