Weight measurement systems and methods for use in textile manufacturing operations

In one aspect, a method of measuring the weight of material used during a textile manufacturing process comprises positioning material used during the textile manufacturing process on a receiving surface associated with a load cell. A first weight of the material may be measured using the load cell. A textile manufacturing machine may be operated such that at least a portion of the material is used in the process, wherein the material remains disposed on the receiving surface during the process. A second weight of the material may be measured using the load cell.

BACKGROUND

1. Technical Field

The present invention relates to systems and methods for measuring the weight of material used during textile manufacturing operations.

2. Background Information

Textile manufacturing operations may be used to make a variety of articles, such as clothing, footwear, accessories, and other goods. Such operations may include, by way of example and without limitation, processes performed by weaving, knitting, felting, or other techniques.

These operations utilize various types of material, such as yarn. Therefore, machines used to make such articles may include, especially for commercial use, several spools of yarn, yarn cones or bobbins to accommodate the variety of yarn used to make the articles. Other factors, such as the pattern of the article, or business objectives, such as to increase productivity in making the article, may require the machines to accommodate several spools of yarn, yarn cones or bobbins and a variety of yarn.

Yarn cones are regularly purchased by weight, yet the amount of yarn that is used for such articles is measured in length. The length of yarn may vary based on the temperature and humidity of the air where the textile manufacturing machine is located. For example, under certain temperature and humidity conditions, yarn may shrink or stretch, which affects the length measurement of the amount of yarn used. As the length of the yarn varies, the density or linear density of the yarn may provide an inaccurate estimate regarding the weight of the yarn used, as the calculation does not take into account the temperature and humidity conditions. Purchasers of yarn therefore often have difficulty accurately identifying the amount of yarn necessary to purchase for a given article or the amount of yarn used to make an article, which leads to the purchase of too much or too little yarn and yarn surplus and waste.

BRIEF SUMMARY

In one aspect, a method of measuring the weight of material used during a textile manufacturing process comprises positioning material used during the textile manufacturing process on a receiving surface associated with a load cell. A first weight of the material may be measured using the load cell. A textile manufacturing machine may be operated such that at least a portion of the material is used in the process, wherein the material remains disposed on the receiving surface during the process. A second weight of the material may be measured using the load cell.

In another aspect, a system comprises a first segment adapted to be stably positioned relative to a textile machine. A block may be coupled to the first segment. A load cell comprises a first end portion and a second end portion, wherein the first end portion of the load cell may be coupled to the block. A receiving surface may be associated with the load cell. The receiving surface may be adapted to receive the material to be used during the textile manufacturing process, and the receiving surface may be positioned at a location enabling the material to be weighed by the load cell during the textile manufacturing process

In another aspect, a system comprises a first segment adapted to be stably positioned relative to a textile machine. A load cell may be coupled to the first segment. A receiving surface may be adapted to receive the material to be used during the textile manufacturing process. The receiving surface may be positioned at a location enabling the material to be weighed by the load cell during the textile manufacturing process

The accompany drawings, which are incorporated herein and constitute part of this specification, and, together with the general description given above and the detailed description given below, serve to explain features of the present invention.

FIGS. 1-5show a system100for measuring the weight of material used in a textile manufacturing operation. The system100may be positioned on a supportive surface, including on a portion of a textile manufacturing machine. In one embodiment, the system100includes a first segment adapted to be stably positioned relative to a textile manufacturing machine. In one example, the first segment comprises a first plate102that may be positioned on a flat surface. The first plate102includes a shape, such as an exemplary rectangular shape as shown inFIG. 3. The material of the first plate102may vary, and may include steel, metal, an alloy of the same, or another suitable material. The first plate102may also include a friction pad104that is coupled to the bottom of the first plate102. The friction pad104may be adhesively secured to the first plate102and minimizes movement of the first plate102along the supportive surface. The shape of the friction pad104may conform to the shape of the first plate102.

The system100may also include a block106that is positioned over the top of the first plate102and connected to the first plate102. The block106may be adhesively connected to the first plate102or mechanically connected to the first plate102through screws, fasteners, bolts, nuts, clamping, or other means of mechanical securement. The material of the block106may be the same or different than the material of the first plate102. The block106provides for an elevated surface and stable foundation for placement of one segment of a load cell108, as explained further below.

As used in the present embodiments, the term “load cell” encompasses a weight measuring component of the system100. Usage of “load cell” in this application may include conventional types of load cells, or other components capable of measuring weight, in accordance with the principles herein. In short, references to load cell are intended to cover any such weight measurement devices.

The load cell108of the system100, as shown inFIG. 5, may be a transducer that is used to convert force, or the mechanical deformation, into an electrical output. The load cell108described herein may comprise a type of strain gauge load cell in the form of a beam; however, the disclosure herein is not limited to beam type strain gauge load cells. Load cells, including bending or shear beam, single point, S-beam or Z-beam, load button, ring, pancake or low profile, or canister load cells may be used. If a compression type load cell is used, the block106may not be necessary to provide an elevated surface for the load cell and can be removed. Pneumatic and helical load cells may also be used. As noted, still other weight measurement devices may be used without departing from the present embodiments.

The load cell108may include a generally linear shape with a first end portion110, a second end portion112, a top114, and a bottom116, as shown inFIG. 5. The first end portion110may be mounted to the block106with one or more coupling elements, such as screws or bolts118. The one or more coupling elements118may be inserted through the top114and then through the bottom116of the load cell108for connection with the block106.

In other embodiments, the block106may be omitted, or both the block106and the first plate102may be omitted. In the latter embodiment, an integral first segment of the load cell is adapted to be stably positioned relative to a textile machine. Therefore, the first segment may refer to the first segment of the load cell itself with the first plate102being omitted or the first segment may refer to the first plate102that is generally external to the load cell. In either embodiment, the first segment is adapted to be stably positioned relative to a textile machine during a manufacturing process.

The second end portion112of the load cell108may be positioned at least partially within a housing120. If a compression type load cell is used, the housing120may not be necessary to mount the load cell and can be removed. The second end portion112may be connected to the housing120with one or more coupling elements, such as screws or bolts122. The one or more coupling elements122may be inserted through a base124of the housing120and then through the bottom116of the load cell108.

As best seen inFIGS. 2 and 4, in one embodiment, the housing120may include the base124, at least two side panels126, a cavity128, a first end130, and a second end132. The second end portion112of the load cell108may be inserted into the first end130of the housing120and positioned within the cavity128. Each of the at least two side panels126includes two sections as shown inFIG. 4. A first section134comprises a first length136and a first height138, and a second section140comprises a second length142and extends from the first height138of the first section134and tapers toward the base124of the housing120to a second height144smaller than the first height138. The first length136and the second length142collectively form the total length146of each of the side panels126.

The system100may also include a receiving surface adapted to receive the material used during the textile manufacturing process. The receiving surface may be positioned at a location suitable for the material to be weighed by the load cell108. In some embodiments, the receiving surface may be part of the load cell108itself, e.g., the material to be weighed may rest directly on the load cell. In other embodiments, the receiving surface may comprise a distinct component that is coupled to the load cell108.

In one example, a distinct receiving surface comprises a second plate148that may be positioned over the first sections134of the side panels126of the housing120as shown inFIGS. 1 and 4. In one embodiment, the second plate148may include a circular shape as shown inFIG. 3. The material of the second plate148may vary, and may include steel, metal, an alloy of the same, or another suitable material. The second plate148may also be coupled to a friction pad150that is disposed on the top of the second plate148. The friction pad150may be adhesively secured to the second plate148. The shape of the friction pad150may conform to the shape of the second plate148.

It will be appreciated that while the first segment and the receiving surface are referred to in certain examples herein as “first plate102” and “second plate148,” respectively, such descriptions are for aiding discussion and it is contemplated that the first segment and the receiving surface need not comprise “plate” shapes. Rather, other suitable non-plate shapes may be used for the first segment and the receiving surface.

A yarn cone152may be positioned on the friction pad150. The yarn cone152may comprise a circular base, and the second plate148and the friction pad150may include a circular shape to adapt to the yarn cone152. The friction pad150helps to minimize movement of the yarn cone152from the second plate148as material is removed during the manufacturing process. It will be understood that while reference is made to a yarn cone, that such a cone may support or house materials other than yarn including thread, monofilament or multifilament, and woven materials. In another embodiment, a bobbin may be used rather than a yarn cone152with yarn disposed around the bobbin. A bobbin may include a reel, spindle, spool or cylinder that yarn, thread, woven or other materials may be wound around.

In one embodiment, the second plate148may also include or be coupled to a shaft, rod, pole or other cylindrical element (not shown) that is positioned generally perpendicular to the second plate148. The supportive cone of the yarn cone152or the bobbin may include a hollow center, and the yarn cone152or the bobbin may be positioned over the cylindrical element to minimize movement of the yarn cone152or the bobbin along or around the second plate148during the manufacturing process.

As noted above, the material to be measured by the load cell108, such as the yarn cone152, may be mounted or positioned on the load cell108, and the system100may not include the second plate148and/or the friction pad150. When the second plate148is not used, the load cell108may comprise one of the types of load cells as previously described, including but not limited to a load button, ring, pancake low profile or other compression type load cell.

In accordance with one aspect, the weight of the yarn cone152may be measured by the load cell108. In one embodiment, the weight of the yarn cone may be measured as the actual weight of the supportive cone itself plus the weight of any material disposed on the supportive cone at a given time, which collectively amounts to the weight of the yarn cone. In another embodiment, the weight of the yarn cone may be measured as only the weight of the material disposed on the supportive cone, if the weight of the supportive cone itself (absent material) is known and can be excluded from the measurement. In either instance, measurements regarding the weight of the yarn cone can be taken at different points in time to calculate the weight of material coming off of the yarn cone between reference times, as will be explained further below.

When the yarn cone152is initially placed on the friction pad150of the second plate148, the force or load from the yarn cone152, based on the weight of the yarn cone152, is applied to the housing120and the second end portion112of the load cell108. When a strain gauge load cell is used, the stress applied to the load cell108causes the load cell108to deflect or deform and thus causes strain on the load cell108and the strain gauges of the load cell108. The strain on the strain gauges of the load cell108leads to a change in resistance in the strain gauges and a change in output voltage that is proportional to the weight of the yarn cone152. When no load is applied, the voltage output is zero or very close to zero. Based on the characteristics of the load cell108, such as the excitation voltage, maximum weight capacity, and sensitivity, the load cell108can convert the voltage output into the weight of the yarn cone152. After a manufacturing process, benchmark or desired interval has been completed, the load cell108can again measure the weight of the yarn cone152to determine how much yarn based on weight was used for the article.

The strain gauges may be adhesively adhered or otherwise mounted on the body of the load cell108. The load cell108may include four strain gauges in a Wheatstone bridge configuration. However, one or two strain gauges may also be used. When a strain gauge load cell is used for the load cell108, the load cell108provides off-center loading compensation that allows the load cell108to still accurately measure the weight of the yarn cone152even if the yarn cone152moves on the friction pad150of the second plate148away from the center of the second plate148.

Referring toFIG. 6, a block diagram of various exemplary aspects of the weight measurement system is shown. The voltage output of the load cell108may not be large enough to be measured accurately and may be in millivolts. Therefore, an amplifier154may be used to amplify the signal a shown inFIG. 6. The amplifier154may be coupled to the load cell108via the wires or electrical cables156of the load cell108. The amplifier154may be coupled to an analog to digital converter158, and the amplified signal may then be input into the analog to digital converter158. The analog to digital converter158may be coupled to the amplifier154via a series of wires or electrical cables. The analog to digital converter158allows the signal to be received by a computer160. The analog to digital converter158may be coupled to the computer158wirelessly or via electrical connection, such as a USB cord or an Ethernet cable.

The temperature of the ambient room, or general location where the textile manufacturing machine is situated, may affect the temperature of the load cell108and thus the output of the load cell108. Temperature effects can be compensated for in strain gauge measurements through software, thermistors on the strain gauges, temperature-compensating resistors, or manually. A temperature and humidity logger may also be used to identify the temperature and humidity at a given time in order to compensate for the temperature effects.

The computer160may include software that continuously logs and stores the weight of the yarn cone152or measures the weight of the yarn cone152at certain times, such as the weight of the yarn cone152before the manufacturing begins and the weight of the yarn cone152after the manufacturing of an article is completed. For example, the software may measure the date and time the measurement is taken, the weight of the yarn cone152at that time, and also the temperature and humidity of the ambient air at the time the weight is measured.

FIGS. 7-8show a second embodiment of a system200for measuring the weight of material used in a textile manufacturing operation. The system200includes a lower profile configuration as compared to the system100. As described previously with the system100, the system200comprises a first segment, such as the first plate102, which may also include the friction pad104.

The system200may also include a bracket202that is positioned over the top of the first plate102and connected to the first plate102. The bracket202may be adhesively connected to the first plate102or mechanically connected to the first plate102through screws, fasteners, bolts, nuts, or other means of mechanical securement. The material of the bracket202may be the same or different than the material of the first plate102. The bracket202provides for a stable foundation and mounting of one segment of the load cell108. The load cell108may comprise one of the types of load cells as previously described, including but not limited to a load button, ring, pancake low profile or other compression type load cell.

The first end portion110of the load cell108may be mounted, coupled or secured to the bracket202with one or more coupling elements, such as screws, fasteners, bolts, nuts or other means of mechanical securement. As shown inFIGS. 7-8, a portion of the bottom116of the load cell108may be mounted or coupled to the bracket202.

As described previously with the system100, the system200may also include a receiving surface that is adapted for receipt of the material to be measured by the load cell108. The receiving surface of the system200may be a part of the load cell itself, or may be a distinct part coupled to the load cell such as the second plate148, which may also include the friction pad150, as explained above with respect to system100.

When the system200includes the second plate148, the system200may also include a bracket204. The bracket204provides for coupling and/or securing the load cell108with the second plate148. The material of the bracket204may be the same or different than the material of the second plate148. The second end portion112of the load cell108may be coupled to the bracket204with one or more coupling elements, such as screws, fasteners, bolts, nuts or other means of mechanical securement. As shown inFIGS. 7-8, a portion of the top114of the load cell108may be mounted or coupled to the bracket204.

In one embodiment, the second plate148may also include or be coupled to a shaft, rod, pole or other cylindrical element (not shown) that is positioned generally perpendicular to the second plate148. The supportive cone of the yarn cone152or the bobbin may include a hollow center, and the yarn cone152or the bobbin may be positioned over the cylindrical element to minimize movement of the yarn cone152or the bobbin along or around the second plate148during the manufacturing process.

Referring toFIG. 9, in some embodiments, a plurality of load cells108may be positioned on a textile manufacturing machine, such as an industrial knitting machine that has a surface to accommodate a plurality of yarn cones152. In the example ofFIG. 9, a load cell108may be positioned underneath each yarn cone152, such that one load cell108will correspond with one yarn cone152. The plurality of load cells108may be in communication with a central computer160that provides the weight output of each yarn cone152on a textile manufacturing machine. If multiple textile manufacturing machines are used, such as in factories, and communicate with the central computer160, the software may also identify the specific machine, the specific yarn cone152, and the type of yarn on the yarn cone that is measured.

In the example ofFIG. 9, the wires or electrical cables156of the load cells108may be connected to a common power source206. The power source206may also include or be coupled to the amplifier154and/or the analog to digital converter158as previously described. The common power source206provides for a single source, for example, for load cells associated with each textile manufacturing machine to have power and communicate with the central computer160.

As shown inFIG. 9, the plurality of load cells108may also be positioned over a cover, mat or pad208. The cover208provides for a common base for the plurality of load cells108and to minimize movement of the plurality of load cells108along the textile manufacturing machine. The cover208also allows for ease of positioning and removal of the plurality of load cells108from a textile manufacturing machine. The cover208may comprise a rectangular or square shape and may extend around the plurality of load cells108to provide for an enclosure around the plurality of load cells108. A second cover, mat or pad may also be positioned over the plurality of load cells108and coupled to the first cover208to encapsulate or otherwise enclose the plurality of load cells108.

Advantageously, the present embodiments measure the weight of material, such as yarn, that is used during a textile manufacturing process. If such material is purchased in weight, and the present embodiments measure the weight of material used at desired benchmarks or intervals, then there is no need to convert length measurements into weight, which leads to simplified purchasing of the material.

As a further advantage, the present embodiments may significant reduce or eliminate incorrect calculations that may arise when converting measurements for length of material into projected measurements for weight of material used. Using yarn as an exemplary material, since the temperature and humidity of the air may significantly vary depending on where the textile manufacturing machine is located, yarn may shrink or stretch, which affects the length measurement of the amount of yarn used. As the length of the yarn varies, the density or linear density of the yarn may provide an inaccurate estimate regarding the weight of the yarn used, as the calculation does not take into account the temperature and humidity conditions. In the present embodiments, purchasers of yarn can have improved accurately identifying the amount of yarn necessary to purchase by weight for a given article or the amount of yarn used to make an article, leading to less material surplus or waste.

As another advantage, a user does not need to remove the yarn cone from the first plate to obtain a proper weight measurement of yarn used. Rather, physical user intervention is minimized or eliminated during the process.

As yet a further advantage, the weight measurements taken using the systems and methods described above may assist in determinations of what locations may be best for certain textile manufacturing operations. For example, an evaluation may be made regarding what factory can produce the most articles in a given amount of time with a certain weight of yarn, with temperature and humidity being monitored and taken into account.

As noted above, while exemplary references have been made to yarn, yarn cones, or weight of a yarn cone, it will be understood that materials other than yarn may be used in textile manufacturing processes and measured according to the foregoing description, and the above systems and methods are intended to cover any such variable materials.