Dynamic tension control system for narrow fabric

Abstract

A dynamic tension control system is described herein for driving linear material off a roll in a controlled manner. The dynamic tension control system may include a frame, a shaft for holding a roll of linear material, a motor for driving the shaft, and a dancer tensioning control system for controlling the motor. The dancer tensioning control system may include an actuator assembly through which the linear material passes and a proximity sensor for detecting whether the actuator assembly is proximate to the proximity sensor. When the linear material is pulled from the roll, tension is created in the linear material, which lifts the actuator assembly away from the proximity sensor. The dynamic tension control system may be configured to command, based on detecting that the actuator assembly is not proximate to the proximity sensor, the motor to drive the shaft to unwind linear material from the roll.

What is claimed is: 
     
         1 . A dynamic tension control system, the system comprising:
 an assembly for receiving a material from a roll of the material held on a shaft, wherein the shaft is driven by a motor;   a sensor configured to:
 detect whether the assembly is proximate the sensor; 
 transmit, based on detecting that the assembly is not proximate the sensor, a signal; and 
 stop transmitting, based on detecting that the assembly is proximate the sensor, the signal; and 
   a controller, wherein the controller is 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. 
   
     
     
         2 . The dynamic tension control system of  claim 1 , comprising a frame configured for positioning and supporting the shaft, the motor, the assembly, the sensor, and the controller. 
     
     
         3 . The dynamic tension control system of  claim 1 , comprising:
 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.   
     
     
         4 . The dynamic tension control system of  claim 3 , wherein:
 the non-drive-side tube insert comprises 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 comprises 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.   
     
     
         5 . The dynamic tension control system of  claim 3 , wherein:
 the non-drive-side tube insert comprises a first conical portion, a first intermediate portion, and a first exterior portion; and   the drive-side tube insert comprises a second conical portion, a second intermediate portion, and a second exterior portion.   
     
     
         6 . The dynamic tension control system of  claim 5 , wherein:
 the first conical portion and the second conical portion have lengthwise increasing outer diameters for receiving the spool;   the first intermediate portion and the second intermediate portion have outer diameters equal to or less than an inner diameter of the spool; and   the first exterior portion and the second exterior portion have outer diameters greater than an outer diameter of the spool.   
     
     
         7 . The dynamic tension control system of  claim 1 , comprising one or more dancer tension control guides for receiving the material from the roll and providing the material to the assembly. 
     
     
         8 . The dynamic tension control system of  claim 1 , comprising a user input device for controlling at least one of a top speed of the motor, acceleration of the motor, deceleration of the motor, or a time period for which the motor drives the shaft. 
     
     
         9 . The dynamic tension control system of  claim 1 , comprising:
 a top block assembly; and   an upper guide assembly extending outward from the top block assembly, wherein the material passes through the assembly and then through the upper guide assembly.   
     
     
         10 . The dynamic tension control system of  claim 9 , comprising a bottom block assembly, wherein the sensor is positioned on the bottom block assembly. 
     
     
         11 . The dynamic tension control system of  claim 10 , comprising guide rods extending between the bottom block assembly and the top block assembly, wherein the assembly moves along the guide rods. 
     
     
         12 . The dynamic tension control system of  claim 1 , comprising:
 another assembly for receiving the material from another roll of the material held on another shaft, wherein the other shaft is driven by another motor;   another sensor configured to:
 detect whether the other assembly is proximate the other sensor; 
 transmit, based on detecting that the other assembly is not proximate the other sensor, another signal; and 
 stop transmitting, based on detecting that the other assembly is proximate the other sensor, the other signal; 
   wherein the dynamic tension control system is 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. 
   
     
     
         13 . A method of controlling tension in a linear fabric material, the method comprising:
 receiving, with an assembly, a linear fabric material from a roll of the linear fabric material held on a shaft, wherein the shaft is driven by a motor;   detecting, with a sensor, whether the assembly is proximate the sensor;   transmitting, with the sensor and based on detecting that the assembly is not proximate the sensor, a signal;   stopping transmitting, with the sensor and based on detecting that the assembly is proximate the sensor, the signal;   causing, in response to the sensor transmitting the signal, the motor to accelerate; and   causing, in response to the sensor stopping transmitting the signal, the motor to decelerate.   
     
     
         14 . The method of  claim 13 , comprising:
 receiving, with one or more dancer tension control guides, the linear fabric material from the roll; and   providing, with the one or more dancer tension control guides, the linear fabric material to the assembly.   
     
     
         15 . The method of  claim 13 , comprising:
 receiving, with a user input device, a control for the motor, wherein the control comprises at least one of a top speed of the motor, acceleration of the motor, deceleration of the motor, or a time period for which the motor drives the shaft; and   controlling the motor based on the received control.   
     
     
         16 . The method of  claim 13 , comprising guiding, using guide rods, movement of the assembly. 
     
     
         17 . The method of  claim 13 , comprising:
 receiving, with another assembly, another linear fabric material from another roll held on another shaft, wherein the other shaft is driven by another motor;   detecting, with another sensor, whether the other assembly is proximate the other sensor;   transmitting, with the other sensor and based on detecting that the other assembly is not proximate the other sensor, another signal;   stopping transmitting, with the other sensor and based on detecting that the other assembly is proximate the other sensor, the other signal;   causing, in response to the other sensor transmitting the other signal, the other motor to accelerate; and   causing, in response to the other sensor stopping transmitting the other signal, the other motor to decelerate.   
     
     
         18 . A dynamic tension control system, the system comprising:
 an assembly for receiving a material from a roll of the material held on a shaft, wherein the shaft is driven by a motor;   a sensor configured to detect whether the assembly is proximate the sensor; and   a controller, wherein the controller is configured to:
 command, based on detecting that the assembly is not proximate the sensor, the motor to accelerate; and 
 command, based on detecting that the assembly is proximate the sensor, the motor to decelerate. 
   
     
     
         19 . The dynamic tension control system of  claim 18 , comprising one or more dancer tension control guides for receiving the material from the roll and providing the material to the assembly. 
     
     
         20 . The dynamic tension control system of  claim 18 , comprising a user input device for controlling at least one of a top speed of the motor, acceleration of the motor, deceleration of the motor, or a time period for which the motor drives the shaft.