Tension control system for converting packages of elastic thread

Abstract

A system and method for tension control in a thread feeding system that provides a fast and reliable method for feeding elastomeric thread or fiber from a package to a thread processing system. The system includes a driven elastomeric thread package holder. The thread feeding system also includes a variable-speed motor configured to drive the driven elastomeric thread package holder.

1 ) A thread feeding system comprising: 
 guide rolls configured to guide an elastomeric thread through a thread path of the thread feeding system;    a driven elastomeric thread package holder;    a variable-speed motor configured to drive the driven elastomeric thread package holder;    a first tension sensor configured to determine the tension on the thread; and    a first tension controller device configured to control a speed of the variable-speed motor.    
   
   
       2 ) The thread feeding system of  claim 1 , wherein the speed of the variable-speed motor is maintained within a first predetermined range of thread tension values by the tension controller device.  
   
   
       3 ) The thread feeding system of  claim 1  further comprising guide rolls and a tension sensor, wherein a wrap angle of the thread around the tension sensor is in the range between 5 and 210 degrees.  
   
   
       4 ) The thread feeding system of  claim 1 , wherein the driven elastomeric thread package holder is adapted to contact a core of an elastomeric thread package.  
   
   
       5 ) The thread feeding system of  claim 1 , wherein the driven elastomeric thread package holder is adapted to contact a circumference of an elastomeric thread package.  
   
   
       6 ) The thread feeding system of  claim 1  further comprising a plurality of driven fiber package holders.  
   
   
       7 ) The thread feeding system of  claim 1  further comprising at least one guide located less than 0.5 meter from the driven package holder.  
   
   
       8 ) A method for controlling elastomeric thread tension in a thread feeding system for a manufacturing system, comprising 
 measuring a thread tension of a moving elastomeric thread;    determining whether the moving thread has a tension that is out of range relative to a predetermined tension value;    controlling the speed of a driven elastomeric thread package holder; and    delivering the thread to a desired location in the manufacturing system.    
   
   
       9 ) The method of  claim 8 , further comprising determining whether an average tension for the moving thread is out of range relative to the predetermined tension value for the thread.  
   
   
       10 ) The method of  claim 8 , further comprising setting an alarm when the thread tension is at a level indicating at least one of broken, not moving and thread out of range tension level.  
   
   
       11 ) The thread feeding system of  claim 8  further comprising at least one guide located less than 0.50 meter from the driven package holder.  
   
   
       12 ) The method of  claim 8 , wherein the driven elastomeric thread package holder is adapted to contact a circumference of an elastomeric thread package.  
   
   
       13 ) The method of  claim 8 , wherein the driven elastomeric thread package holder is adapted to contact a core of an elastomeric thread package.  
   
   
       14 ) The method of  claim 8  further comprising a plurality of driven fiber package holders.  
   
   
       15 ) The method of  claim 11 , wherein the elastomeric thread package is an as-spun elastomeric thread package.  
   
   
       16 ) A thread feeding system comprising: 
 guide rolls configured to guide an elastomeric thread through a thread path of the thread feeding system;    a driven elastomeric thread package holder;    a variable-speed motor configured to drive the driven elastomeric thread package holder;    at least one guide located less than  0 . 5  meter from the driven package holder;    a first tension sensor configured to determine the tension on the thread; and    a first tension controller device configured to control a speed of the variable-speed motor;    wherein the speed of the variable-speed motor is adjusted to maintain the tension on the thread within a predetermined range of thread tension values.    
   
   
       17 ) The thread feeding system of  claim 16  further comprising guide rolls and a tension sensor, wherein a wrap angle of the thread around the tension sensor is in the range between about 5 and about 210 degrees.  
   
   
       18 ) The thread feeding system of  claim 16 , wherein the driven elastomeric thread package holder is adapted to contact a core of an elastomeric thread package.  
   
   
       19 ) The thread feeding system of  claim 16 , wherein the driven elastomeric thread package holder is adapted to contact a circumference of an elastomeric thread package.  
   
   
       20 ) The thread feeding system of  claim 16  further comprising a plurality of driven fiber package holders.