SELF-SYNCHRONIZING YARN TENSION MONITORING AND CONTROL SYSTEM

Abstract

A self-synchronizing yarn tension control system is provided. Self-synchronizing yarn tension control includes a yarn brake, a yarn movement sensor, a yarn tension sensor, a yarn brake, and a controller configured to control the system. The controller is configured to store one or more tension thresholds and store instructions that when executed cause one or more processors to perform operations. The operations include obtaining a yarn movement signal from the yarn movement sensor, determining whether a textile machine is operational based, at least in part on the yarn movement signal, obtaining a yarn tension signal from the yarn tension sensor, comparing the yarn tension signal to the one or more tension thresholds, generating one or more brake control signals based on said comparison, and operating the yarn brake based upon each of the one or more brake signals.

Claims

1. A self-synchronizing yarn tension system, the system comprising: a yarn movement sensor; a yarn tension sensor; a yarn brake; and a controller configured to control the system, wherein the controller includes, one or more processors and one or more memory devices, the one or more memory devices configured to store one or more tension thresholds and store instructions that when executed by the one or more processors cause the one or more processors perform operations, the operations comprising: obtaining a yarn movement signal from the yarn movement sensor; determining whether a textile machine is operational based, at least in part on the yarn movement signal; obtaining a yarn tension signal from the yarn tension sensor; comparing the yarn tension signal to the one or more tension thresholds; generating one or more brake control signals based on said comparison; and operating the yarn brake based upon each of the one or more brake signals.

2. The self-synchronizing yarn tension system of claim 1, wherein the controller is not in communication with the textile machine.

3. The self-synchronizing yarn tension system of claim 2, wherein the one or more tension thresholds comprise a high tension threshold and a low tension threshold.

4. The self-synchronizing yarn tension system of claim 3, wherein the high tension threshold and low tension threshold define a tension range.

5. The self-synchronizing yarn tension system of claim 4, wherein the comparing the yarn tension signal to the one or more tension thresholds further comprises: comparing yarn tension signal to the tension range; comparing yarn tension signal to the low tension threshold; and comparing yarn tension signal to the high tension threshold.

6. The self-synchronizing yarn tension system of claim 5, wherein if the controller determines the textile machine is not operational based on the yarn movement signal, the operations performed by the one or more processors further comprise: generating a stop signal; generating an alarm signal; and operating the controller and the yarn brake based on the stop signal.

7. The self-synchronizing yarn tension system of claim 6, wherein operating the yarn brake based upon each of the one or more brake signals further comprises: increasing the yarn brake pressure, based on a braking increment, in response to determining the yarn tension signal is below the low-tension threshold; and decreasing the yarn brake pressure, based on a braking increment, in response to determining the yarn tension signal is above the high-tension threshold.

8. The self-synchronizing yarn tension system of claim 7, wherein the braking increment is based, at least in part, on a type of yarn being utilized by the textile machine.

9. A method for controlling self-synchronizing yarn tension system, wherein the system comprises one or more controllers, a yarn brake, a yarn movement sensor, a yarn tension sensor, and a yarn brake, the method comprising: monitoring movement of a strand of yarn with the yarn movement sensor and without being in communication with a textile machine; generating a yarn movement signal based on said monitoring; determining, by the one or more controllers, the operational status of the textile machine based on the yarn movement sensor; comparing a yarn tension signal to the one or more tension thresholds; generating one or more brake control signals based on said comparison; and operating the yarn brake based upon each of the one or more brake signals.

10. The method of claim 9, wherein the one or more tension thresholds comprise a high tension threshold and a low tension threshold and, wherein the high tension threshold and low tension threshold define a tension range.

11. The method of claim 10, wherein the method further comprises: comparing the yarn tension signal to the tension range; comparing the yarn tension signal to the low tension threshold; and comparing the yarn tension signal to the high tension threshold.

12. The method of claim 11, wherein in response to determining the textile machine is not operational, the method further comprises: generating a stop signal; generating an alarm signal; and operating the controller and the yarn brake based on the stop signal.

13. The method of claim 12, wherein the method further comprises: increasing the yarn brake pressure, based on a braking increment, in response to determining the yarn tension signal is below the low-tension threshold; and decreasing the yarn brake pressure, based on a braking increment, in response to determining the yarn tension signal is above the high-tension threshold.

14. The method of claim 13, wherein the braking increment is based, at least in part, on a type of yarn being utilized by the textile machine.

15. The method of claim 14, wherein the method further comprises: monitoring yarn breakage with a yarn breakage sensor; transmitting a yarn breakage signal to controller; and generating a stop signal based, at least in part, on the yarn breakage signal.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] A full and enabling disclosure of the present subject matter, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which: FIG. 1 depicts a self-synchronizing yarn tension control system according to exemplary embodiments of the present disclosure.

[0016] FIG. 2 depicts a partial perspective view of the yarn movement and tension sensor of the self-synchronizing yarn tension system of FIG. 1.

[0017] FIG. 3 depicts a flow diagram for a method for self-synchronizing yarn tension monitoring and control to facilitate necessary yarn tensioning on textile machines, but without connection to, interface with, or being in communication with the control unit of the textile machine according to example embodiments of the present disclosure.

[0018] Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present disclosure.

DETAILED DESCRIPTION

[0019] Reference now will be made in detail to embodiments of the disclosure, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the disclosure, not limitation of the disclosure. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present disclosure without departing from the scope or spirit of the disclosure. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present disclosure covers such modifications and variations as come within the scope of the appended claims and their equivalents.

[0020] The detailed description uses numerical and letter designations to refer to features in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar parts of the invention. As used herein, the terms first, second, and third may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. The singular forms a, an, and the include plural references unless the context clearly dictates otherwise. As used herein, terms of approximation, such as approximately, substantially, or about, refer to being within a ten percent margin of error.

[0021] Aspects of the present disclosure are directed to systems and methods for self-synchronizing yarn tension for textile machines. The systems and methods for self-synchronizing yarn tension for textile machines of the present disclosure can monitor and control yarn tension and synchronize the operation(s) of the self-synchronizing yarn tension system with the operation(s) of the textile machines.

[0022] The systems and methods for self-synchronizing yarn tension monitoring and control of the present disclosure can be added to or incorporated to textile machines without connection to or interface with the control unit or control system of the textile machine (e.g., textile machine control unit 122). In this way, the systems and methods of the present disclosure can execute or provide self-synchronizing yarn tension monitoring and control for a textile machine (e.g., textile machine 118) without receiving a command, signal, output or other instruction from textile machine control unit 122 and without being in electrical communication with the control system, controller, or computer operating or controlling the textile machine (e.g., control unit 122). Stated differently, the self-synchronizing yarn tension system of the present disclosure operates autonomously without direct connection to the control unit (e.g., control unit 122) of the textile machine (e.g., textile machine 118).

[0023] Referring now to the figures, example aspects of the present disclosure will be discussed in greater detail.

[0024] FIG. 1 depicts a self-synchronizing yarn tension system 100 according to exemplary embodiments of the present disclosure. The self-synchronizing yarn tension system 100 can be utilized on any textile machine 118 where yarn is fed from a yarn source 116, such as a bobbin, spool or other yarn storage or dispensing device into a textile machine 118 for use in manufacturing textile products. The textile machine 118 in FIG. 1 can be any known textile machine that utilizes threads, textile yarns, fibers, and the like to produce, fabricate or process various textile products, such as fabric, rugs, carpeting or the like. In this regard the textile machine 118 with which the self-synchronizing yarn tension system 100 can be any known textile machine utilizing yarn to manufacture textile products.

[0025] The embodiment of the self-synchronizing yarn tension system 100 depicted in FIG. 1 includes a yarn brake 106, a yarn tension sensor 102, a controller 110, a yarn movement sensor 108 and a plurality of control or signal cables 124.

[0026] In some exemplary embodiments of the present disclosure, the self-synchronizing yarn tension system 100 can include a yarn movement sensor 108 can generate a movement signal and transmit the movement signal to the controller 110. In response to the controller 110 receiving a movement signal from yarn movement sensor 108, the controller 110 can perform operations such as generating an alarm signal. The alarm signal can be a visual, auditory, or other type of indicator which informs a user or operator of an operational condition of textile machine 118. In response to the controller 110 receiving a movement signal from yarn breakage sensor, the controller 110 can perform other operations such as, setting the brake 106 to a predetermined, or setting the brake 106 in resting position, or deenergizing or turn-off elements of the self-synchronizing yarn tension system 100 which are not needed to allow yarn movement sensor 108 and tension sensor 102 to monitor the yarn tension obtaining a movement signal from the movement sensor 108. For instance, the controller 110 can be deactivated or placed into a hibernation mode until it receives a movement signal from yarn movement sensor 108 and/or tension sensor 102. Thereafter, based on the movement signal generated by the yarn movement sensor 108 and/or yarn tension sensor 102, the controller 110 can activate or come out of hibernation and perform certain operations of the self-synchronizing yarn tension system 100 as described herein. It should be appreciated that in some exemplary embodiments of the present disclosure tension sensor 102 can be a combination sensor that includes functionalities of a yarn movement sensor (e.g., such as sensor 108), therefore, in such exemplary embodiments the functions performed by movement sensor 108 could also be performed by tension sensor 102 that has the capability of also detecting yarn movement.

[0027] It should be appreciated that the present disclosure is not limited to any particular style, model, or configuration of controller 110, yarn brake 106, or yarn movement sensor 108 and tension sensor 102. The yarn brake 106 depicted in FIG. 1 is an electromechanical flap brake. However, the yarn brake 106 utilized with the self-synchronizing yarn tension system 100 can be a different type or configuration of brake that is configured to apply force or tension to the yarn 104 that is passing through or in physical communication with the yarn brake 106.

[0028] The exemplary embodiment depicted in the figures is for illustrative purposes only. For example, different locations may be provided for the controller 110, different configurations may be provided for the graphical user interface 120, and a yarn break sensor 108 may be excluded from the self-synchronizing yarn tension system 100. Furthermore, it should be appreciated that different sensor types may be used in place of tension sensor 102 depicted in FIG. 1 (such as a combination movement and tension sensor). For example, a separate yarn movement sensor 108 and separate yarn tension sensor 102 may be used with the self-synchronizing yarn tension system 100 to detect yarn movement and yarn tension but a single, combination sensor could be used in place of yarn tension sensor 102.

[0029] The self-synchronizing yarn tension system 100 of FIG. 1 includes a yarn supply side 112 and a yarn feed side 114. The yarn supply side 112 represents the direction or location from which yarn 104 is drawn into the self-synchronizing yarn tension system 100 from a yarn source 116. The yarn source 116 can be any known yarn storage device used with textile machines, such as a bobbin or spool. The yarn feed side 114 represents the direction or location from which yarn 104 is supplied to the textile machine 118 or the direction from which yarn 104 is drawn through the self-synchronizing yarn tension system 100 and fed to a textile machine 118, where the yarn 104 will be utilized the manufacture a textile product.

[0030] It should be appreciated that while one self-synchronizing yarn tension system 100 is depicted in FIG. 1, a plurality of self-synchronizing yarn tension systems 100 may be used with a textile machine 118, wherein the textile machine 118 utilizes a plurality of strands of yarn 104 to manufacture textile products. For example, a self-synchronizing yarn tension system 100 can be used with each of the plurality of strands of yarn 104. Use of a separate self-synchronizing yarn tension system 100 for each strand of yarn 104 being fed to the textile machine 118 is advantageous because all yarn sources 116 are not wound or created with the same or a consistent tension on the yarn as stored on the yarn source 116 (e.g., yarn may not be wrapped or wound as tightly on different bobbins or spools). Similarly, as a yarn 104 is used from a yarn source 116 (e.g., removed from bobbins or spools and used by the textile machine 118 to produce a textile product) the amount of tension in the yarn source 116 can change. Therefore, all strands of yarn 104 in a textile machine may not have a consistent tension at the yarn supply side 112 of each of the separate self-synchronizing yarn tension systems 100 when the yarn 104 is being drawn or pulled from a yarn source 116 for use in an operating textile machine 118.

[0031] Therefore, each strand of yarn 104 will reach each of the plurality of separate self-synchronizing yarn tension systems 100 at the yarn supply side 112 with a different tension. In this way each of the separate self-synchronizing yarn tension systems 100 for each strand of yarn 104 being fed to the textile machine 118 can apply a consistent tension to the yarn 104 at the yarn feed side 114 of each of the separate self-synchronizing yarn tension systems 100.

[0032] The yarn movement sensor 108 and/or tension sensor 102 can detect movement of the yarn 104. When the yarn movement sensor 108 (or tension sensor 102, if equipped with movement detector) detect yarn movement, the sensor 108 or 102 generates a movement signal or run signal which is obtained by the controller 110. The movement signal or run signal is indicative of the textile machine 118 being in an operational state (i.e., the textile machine 118 is running and yarn 104 is moving in a lateral direction L from the yarn supply side 112 to the yarn feed side 114 of the self-synchronizing yarn tension system 100). Such movement signal is created or generated by sensors 102 or 108 without connection to or being in communication with the control-unit 122 of the textile machine 118. Control-unit 122 can include one or more processors and one or more memory devices 126, the one or more memory devices 126 configured to store instructions that when executed by the one or more processors cause the one or more processors to perform operations causing the textile machine 118 to function, run or otherwise operate.

[0033] The systems and methods for self-synchronizing yarn tension of the present disclosure can provide yarn tension monitoring and control functions based, at least in part, on the detection of yarn movement. The self-synchronizing yarn tension system 100 can detect the operation of textile machine 118 based on yarn movement. For example, the self-synchronizing yarn tension system 100 includes a yarn movement senor 108 or tension sensor 102 which can detect movement of yarn 104 which is drawn from a yarn source 116 (e.g., a bobbin or spool) and fed into a textile machine 118 for use in the production or manufacture of a textile product. The yarn movement sensor 108 and tension sensor 102 can detect movement of the yarn and based on the detection of yarn movement at sensing element 202 or at movement sensor 108. Yarn movement sensor 108 and/or tension sensor 102 can provide a movement signal or run signal to a controller 110. The movement signal or run signal is indicative of the textile machine 118 being in operation or running (e.g., yarn 104 is moving in a lateral direction L from the yarn supply side 112 to the yarn feed side 114 of the self-synchronizing yarn tension system 100.

[0034] The yarn movement sensor 108 and/or tension sensor 102 can detect or monitor yarn movement on a continuous, real-time basis or at one or more monitoring intervals. The monitoring intervals can be pre-determined periods of time (e.g., between 10 and 100 milliseconds) that are stored in one or more memory devices 130 of the controller 110. The monitoring interval can also be one or more increments of time entered into controller 110 by a user or operator through a graphical user interface 120 or other input devices (e.g., keyboard, button(s), mouse, etc.) that is part of or in communication with the controller 110 and stored in the one or more memory devices 130 of the controller 110. The graphical user interface 120 depicted in FIG. 1 is a touch screen, however it should be appreciated that other user input or user interfaces can be utilized. The monitoring interval(s) represent(s) the frequency at which or time intervals at which the yarn movement sensor 108 and tension sensor 102 detect or monitor for yarn movement, generate a yarn movement signal, and said yarn movement signal is received by the controller 110. The yarn movement signal is received by the controller 110 through one or more communication cables 124.

[0035] Communication cables 124 can be various electrical conductors, wires, and cables, such as coaxial cable or M8 sensor cable. While certain cables, pins, connectors, conductors, and coaxial cable may be discussed as being compatible with respect to certain example embodiments of the present disclosure, it will be appreciated by those of skill in the art that other electrical conductors, wires, or cables may be utilized to interconnect sensors, controllers, and other devices of the present disclosure. It will also be appreciated that communication between controller 110, yarn movement sensor 108 and tension sensor 102 and yarn brake 106, does not necessarily require communication cables 124, but could be accomplished by other known means such as with any suitable wired or wireless communications network for communicating data by and between components and/or other components or systems not depicted. For example, controller 110 could utilize a wireless communication network to communicate data with other components, including the yarn movement and tension sensor 102 and yarn brake 106.

[0036] In response to the controller 110 receiving a movement signal from yarn movement sensor 108 or tension sensor 102, the controller 110 can perform operations to such that the yarn 104 has or maintains an appropriate or designated yarn tension on the yarn feed side 114 of the yarn tension system 100. In some example embodiments, including the exemplary embodiment depicted in FIG. 1, self-synchronizing yarn tension system 100 can include a separate yarn tension sensor 102 and a separate yarn movement sensor 108. In some embodiments, yarn movement sensor 108 can be a single multi-function sensor or combination sensor (i.e., a yarn movement and tension sensor) situated in place of yarn tension sensor 102 as depicted in FIG. 1. Yarn movement sensor 108 can be an optical sensor, piezoelectric sensor, magnetic sensor, acoustic sensor, or another type of sensor configured to detect yarn movement and/or tension.

[0037] The controller 110 can include one or more processors 132 and one or more memory devices 130, the one or more memory devices 130 configured to store the one or more tension thresholds and store instructions that when executed by the one or more processors 132 cause the one or more processors 132 to perform operations. The one or more tension thresholds (i.e., low tension threshold 608 or high tension threshold 610) or a tension target point can be entered in the controller 110 by a user or operator through a graphical user interface 120 (e.g., a touch screen) or other input devices (e.g., keyboard, buttons, etc.) that is part of or in communication with the controller 110 and said user input(s) are stored in the one or more memory devices 130 of the controller 110. The tension thresholds or tension target point can also be pre-determined values, stored or programmed into the one or more memory devices 130 by, e.g., the manufacturer of the self-synchronizing yarn tension system 100. Said tension thresholds or tension target point can be based on the type of yarn 104 or type of textile machine 118 with which the self-synchronizing yarn tension system 100 is being used. The tension target point represents a specific amount of tension that is required or desired on the yarn 104 at the yarn feed side 114 of the self-synchronizing yarn tension system 100.

[0038] In some embodiments, self-synchronizing yarn tension system 100 controller 110 can regulate operation of the components of self-synchronizing yarn tension system 100. Controller 110 may include one or more memory devices 130 and one or more microprocessors 132, such as general or special purpose microprocessors operable to execute programming instructions or micro-control code associated with a tension monitoring cycle as described in FIG. 3. The memory may represent random access memory RAM or read only memory such as ROM or FLASH. In one embodiment, the processor executes programming instructions stored in memory. For certain embodiments, the instructions include a software package configured to operate system 100 and, for example, execute the commands associated with the control method referenced in FIG. 3. For certain embodiments, data can be communicated to or from controller 100 in order to control operation of self-synchronizing yarn tension system 100, including brake 106, movement sensor 108 and tension sensor 102. The memory 130 may be a separate component from the processor 132 or may be included onboard within the processor 132.

[0039] Input/output (I/O) signals may be routed between the controller 110 and various operational components (e.g., brake 106, movement sensor 108and tension sensor 102) of self-synchronizing yarn tension system 100 along one or more wiring harnesses or cables 124 that may be routed through the self-synchronizing yarn tension system 100.

[0040] Optionally, the controller 110 includes a user interface 120 through which a user may select various operational features and modes and monitor progress of the self-synchronizing yarn tension system 100. In exemplary embodiments, the user interface 120 may represent a general purpose I/O (GPIO) device or functional block. For instance, the user interface 120 may include input components, such as one or more of a variety of electrical, mechanical, or electro-mechanical input devices including rotary dials, push buttons, and touch pads. The user interface 120 may include a display component, such as a digital or analog display device designed to provide visual operational feedback to a user. Additionally or alternatively, the user interface 120 may include one or more feedback devices (e.g., audio or visual devices such as speakers or lights, or other devices capable of providing a signal to a user) designed to provide operational feedback to a user. The user interface 120 may be in communication with the controller 110 via one or more signal lines or shared communication buses. In some embodiments, the user interface 120 is configured to receive one or more alert signals from the controller 110 and, in turn, generate a visual or audio alert response (e.g., at the display device or audio device of the user interface 120).

[0041] In additional or alternative embodiments, controller 110 is configured to operably communicate (e.g., wirelessly communicate) with one or more user devices (not pictured), such as a general purpose computer, special purpose computer, laptop, desktop, integrated circuit, mobile device, smartphone, tablet, or other suitable computing device. For instance, controller 110 may be in wireless communication with a user device via a suitable wireless network; such as a local area network (e.g., intranet), wide area network (e.g., internet), low power wireless networks [e.g., Bluetooth Low Energy (BLE)], or some combination thereof and can include any number of wired or wireless links. In general, communication over the network can be carried via any type of wired or wireless connection, using a wide variety of communication protocols (e.g., TCP/IP, HTTP, SMTP, FTP, CAN, LIN RS, IIC, SPI or other know protocols), encodings or formats (e.g., HTML, XML), or protection schemes (e.g., VPN, secure HTTP, SSL).

[0042] The yarn tension thresholds (608 and 610) can be a low-tension threshold 608 and a high-tension threshold 610 which form a yarn tension range 606. The low-tension threshold 608 represents the least amount of tension that can be applied to the yarn 104 located on the yarn feed side 114 of the self-synchronizing yarn tension system 100. The high-tension threshold 610 represents the highest amount of tension that can be applied to the yarn 104 located on the yarn feed side 114 of the self-synchronizing yarn tension system 100. In some embodiments, the high-tension threshold 610 can represent the amount of tension above which the yarn 104 is likely to break, fray or otherwise become damaged. In some exemplary embodiments of the present disclosure the yarn tension range 606 represents a plurality of values representing the appropriate tension amounts that must be maintained on the yarn 104 located on the yarn feed side 114 of the self-synchronizing yarn tension system 100, to allow for the yarn 104 that is fed into the textile machine 118 to be maintained at an appropriate tension to produce the most efficient and proper operation of the textile machine 118 and produce the highest quality textiles as is possible by said textile machine 118. In other exemplary embodiments, yarn tension range 606 represents a tension target point which is a singular set value (within an approximate range of error such as 10%) representing the appropriate, desired or set tension amount that must be maintained on the yarn 104 located on the yarn feed side 114 of the self-synchronizing yarn tension system 100, to allow for the yarn 104 that is fed into the textile machine 118 to be maintained at an appropriate tension to produce the most efficient and proper operation of the textile machine 118 and produce the highest quality textiles as is possible by said textile machine 118.

[0043] As noted above, in response to the controller 110 receiving a movement signal from yarn movement sensor 108 or tension sensor 102, the controller 110 can perform operations to such that the yarn 104 has or maintains an appropriate or designated yarn tension set point (e.g., a target tension point) on the yarn feed side 114 of the yarn tension system 100. The operations performed by the controller 110 can include obtaining a movement signal from the movement sensor 108 or tension sensor 102. Based on the movement signal generated by the yarn tension sensor 102 or movement sensor 108, the controller 110 can perform certain operations of the self-synchronizing yarn tension system 100. These operations include obtaining a yarn tension signal from tension sensor 102, comparing the tension signal to the yarn tension range, determining whether the tension signal 607 is within the yarn tension range 606 (e.g., including whether the tension signal is equivalent to target tension point), generating one or more brake control signals 612 based on the determination whether the tension signal is within the yarn tension range 606 and operating the yarn brake 106 based on the one or more brake control signals. Tension signal 607 is indicative of the yarn tension measured by tension sensor 102 at sensor element 202. It should be appreciated that in exemplary embodiments with a combined tension sensor and movement sensor, the movement signal may include a signal indicative of the yarn tension and/or may be equivalent to tension signal 607. For example, if based on the comparison, the controller 110 determines the yarn tension signal 607 is not within the yarn tension range 606, the controller 110 will perform further operations to include determining whether the yarn tension signal 607 is below the low-tension threshold 608, determining whether the yarn tension signal 607 meets the target tension point, and determining whether the yarn tension 607 signal exceeds the high-tension threshold 608. If the yarn tension signal 607 is below the low-tension threshold 608 or below target tension point, the controller 110 will generate a brake control signal 612 causing the yarn brake 106 to apply more pressure to the yarn 104 passing through the yarn brake 106, such that the tension on the yarn 104 increases at the yarn feed side 114 of the self-synchronizing yarn tension system 100. If the yarn tension signal 607 is above the high-tension threshold 610 or above target tension point, the controller 110 will generate a brake control signal 612 causing the brake 106 to release pressure from or reduce tension to the yarn 104 passing through the brake 106, such that the tension on the yarn 104 decreases at the yarn feed side 114 of the self-synchronizing yarn tension system 100. If based on the comparison of the tension signal 607 to the yarn tension range 606, the controller 110 determines that the tension signal 607 is within the yarn tension range 606, the controller 110 will generate a brake control signal 612 causing the brake 106 to maintain the position of the brake 106 or otherwise maintain the current pressure on the yarn 104 at the yarn feed side 114 of the self-synchronizing yarn tension system 100.

[0044] Brake control signal 612 can be based on predetermined braking increments for the operation of brake 106 stored in one or more memory devices 130 of the controller 110. The braking increments represent the amount of change of force or tension that brake 106 may apply to or release from brake 106 based on the brake control signal. For example, if the braking increment is 2 cN, the brake will open or close such that it applies force to the yarn so that the tension at the yarn feed side 114 of the self-synchronizing yarn tension system 100 is raised or lowered in increments of 2 cN. The braking increments can also be a percentage (e.g., usually between 1% and 20%) of the tension range that can be measured by yarn tension sensor 102. For example, if the yarn tension sensor 102 is capable of measuring a tension range of 0 cN to 1000 cN, the braking increments would be between 10 cN and 200 cN.

[0045] The braking increment can also be one or more increments entered in the controller 110 by a user or operator through a graphical user interface 120 or other input devices (e.g., keyboard, button, touch screen, etc.) that is part of or in communication with the controller 110 and stored in the one or more memory devices 130 of the controller 110. The braking increments can also be a plurality of stored and pre-determined values corresponding to certain types of yarn or the type of textile machine with which the self-synchronizing yarn tension system 100 is being used. For example, if a user indicates through an input entered in the controller 110 by a user or operator through a graphical user interface 120 or other input devices (e.g., keyboard, button, touch screen, etc.) that the yarn 104 is cotton, the controller will access the plurality of pre-determined and stored braking increments and utilize the braking increment associated with cotton yarns.

[0046] The self-synchronizing yarn tension system 100 can detect the non-operation of textile machine 118 based on yarn movement. If the yarn movement sensor 108 and tension sensor 102 do not detect movement of the yarn 104 at sensing element 202 for more than one monitoring interval, the yarn movement sensor 108 or tension sensor 102 can provide a non-movement signal or stop signal to a controller 110. The non-movement signal or stop signal is indicative of the textile machine 118 being stopped or otherwise not in operation (e.g., yarn 104 is not moving in a lateral direction L from the yarn supply side 112 to the yarn feed side 114 of the self-synchronizing yarn tension system 100).

[0047] In response to the yarn movement signal 604 from yarn movement and tension sensor 102 is indicative or no yarn movement, controller 110 can generate or transmit a stop signal 618. In response to the controller 110 generating a stop signal 618, the controller 110 can perform operations such as, generating an alarm signal 616. The alarm signal 616 can be a visual, auditory, or other type of indicator which informs a user or operator of an error in the operation of the textile machine 118. Such errors could include that the yarn 104 has broken, become improperly tensioned at the yarn feed side 114 of the self-synchronizing yarn tension system 100 and cannot be brought into the tension range based upon a pre-determined number of changes of the braking increment. The pre-determined number of occurrences of change of the braking increment can be a pre-determined threshold (e.g., 5 changes to the braking increment) stored in one or more memory devices 130.

[0048] In response to the controller 110 receiving a stop signal 618 from yarn movement sensor 108 or tension sensor 102, the controller 110 can perform other operations such as, setting the brake 106 to a predetermined or resting position or deenergizing or turn-off elements of the self-synchronizing yarn tension system 100 which are not needed to allow yarn movement sensor 108 and/or tension sensor 102 to monitor the yarn movement or tension. For instance, the controller 110 can be deactivated or placed into a hibernation mode until it receives a movement signal from yarn movement and tension sensor 102. Thereafter, based on the movement signal generated by the movement sensor 102, the controller 110 can activate or come out of hibernation and perform certain operations of the self-synchronizing yarn tension system 100 as described herein above.

[0049] FIG. 2 depicts a partial perspective view of the yarn movement and tension sensor 102 of the self-synchronizing yarn tension system 100 of FIG. 1. Yarn movement and tension sensor 102, includes a sensing element 202. Sensing element 202 detects movement and/or tension of yarn 104 which passes from the first eyelet 204 across sensing element 202 and through the yarn guide 208 and through second eyelet 206. Yarn movement and tension sensor 102, includes one or more guide bars 210 to all the yarn 104 to angle across sensing element 202 at a predetermined angle. Guide bars 210 can be ceramic or another material which will not damage yarn 104 that is pulled or drawn across said guide bars 210. Yarn movement and tension sensor 102, includes a communication port 212 at which one or more communication cables 124 can be connected to or in electrical communication with the yarn movement and tension sensor 102. Yarn movement and tension sensor 102, includes a potentiometer 214 which can be used to adjust or set the sensitivity of the sensing element 202. Yarn movement and tension sensor 102, includes an indicator light 216 which can display different visual indicators reflecting the operational status of yarn movement and tension sensor 102. For example, a steady green color of indicator light 216 means the sensor is ok and yarn movement signal is indicative of the yarn 104 not moving. If the indicator light 216 is not illuminated, it means the sensor is ok and yarn movement signal is indicative of the yarn 104 moving. If the indicator light 216 is flashing red the yarn movement and tension sensor 102 has detected an error.

[0050] FIG. 3 depicts a flow diagram 300 for a method for self-synchronizing yarn tension monitoring and control to facilitate necessary yarn tensioning on textile machines, but without connection to, interface with, or being in communication with the control unit of the textile machine, according to an example embodiment of the present disclosure.

[0051] One or more portion(s) of the method 300 can be implemented by a computing system that include one or more computing devices such as, for example, the computing systems described with reference to the other figures (e.g., controller 110, etc.). Each respective portion of the method 300 can be performed by any (or any combination) of one or more computing devices. Moreover, one or more portion(s) of the method 300 can be implemented as an algorithm on the hardware components of the device(s) described herein (e.g., as in FIG. 1), for example, to manage and administer a self-synchronizing yarn tension monitoring and control system. FIG. 3 depicts functions performed in a particular order for purposes of illustration and discussion. Those of ordinary skill in the art, using the disclosures provided herein, will understand that the elements of any of the methods discussed herein can be adapted, rearranged, expanded, omitted, combined, and/or modified in various ways without deviating from the scope of the present disclosure. FIG. 3 is described with reference to elements/terms described with respect to other systems and figures for exemplary illustrated purposes and is not meant to be limiting. One or more portions of method 300 can be performed additionally, or alternatively, by other systems.

[0052] At 302, the method 300 can include monitoring yarn movement 602 with a yarn movement sensor (e.g., yarn movement and tension sensor 102) and transmitting a yarn movement signal 604 to a controller 110. At 302, the method can also include monitoring yarn breakage 603 with a yarn breakage sensor 108 and transmitting a yarn breakage signal 605 to controller 110.

[0053] At 304, the method 300 can include determining, by a controller 110, whether the yarn movement signal 604 is indicative of yarn movement (e.g., yarn 104 is moving in a lateral direction L from the yarn supply side 112 to the yarn feed side 114 of the self-synchronizing yarn tension system 100). If controller 110 determines at 304 that yarn movement signal 604 is indicative of yarn movement, method proceed to 306.

[0054] At 304, if controller 110 determines that yarn movement signal 604 is not indicative of yarn movement, method proceeds to 305 and/or 322. As noted herein, some exemplary embodiments of the method of the present disclosure may exclude 305. In such an exemplary embodiment, if at 304 the yarn movement signal 604 is not indicative of yarn 104 movement method proceeds to 322. At 322 the controller can generate a non-movement signal or stop signal 618. The non-movement signal or stop signal 618 is indicative of the textile machine 118 being stopped or otherwise not in operation (e.g., yarn 104 is not moving in a lateral direction L from the yarn supply side 112 to the yarn feed side 114 of the self-synchronizing yarn tension system 100) or the stop signal 618 can indicate the textile machine 118 is not in a state of proper operation. After generation of the stop signal 618, the method proceeds to 324.

[0055] At 324, the method 300 can include in response to stop signal 618 controller 110 can perform operations such as setting the brake 106 to a predetermined or resting position or deenergizing or turn-off elements of the self-synchronizing yarn tension system 100 which are not needed to allow yarn movement and tension sensor 102 to monitor the yarn tension obtaining a movement signal from the movement sensor 102. For instance, the controller 110 can be deactivated, turned off or placed into a hibernation mode until controller 110 receives a movement signal from yarn movement and tension sensor 102. Thereafter, method 300 returns to 302 and based on the movement signal 604 generated by the yarn tension and movement sensor 102, the controller 110 can activate, turn-on or come out of hibernation and perform certain operations of the self-synchronizing yarn tension system 100 as described herein above.

[0056] At 305, method 300 can include determining, by a controller 110, whether a yarn breakage signal 605 was generated at 302 and received by controller 110. A yarn breakage sensor 108 can generate the yarn breakage signal 605 and transmit the breakage signal to the controller 110. If controller 110 did not receive a yarn breakage signal at 305, method returns to 302. If controller 110 receives a yarn breakage signal at 305, method proceeds to 322. As described herein at 322, in response to the controller 110 receiving a breakage signal from yarn breakage sensor 108, the controller 110 can perform operations such as generating an alarm signal 616. The alarm signal 616 can be a visual, auditory, or other type of indicator which informs a user or operator of an error (i.e., a yarn break event) in the operation of textile machine 118. At 322 the controller can generate a non-movement signal or stop signal 618. The non-movement signal or stop signal 618 is indicative of the textile machine 118 being stopped or otherwise not in operation (e.g., yarn 104 is not moving in a lateral direction L from the yarn supply side 112 to the yarn feed side 114 of the self-synchronizing yarn tension system 100) or the stop signal 618 can indicate the textile machine 118 is not in a state of proper operation. After generation of the stop signal 618, the method proceeds to 324.

[0057] At 306, method 300 can include obtaining a yarn tension signal 607 from yarn tension signal 102. After obtaining tension signal 607, the method proceeds to 307.

[0058] At 307, method 300 can include comparing, by a controller 110, the yarn movement signal 604 or tension signal 607 to a yarn tension range 606 (or in some example embodiments a target tension point). A low-tension threshold 608 and a high-tension threshold 610 form the yarn tension range 606. The low-tension threshold 608 represents the least amount of tension that can be applied to yarn 104 located on the yarn feed side 114 of the self-synchronizing yarn tension system 100. The high-tension threshold 610 represents the highest amount of tension that can be applied to the yarn 104 located on the yarn feed side 114 of the self-synchronizing yarn tension system 100. In some embodiments, the high-tension threshold 610 can represent the amount of tension above which the yarn 104 is likely to break, fray or otherwise become damaged. The yarn tension range 606 represents a plurality of tension amounts or values representing the appropriate tension that must be maintained on the yarn 104 located on the yarn feed side 114 of the self-synchronizing yarn tension system 100, to allow for the yarn 104 that is fed into the textile machine 118 to be maintained at an appropriate tension to produce the most efficient and proper operation of the textile machine 118 and produce the highest quality textiles as is possible by said textile machine 118.

[0059] At 308, method 300 can include determining, by a controller 110, if the yarn movement signal 604 or yarn tension signal 607 is within yarn tension range 606 based on the comparison at 306. If at 308, the yarn movement signal 604 or yarn tension signal 607 is within yarn tension range 606, the method proceeds to 318. It should be appreciated that in some example embodiments of the method of the present disclosure, if at 308, the yarn movement signal 604 or yarn tension signal 607 is within yarn tension range 606 (or meets the target tension point), the method returns to the yarn monitoring step at 302, thereby bypassing 318 and 320. If at 308, the yarn movement signal 604 or yarn tension signal 607 is determined not to be within the yarn tension range 606, the method proceeds to 310.

[0060] At 310, method 300 can include comparing, by a controller 110, the yarn movement signal 604 or yarn tension signal 607 to the low-tension threshold 608.

[0061] At 312, method 300 can include determining, by a controller 110, whether the yarn movement signal 604 or yarn tension signal 607 is below or less than the low-tension threshold 608. If at 312 the yarn movement signal 604 or yarn tension signal 607 is less than the low-tension threshold 608, then method proceeds to 318. If at 312 the yarn movement signal 604 or yarn tension signal 607 is greater than the low-tension threshold 608, then method proceeds to 314.

[0062] At 314, method 300 can include comparing, by a controller 110, the yarn movement signal 604 or yarn tension signal 607 to the high-tension threshold 610.

[0063] At 316, method 300 can include determining, by a controller 110, whether the yarn movement signal 604 or yarn tension signal 607 is greater than the high-tension threshold 610. If at 316 the yarn movement signal 604 or yarn tension signal 607 is greater than the high-tension threshold 610, then method proceeds to 318. If at 316 the yarn movement signal 604 or yarn tension signal 607 is less than the low-tension threshold 608, then method proceeds to 322 because an error has occurred during the performance of one or more of the comparisons and determinations occurring at 306, 308, 310, 312, 314 or 316.

[0064] At 318, method 300 can include generating, by the controller 110, a brake control signal 612 based, at least in part, on the comparison of the yarn movement signal 604 or yarn tension signal 607 to the yarn tension range 606, the low-tension threshold 608 or the high tension threshold 610. If at 316 it is determined that the yarn movement signal 604 or yarn tension signal 607 is greater than the high-tension threshold 610, at 318 the controller 110 will generate a brake control signal 612 which causes the brake 106 to release pressure from or reduce tension to the yarn 104 passing through the brake 106, such that the tension on the yarn 104 decreases at the yarn feed side 114 of the self-synchronizing yarn tension system 100. If at 308 it is determined based on the comparison of the yarn movement signal 604 or yarn tension signal 607 (which can include a value or signal indicative of the pressure on the yarn 104 at the yarn feed side 114 of the self-synchronizing yarn tension system 100) to the yarn tension range 606, the controller 110 determines that the yarn movement signal 604 or yarn tension signal 607 is within the yarn tension range 606, at 318 the controller 110 will generate a brake control signal 612 causing the brake 106 to maintain the position of the brake 106 or otherwise maintain the current pressure on the yarn 104 at the yarn feed side 114 of the self-synchronizing yarn tension system 100. If at 312 it is determined that the yarn movement signal 604 is less than the low-tension threshold 608, at 318 the controller 110 will generate a brake control signal 612 which causes the brake 106 to increase pressure to the yarn 104 passing through the brake 106, such that the tension on the yarn 104 increases at the yarn feed side 114 of the self-synchronizing yarn tension system 100. After generation of brake control signal 612, method 300 proceeds to 320.

[0065] At 320, method 300 can include operating the brake 106 based on the brake control signal 612. Brake control signal 612 can be based on predetermined braking increments for the operation of brake 106 stored in one or more memory devices 130 of the controller 110. The braking increments represent the amount of change of force that brake 106 may apply to or release from brake 106 based on the brake control signal. For example, if the braking increment is 2 cN, the brake 106 will open or close such that it applies force to the yarn 104 so that the tension at the yarn feed side 114 of the self-synchronizing yarn tension system 100 is raised or lowered in increments of 2 cN. The braking increments can also be a percentage (e.g., usually between 1% and 20%) of the tension range 606 that can be measured by yarn movement and tension sensor 102. For example, if the yarn movement and tension sensor 102 is capable of measuring a tension range of 0 cN to 1000 cN, the braking increments would be between 10 cN and 200 cN.

[0066] Although specific features of various embodiments may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the present disclosure, any feature of a drawing can be referenced and/or claimed in combination with any feature of any other drawing.

[0067] This written description uses examples for the disclosure, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and can include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.