The present invention embraces a dynamic tension control system for narrow fabric.
During the assembly of face masks (e.g., surgical masks, medical masks, and/or the like), an ear loop welding machine may be used to create and attach (e.g., weld) ear loops to a piece of mask fabric. For example, the ear loop welding machine may pull linear ear loop material from a roll of linear ear loop material, cut a section of the linear ear loop material, and weld the ends of the section of linear ear loop material onto a piece of mask fabric to form an ear loop.
The following presents a simplified summary of one or more embodiments of the present invention, in order to provide a basic understanding of such embodiments. This summary is not an extensive overview of all contemplated embodiments and is intended to neither identify key or critical elements of all embodiments nor delineate the scope of any or all embodiments. This summary presents some concepts of one or more embodiments of the present invention in a simplified form as a prelude to the more detailed description that is presented later.
In one aspect, the present invention embraces a dynamic tension control system including a shaft for holding a roll of material (e.g., linear material), a motor for driving the shaft, and a dancer tensioning control system. The dancer tensioning control system may include an actuator assembly for receiving the material (e.g., with an eyelet) and a sensor (e.g., a proximity sensor). The sensor may be positioned below the actuator assembly. The sensor may be configured to detect whether the actuator assembly is proximate the sensor, transmit, based on detecting that the actuator assembly is not proximate the sensor, a signal, and stop transmitting, based on detecting that the actuator assembly is proximate the sensor, the signal. The dynamic tension control system may be configured to command, based on receiving the signal from the sensor, the motor to accelerate and command, based on stopping receiving the signal from the sensor, the motor to decelerate.
In some embodiments, the dynamic tension control system may include a frame configured for positioning and supporting the shaft, the motor, and the dancer tensioning control system.
In some embodiments, the dynamic tension control system may include a non-drive-side tube insert to position a spool of the roll such that the shaft passes through a center of the spool and a drive-side tube insert to position the spool of the roll such that the shaft passes through the center of the spool. Additionally, or alternatively, the non-drive-side tube insert may include a first attachment mechanism for attaching the non-drive-side tube insert to the shaft to prevent the non-drive-side tube insert and the roll from sliding off the shaft, and the drive-side tube insert may include a second attachment mechanism for attaching the drive-side tube insert to the shaft to prevent the drive-side tube insert and the roll from sliding off the shaft. In some embodiments, the non-drive-side tube insert may include a first conical portion, a first intermediate portion, and a first exterior portion, and the drive-side tube insert may include a second conical portion, a second intermediate portion, and a second exterior portion. Additionally, or alternatively, the first conical portion and the second conical portion may have lengthwise increasing outer diameters for receiving the spool, the first intermediate portion and the second intermediate portion may have outer diameters equal to or less than an inner diameter of the spool, and the first exterior portion and the second exterior portion may have outer diameters greater than an outer diameter of the spool.
In some embodiments, the dynamic tension control system may include one or more dancer tension control guides for receiving the material from the roll and providing the material to the dancer tensioning control system.
In some embodiments, the dynamic tension control system may include a user input device for controlling a top speed of the motor, acceleration of the motor, deceleration of the motor, a time period for which the motor drives the shaft, and/or the like.
In some embodiments, the dancer tensioning control system may include a top block assembly and an upper guide assembly extending outward from the top block assembly, where the material passes through the actuator assembly and then through the upper guide assembly. Additionally, or alternatively, the dancer tensioning control system may include a bottom block assembly, where the sensor is positioned on the bottom block assembly. In some embodiments, the dancer tensioning control system may include guide rods extending between the bottom block assembly and the top block assembly, where the actuator assembly moves along the guide rods.
In some embodiments, dynamic tension control system may include another shaft for holding another roll of material (e.g., linear material), another motor for driving the other shaft, and another dancer tensioning control system. The other dancer tensioning control system may include another actuator assembly for receiving (e.g., with another eyelet) the linear material from the other roll, another sensor (e.g., another proximity sensor), where the other sensor is configured to detect whether the other actuator assembly is proximate the other sensor, transmit, based on detecting that the other actuator assembly is not proximate the other sensor, another signal, and stop transmitting, based on detecting that the other actuator assembly is proximate the other sensor, the other signal. The dynamic tension control system may be configured to command, based on receiving the other signal from the other sensor, the other motor to accelerate and command, based on stopping receiving the other signal from the other sensor, the other motor to decelerate.
In another aspect, the present invention embraces a dynamic tension control system including a shaft for holding a roll of linear material, a motor for driving the shaft, and a dancer tensioning control system. The dancer tensioning control system may include a top block assembly, a bottom block assembly below the top block assembly, guide rods extending between the bottom block assembly and the top block assembly, an actuator assembly movably positioned on the guide rods between the bottom block assembly and the top block assembly, and a proximity sensor positioned on the bottom block assembly. The actuator assembly may include an eyelet for receiving the linear material. The proximity sensor may be configured to detect whether the actuator assembly is proximate the proximity sensor, transmit, based on detecting that the actuator assembly is not proximate the proximity sensor, a signal, and stop transmitting, based on detecting that the actuator assembly is proximate the proximity sensor, the signal. The dynamic tension control system may be configured to command, based on receiving the signal from the proximity sensor, the motor to accelerate and command, based on stopping receiving the signal from the proximity sensor, the motor to decelerate.
In some embodiments, the dancer tensioning control system may include an upper guide assembly extending outward from the top block assembly, where the linear material passes through the eyelet of the actuator assembly and then through the upper guide assembly.
In some embodiments, the dancer tensioning control system may include variable tensioners on the guide rods, where a position of the variable tensioners on the guide rods is adjustable to increase tension in the linear material when the actuator assembly reaches the position of the variable tensioners on the guide rods.
In some embodiments, the dancer tensioning control system may include adjustable mechanical upper limits on the guide rods, where a position of the adjustable mechanical upper limits on the guide rods is adjustable to provide a mechanical upper limit for the actuator assembly.
In some embodiments, the dancer tensioning control system may include a safety stop proximity sensor configured to detect whether the actuator assembly is proximate the safety stop proximity sensor and transmit, based on detecting that the actuator assembly is proximate the safety stop proximity sensor, another signal, and the dynamic tension control system may be configured to command, based on receiving the other signal from the safety stop proximity sensor, the motor to decelerate.
In yet another aspect, the present invention embraces a dynamic tension control system including a shaft for holding a roll of linear material, a motor for directly driving the shaft, a dancer tensioning control system, a frame for positioning and supporting the shaft, the motor, and the dancer tensioning control system, and a dancer tension control guide positioned on the frame. The dancer tensioning control system may include an actuator assembly and a proximity sensor positioned below the actuator assembly. The actuator assembly may include an eyelet for receiving the linear material. The proximity sensor may be configured to detect whether the actuator assembly is proximate the proximity sensor, transmit, based on detecting that the actuator assembly is not proximate the proximity sensor, a signal, and stop transmitting, based on detecting that the actuator assembly is proximate the proximity sensor, the signal. The dancer tension control guide may receive the linear material from the roll and provide the linear material to the dancer tensioning control system. The dynamic tension control system is configured to command, based on receiving the signal from the proximity sensor, the motor to accelerate and command, based on stopping receiving the signal from the proximity sensor, the motor to decelerate.
In some embodiments, the dancer tension control guide may include a dancer tension control L-guide and an eyelet, where the linear material passes through the eyelet, and where the eyelet includes a ceramic material.
In some embodiments, the dancer tensioning control system may include another dancer tension control guide for receiving the linear material from the dancer tension control guide.
The features, functions, and advantages that have been discussed may be achieved independently in various embodiments of the present invention or may be combined with yet other embodiments, further details of which may be seen with reference to the following description and drawings.
Having thus described embodiments of the invention in general terms, reference will now be made the accompanying drawings, wherein:
Embodiments of the present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the invention are shown. Indeed, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Where possible, any terms expressed in the singular form herein are meant to also include the plural form and vice versa, unless explicitly stated otherwise. Also, as used herein, the term “a” and/or “an” shall mean “one or more,” even though the phrase “one or more” is also used herein. Furthermore, when it is said herein that something is “based on” something else, it may be based on one or more other things as well. In other words, unless expressly indicated otherwise, as used herein “based on” means “based at least in part on” or “based at least partially on.” Like numbers refer to like elements throughout.
As noted, during the assembly of face masks (e.g., surgical masks, medical masks, and/or the like), an ear loop welding machine may be used to create and attach (e.g., weld) ear loops to a piece of mask fabric. For example, the ear loop welding machine may pull linear ear loop material from a roll of linear ear loop material, cut a section of the linear ear loop material, and weld the ends of the section of linear ear loop material onto a piece of mask fabric to form an ear loop. However, when the ear loop welding machine pulls the linear ear loop material from the roll (e.g., a roll on which linear ear loop material is transversely wound under tension), the tension and the amount of material pulled from the roll may vary based on the position on the roll from which the material is pulled. Additionally, the linear ear loop material may twist when passing from the roll to the ear loop welding machine, may be distorted when pulled from the roll (e.g., due to its elasticity), and/or the like. Furthermore, when the ear loop welding machine pulls the linear ear loop material from the roll, the roll may continue to spin and unwind additional material, which may create knots in the linear ear loop material.
Some embodiments described herein provide a dynamic tension control system for narrow fabric, such as linear ear loop material and/or the like. The dynamic tension control system may include a frame for holding components of the dynamic tension control system, a shaft for holding a roll of material (e.g., linear material), a motor for driving the shaft, and a dancer tensioning control system for controlling the motor. In some embodiments, the dancer tensioning control system may include an actuator assembly through which the linear material passes and a sensor (e.g., a proximity sensor) for detecting whether the actuator assembly is proximate to the sensor. When the material is pulled from the roll (e.g., by an ear loop welding machine, a face mask assembly machine, and/or the like), tension is created in the material, which lifts the actuator assembly away from the sensor. In some embodiments, the dynamic tension control system may be configured to command, based on the sensor detecting that the actuator assembly is not proximate to the sensor, the motor to accelerate, which drives the shaft to unwind material from the roll. Additionally, or alternatively, as the motor accelerates and material is unwound from the roll, the tension in the material may be reduced, and the actuator assembly may return, based on the reduced tension, to its original position proximate the sensor. In some embodiments, the dynamic tension control system may be configured to command, based on the sensor detecting that the actuator assembly is proximate to the sensor, the motor to decelerate, which slows and stops the rotation of the shaft and the roll.
By accelerating the motor based on increased tension in the material as sensed by the actuator assembly and sensor, the dynamic tension control system may drive material off the roll in a controlled manner. Additionally, by accelerating and decelerating the motor based on increases and decreases, respectively, in tension in the material, the dynamic tension control system may stabilize the tension and the amount of material coming off the roll. In some embodiments, the dynamic tension control system may include components, such as the actuator assembly, dancer tension control guides, and/or the like, which prevent the material from twisting. Furthermore, by decelerating the motor based on decreases in tension in the material, the dynamic tension control system may prevent the roll from continuing to spin and unwinding additional material, which may prevent knotting of the material.
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In some embodiments, the tube inserts (e.g., the first non-drive-side tube insert 104, the second non-drive-side tube insert 204, the second drive-side tube insert 214, and the first drive-side tube insert 114) may each include an attachment mechanism (e.g., a threaded hole and a set screw) for attaching the tube insert to a shaft (e.g., the first shaft 102 and/or the second shaft 202), thereby preventing the tube insert and a roll (e.g., the first roll 100 and/or the second roll 200) from sliding off an end of the shaft. Additionally, or alternatively, the tube inserts may each include a conical portion, an intermediate portion, and/or an exterior portion (e.g., as shown in
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In some embodiments, the dancer tension control guides 106, 108, and 208 may prevent the linear material from tangling and/or twisting as the linear material passes from the first roll 100 and/or the second roll 200 to the first dancer tensioning control system 120, the second dancer tensioning control system 220, a machine receiving the linear material from the dynamic tension control system 10, and/or the like. Additionally, or alternatively, and as described further herein with respect to
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In some embodiments, the first motor 112 directly drives the first shaft 102, and the second motor 212 directly drives the second shaft 202. For example, the first shaft 102 may pass through a portion of the frame 12 and insert into the first motor 112, and the second shaft 202 may pass through a portion of the frame 12 and insert into the second motor 212. In some embodiments, a first direct drive internal coupling may couple the first shaft 102 to the frame 12 and maintain a vertical position of the first shaft 102. Additionally, or alternatively, a second direct drive internal coupling may couple the second shaft 202 to the frame 12 and maintain a vertical position of the second shaft 202.
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In some embodiments, the linear material may pass through the first eyelet 118 as shown in
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In some embodiments, the first eyelet 132 and/or the second eyelet 232 may be attached to the first actuator assembly 130 and/or the second actuator assembly 230, respectively, by passing through holes in the top of the first actuator assembly 130 and/or the second actuator assembly 230 and being secured in the holes via an attachment mechanism (e.g., a threaded hole and a set screw) as shown in
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In some embodiments, when the first actuator assembly 130 is lifted upward along the first guide rods 134, the first proximity sensor 128 (see
Additionally, or alternatively, as the first motor 112 accelerates and linear material is unwound from the first roll 100, the tension in the linear material may be reduced, and the first actuator assembly 130 may return, based on the reduced tension, to its original position proximate the first proximity sensor 128. The first proximity sensor 128 may detect that the first actuator assembly 130 is proximate to the first proximity sensor 128 and may stop transmitting, based on detecting that the first actuator assembly 130 is proximate to the first proximity sensor 128, the signal to the tension control housing 14. The tension control housing 14 may be configured to command, based on not receiving the signal from the first proximity sensor 128, the first motor 112 to decelerate, which slows and stops the rotation of the first shaft 102 and the first roll 100.
Similarly, when the second actuator assembly 230 is lifted upward along the second guide rods 234, the second proximity sensor may detect that the second actuator assembly 230 is not proximate to the second proximity sensor and may transmit, based on detecting that the second actuator assembly 230 is not proximate to the second proximity sensor, a signal to the tension control housing 14 (see
Additionally, or alternatively, as the second motor 212 accelerates and linear material is unwound from the second roll 200, the tension in the linear material may be reduced, and the second actuator assembly 230 may return, based on the reduced tension, to its original position proximate the second proximity sensor. The second proximity sensor may detect that the second actuator assembly 230 is proximate to the second proximity sensor and may stop transmitting, based on detecting that the second actuator assembly 230 is proximate to the second proximity sensor, the signal to the tension control housing 14. The tension control housing 14 may be configured to command, based on not receiving the signal from the second proximity sensor, the second motor 212 to decelerate, which slows and stops the rotation of the second shaft 202 and the second roll 200.
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As noted, in some embodiments, the dancer tensioning control system 520 may be similar to and/or have characteristics of the first dancer tensioning control system 120 or the second dancer tensioning control system 220. For example, the dancer tensioning control system 520 may include a top block assembly, an upper guide, a bottom block assembly, a proximity sensor, an actuator assembly, an eyelet, guide rods, variable tensioners, adjustable mechanical upper limits, and/or the like. Additionally, or alternatively, the components of the dancer tensioning control system 520 may perform functions similar to the functions described herein with respect to the first dancer tensioning control system 120 or the second dancer tensioning control system 220.
In some embodiments, the dynamic tension control system 50 may perform functions similar to the functions described herein with respect to the dynamic tension control system 10. For example, when the actuator assembly of the dancer tensioning control system 520 is lifted upward along the guide rods, the proximity sensor may detect that the actuator assembly is not proximate to the proximity sensor and may transmit, based on detecting that the actuator assembly is not proximate to the proximity sensor, a signal to the tension control housing 54. The tension control housing 54 may be configured to command, based on receiving the signal from the proximity sensor, the motor 512 to drive the shaft 502, which rotates a roll of linear material to unwind linear material from the roll.
Additionally, or alternatively, as the motor accelerates and linear material is unwound from the roll, the tension in the linear material may be reduced, and the actuator assembly may return, based on the reduced tension, to its original position proximate the proximity sensor. The proximity sensor may detect that the actuator assembly is proximate to the proximity sensor and may stop transmitting, based on detecting that the actuator assembly is proximate to the proximity sensor, the signal to the tension control housing 54. The tension control housing 54 may be configured to command, based on not receiving the signal from the proximity sensor, the motor to decelerate, which slows and stops the rotation of the shaft 502 and the roll.
Although many embodiments of the present invention have just been described above, the present invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Also, it will be understood that, where possible, any of the advantages, features, functions, devices, and/or operational aspects of any of the embodiments of the present invention described and/or contemplated herein may be included in any of the other embodiments of the present invention described and/or contemplated herein, and/or vice versa. In addition, where possible, any terms expressed in the singular form herein are meant to also include the plural form and/or vice versa, unless explicitly stated otherwise. Accordingly, the terms “a” and/or “an” shall mean “one or more,” even though the phrase “one or more” is also used herein. Like numbers refer to like elements throughout.
While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that this invention not be limited to the specific constructions and arrangements shown and described, since various other changes, combinations, omissions, modifications and substitutions, in addition to those set forth in the above paragraphs, are possible. Those skilled in the art will appreciate that various adaptations, modifications, and combinations of the just described embodiments can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.
The present application claims the benefit of U.S. Provisional Application No. 63/124,415 for a “Dynamic Tension Control System for Narrow Fabric,” filed Dec. 11, 2020, which is hereby incorporated by reference in its entirety.
Number | Date | Country | |
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63124415 | Dec 2020 | US |