System and method of unspooling a material into a textile machine

A system operable to incorporate materials into textile constructions, the system comprising:

• an unspooling assembly capable of tensioned dispensing of a material at a plurality of speeds without applying torque to the material itself, the unspooling assembly comprising:
• a variable motor drive assembly comprising:
• a motor coupled to a material package and to rotate the material package to deploy the material at a speed in coordination to movements of a textile machine;
• a variable motor drive coupled to the motor and configured to drive the motor in a first rotational direction at a plurality of speeds in order to reduce tension on the dispensed material and in a second rotational direction that differs from the first rotational direction in order to increase tension on the dispensed material;
• a roller guided stop motion assembly comprising:
• roller guides for guiding the material;
• a spring arm trigger sensor;
• and a spring arm and arm guide, wherein the spring arm trigger sensor:
• signals various tensions of the material during rotation of the motor by sensing a repositioning of the spring arm and the arm guide to one of a plurality of discrete positions on an arc that each correspond to a tension of the material;
• and
• a controller electronically coupled to the variable motor drive and the roller guided stop motion assembly to:
• receive a first signal from the roller guided stop motion assembly, wherein the first signal is indicative of the position of the spring arm and the arm guide;
• and
• generate a second signal for supply to the variable motor drive in response to receipt of the first signal indicative of the position of the spring arm and the arm guide, wherein the second signal indicates a selected speed of the plurality of speeds as well as either the first rotational direction or the second rotational direction;
• wherein the variable motor drive, in response to the second signal, adjusts the motor to the selected speed to rotate the material package so that deployment speed of the material is varied depending upon the position of the spring arm.

A method of dispensing a material wound on a material package to a textile machine without adding torque to the material wound on the material package, and varying speed at which the material is dispensed during a fabric construction process, the method comprising:

• constructing the material into a textile on the textile machine by feeding the material from the material package and rotating the material package;
• rotating the material package at a first speed in a first rotational direction by using a variable motor assembly coupled to the material package in order to reduce tension on the dispensed material;
• rotating the material package in a second rotational direction that is opposite from the first rotational direction by using the variable motor assembly coupled to the material package in order to increase tension on the dispensed material;
• where speed of the material deployed from the material package is sensed by positioning of a spring arm and arm guide on a roller guided stop motion assembly;
• where the positioning of the spring arm and the arm guide is located at a first position on an arc, where an angle of the arc is based on the first speed of the material being fed through wheel rollers and the spring arm and the arm guide on the roller guided stop motion assembly, where the roller guided stop motion assembly senses the positioning of the spring arm and the arm guide at the first position on the arc based on the first speed;
• generating a first signal from the roller guided stop motion assembly and sending the first signal to a motor assembly of the textile machine based on the first position of the spring arm and the arm guide;
• in response to the first signal, rotating the material package at the first speed by using the variable motor assembly coupled to the material package;
• sensing a repositioning of the spring arm and the arm guide at a second position based on a speed of deployment for the material and generating a second signal to control the variable motor assembly to rotate the material package at a second speed that differs from the first speed so that the speed of deployment of the material is varied depending upon the position of the spring arm without stopping the fabric construction process.