Zhisuo Drop-Wire-Free Light-Beam Warp Breakage Detection Device

Test conditions (laboratory typical scenario):

At a room temperature of 25°C, with stable DC 24V power, warp ends moving at constant speed through the light path, and using a manually triggered yarn-break simulator, response times were recorded over 1,000 consecutive triggers; the 95th-percentile value was ≤0.3 s, and the higher end did not exceed 0.5 s.

Factors in real workshops that may affect response:

Response time will increase if workshop power ripple is excessive, ambient temperature exceeds the -20°C to 60°C operating range, or lint obscures the optical lens surface. A visual lens cleaning once per shift is recommended (typical-scenario recommendation).

Basis of calculation: "≤0.3 s" is a 95th-percentile result from a laboratory typical scenario, not an absolute-value commitment for every single warp-break event.

Under typical scenarios (normal speeds on water-jet/air-jet looms, lens cleaned once per shift, workshop humidity 40%-85% RH), over 99.9% of genuine warp-break events with diameter within the detection specification are recognized within a short time and trigger a stop/alarm, with the false alarm rate kept within 0.18%.

Lint, yarn hairiness, water droplets and obvious dust buildup on the lens fall within the scope of routine maintenance and environmental control, and are not covered by the typical-scenario definition above, and are outside the applicability range of the 99.9% metric. Users can minimize such false/missed alarms by establishing a per-shift lens wiping routine.

"Zero mechanical wear" is stated relative to traditional drop-wire solutions: this device uses no metal strips/contacts in direct physical contact with the warp ends, so there is neither long-term friction wear between "drop wire and warp yarn" nor replacement cost after strips deform or rust.

"Maintenance-free" is likewise a no-replacement claim relative to drop-wire solutions: once the device body is installed and fixed, wear parts do not need to be replaced loom by loom as in traditional solutions; a simple visual/air-blow cleaning of the optical lens surface once per shift is still recommended (this counts as routine environmental control, not maintenance in the sense of "replacement parts").

The adaptation package is a three-piece set of "N52/N35 magnetic attachment + DC 24V power take-off + LoRa reporting":
Water-jet/air-jet/rapier looms can be fitted as long as the crossbeam offers a flat magnetic metal surface; where it does not, a custom aluminum alloy bracket can be made (reserved option).
Power is supplied at DC 24V and can be taken from the 24V terminal block in the loom electrical cabinet; No changes to the main control circuit and no insertion into the emergency-stop loop, and the warp-break stop logic is implemented via parallel connection to existing discrete signals.
If the workshop has no LoRa gateway, the device can initially run standalone locally (warp-break events directly trigger the loom brake/stop signal and are recorded in a local log), with gateway access to the MES added later.

LoRa wall penetration / coverage distance is heavily affected by wall materials, the density of metal equipment, gateway mounting height and on-site interference sources (VFDs / servo motors / welders), so there is no universal figure.
Typical open workshop: with the gateway mounted over 3 m above the floor, stable coverage on the scale of several hundred meters;
Older workshops with many reinforced-concrete partition walls: plan for one gateway per workshop span, or run an on-site wireless survey first.

Zhisuo Zhikong can provide a typical-scenario wireless survey template during the pre-sales phase, and customers can also use standard LoRa test tools to conduct their own on-site assessment.

Rated DC 24V, with a typical operating voltage range of DC 12V-28V (wide-voltage design, accommodating common 24V supply fluctuations on looms).
The device has a built-in log buffer: warp-break events, timestamps, alarm states and so on are written to local non-volatile memory; after a normal workshop outage and repowering, stored historical logs are not lost. If second-level power ride-through is required, users are advised to select an industrial-grade DC 24V UPS on the loom electrical cabinet side (a user-side option, not standard equipment).

Typical consumption of a single unit is ≤0.6 W (standby + normal monitoring), with a peak of ≤1.5 W (millisecond-level) the instant the relay/LED is driven during an alarm.
Estimated for a 1,000-unit workshop: total typical power is <0.6 kW, far below the load of the loom main shafts and VFDs themselves, so it creates virtually no perceptible additional pressure on workshop power (typical-scenario estimate).

The density of looms per operator is affected by multiple factors such as "fabric count / loom speed / number of batches / team management practices / worker proficiency", so the device cannot simply be equated with the basis for staffing management decisions.

In some pilot scenarios, after warp-break events are identified and alarmed quickly and stably, operators can focus more on actual handling rather than frequent patrols, and patrol frequency and walking distance decrease under typical scenarios; in typical pilots looms per operator can rise from 25 to 40, though the actual staffing density is arranged by the enterprise in light of its own team structure.

The core technology involved is invention patent (application No. CN202610310917.4 / application publication No. CN122358386A); the application has been duly published and entered substantive examination.
· Company total 10 invention patents · all under substantive examination, 1 software copyright registered (registration No. 2026SR1016542), with 2 more under review, 9 utility model patents | accepted and filed.
· Registered technology-based SME; Jiangsu Provincial IP Management Standards enterprise.
· Examination conclusions and grant timing are subject to the official documents of the China National Intellectual Property Administration.

Typical integration dimensions (tailorable to customer MES requirements): loom ID / warp-beam lot / shift / operator ID / warp-break timestamp / response handling time / downtime / position of the broken end / whether restart after the stop succeeded.

All the above dimensions come from a combination of the device plus manual MES entry; if the customer does not enter operators and shifts, only the loom + timestamp dimensions are displayed. For more dashboard examples, see the Textile MES product page.

Every light-beam warp breakage detection device passes the ten Station-Test inspections before delivery, with five-state SN programming permanently locked, and the written SN is bound to the hardware UID:
If any device at the customer site becomes abnormal, its SN/UID can be used to retrieve the factory baseline acquisition values, inspector, delivery date and corresponding inspection batch;
R&D can conduct cross-end data comparison on devices of the same model and version, helping improve the next generation of optical and firmware parameters.

For the detailed process, see Zhisuo Host-Computer Workstation Inspection System.

Hardware warranty (typical commercial basis; the actual contract prevails):

Free warranty handling is provided for non-human-caused hardware quality issues within 12 months of delivery; human-caused dropping, scratching or unauthorized disassembly of the optical lens, magnets, aluminum alloy housing and so on is not covered by the warranty.

Firmware upgrades:

The firmware upgrade path (if released later) is: Upgrade via OTA through the LoRa gateway, or via the on-site reserved maintenance interface; the binding relationship between SN and UID is not changed during the upgrade.

Note: all service descriptions such as "12-month warranty" and "free warranty" refer to the commercial terms under the contract signed between Zhisuo Zhikong and the customer; the content of this page does not constitute a contractual offer.