[0001] The present invention refers to an integrated yarn-winder machine.
[0002] In industrial practice, the yarn production technique is widely prevalent that includes
a first stage of ring spinning which produces bobbin yarn, followed by a second winding
stage in which the yarn is unwound from its bobbin, cleaned of its defects and rewound
in a package, which contains a much greater yarn quantity and which corresponds to
a considerable number of processed bobbins.
[0003] As is known, a spinning unit or spinning frame is composed of a plurality of spinning
stations aligned along its faces. Every spinning frame face is composed of hundreds
of such stations which commonly derive their driving from motors which actuate longitudinal
axes, and their functions from dispenser units which distribute them along the machine.
In turn, also the winders are composed of a plurality of winding units aligned along
the face of the machine, also provided with their own common control and service equipment.
[0004] The transfer between the two processing stages, i.e. the bobbins replete with yarn
from the spinning frame to the winder, and the transfer of their empty tubes from
the winder to the spinning frame, generally occurs by means of a system which provides
for the movement of the bobbins and the tubes along a continuous path which extends
around the spinning unit and the winding unit, employing peg supports to be placed
on conveyor belts or similar movement members, so to individually bear each bobbin
or each tube.
[0005] The winding processing is much faster than the spinning, and thus a small quantity
of winding stations or units, on the order of several dozen, is capable of completing
the production of a great number of ring spinning units, on the order of several thousand.
Generally, in order to complete, within a certain margin, the entire production without
dead times, a spinning frame is coupled to a winder having hourly winding capacity
that considerably exceeds the spinning capacity of the spinning frame.
[0006] Overall, the two machines, i.e. the spinning frame and the winder, are generally
made by different manufacturers, and are achieved with highly standardised configurations.
Their mechanical production type thus results dissimilar, along with the various optimised
management, logic and functioning programs (work and production cycles).
[0007] These differences in particular regard, in most cases, both the program architecture
(software), and the electronics instrumentation (hardware) composed of electronics
processors, programmable logic controllers (PLC), and/or process transducers.
[0008] In order to achieve their presetting for the connection, the two machines thus require
various modifications, including:
- mechanical and structural modifications of the respective ends, so to be able to allow
the most rational and simplest possible connection, always keeping in mind market
logic, i.e. that every spinning frame can be connected with any winder and vice versa;
- electrical and electronic modifications of communications and signal exchange, comprising
the interfacing logics and the related management programs (for example at the start
and end of the run, machine shutdown, troubleshooting, etc.);
- pneumatic modifications, with related interfacing logics.
[0009] In this manner, every machine affected by the connection, in addition to maintaining
its essential structural characteristics, is further complicated by one or more additional
components in order to allow such connection.
[0010] The object of the present invention is therefore that of making an integrated yarn-winder
capable of overcoming all the problems related to the mechanical and functional connection
of a spinning frame and a winder according to the prior art.
[0011] This object according to the present invention is achieved by making an integrated
yarn-winder machine as set forth in claim 1.
[0012] Further characteristics of the invention are shown in the subsequent claims.
[0013] The characteristics and advantages of an integrated yarn-winder machine according
to the present invention will be more evident from the following exemplifying and
non-limiting description, referred to the attached schematic drawings in which:
Figure 1 illustrates, in its essential components, a single spinning station belonging
to an integrated yarn-winder machine according to the present invention;
Figure 2 illustrates, in its essential components, a single winder station belonging
to an integrated yarn-winder machine according to the present invention;
Figure 3 illustrates, in side elevation and partial section view, a preferred embodiment
of an integrated yarn-winder machine according to the present invention;
Figure 4 is another partial cross section view of the integrated yarn-winder machine
shown in figure 3;
Figure 5 illustrates, in side elevation and partial section view, an electro-suction
unit which equips an integrated yarn-winder machine according to the present invention;
and
Figure 6 is another partial section view of the electro-suction unit of figure 5.
[0014] With reference in particular to figure 1, the conventional functioning scheme is
shown overall of a generic spinning station 6 belonging to the spinning unit 2 of
an integrated yarn-winder machine according to the present invention.
[0015] The sliver 10 comes from a package hung above the spinning station 6, not indicated
in the figure for the sake of simplicity, and is first brought forward to a drafting
unit 12. It generally consists of a plurality of members for driving the sliver 10
at increasing linear speeds; the driving members gradually refine the sliver by making
the sliver fibres slide between them. In figure 1, the drafting group 12 is depicted
as an example with an initial pair of strips 14 and 16, of which the lower strip 14
is driven in movement by a knurled segment 18 of a longitudinal bar 20, shared with
the adjacent spinning stations 6 and rotating in accordance with the arrow A.
[0016] The path of the lower strips 14 is approximately triangular and is determined by
a common terminal bar 22 which is longitudinally extended. The upper strip 16 is idle
and is driven in motion in accordance with the arrow B by the underlying strip 14,
on which it is pressed by an upper support, not indicated in figure 1 for the sake
of simplicity. Also the path of the upper strip 16 is approximately triangular and
is determined by a roller 24 and by a fixed terminal bar 26.
[0017] Downstream of the strips 14 and 16, there is a pair of drafting rollers 28 and 30
which impart the final drafting to the sliver 10, since they are provided with a linear
speed greater than the preceding pair of strips 14 and 16. More precisely, the lower
roller is composed of a grooved segment 28 of a longitudinal bar 32, shared with the
adjacent spinning stations 6 and rotating in accordance with the arrow C. The upper
counter-roller 30 is idle and is also pressed by an upper support, not indicated in
figure 1, against the roller segment 28 which drives it in rotation in accordance
with the arrow D, with the refined sliver 10 interposed between them, giving rise
to the yarn 34.
[0018] The yarn 34 first passes into a fixed thread guide 36, typically in spiral form,
and from here into a small rotating ring 38 which rotates on a fixed ring 40 borne
by a ring-rail 42 shared with the adjacent spinning stations 6, continuously moved
in accordance with the arrow E in two directions, to continuously lift and lower all
the fixed rings 40 of the single spinning stations 6 and to distribute the yarn 34
winding onto a bobbin 44 wound on a related tube 46. The tube 46 is fit on an underlying
rotating spindle (not shown) driven in rotation at high speeds, which currently are
in the range of 10,000÷20,000 rpm. In general, such driving is carried out with longitudinal
drive belts which slidingly engage the lower part of the bobbin carrier spindle.
[0019] With every rotation of the spindle, i.e. of the bobbin 44, the yarn 34 released by
the drafting group 12 is drawn so to be wound on such bobbin 44. Substantially, a
twisting turn of the yarn 34 is generated, which drives in rotation the rotating small
ring 38, although with a slight delay due to its friction with the guide ring 40.
If the spindle rotates at N revolutions per minute and the cylinders 28 and 30 release
L meters per minute of drafted sliver (yarn) 34, except for shortening due to twisting,
the twists T applied to a meter of produced yarn 34 result equal to N/L.
[0020] The yarn 34 rotates in a whirling manner around the bobbin 44, forming the so-called
"balloon" due to the centrifugal force. The balloon is due to significant stress on
the yarn 34 and can be limited with a containment ring 48, in general with slightly
greater diameter than the transverse size of the bobbin 44. The balloon containment
ring 48 is firmly mounted on a platform or rail thereof, capable of vertical travel
movements which in any case keep it above the level of the ring-rail 42.
[0021] The yarn 34 twisting is caused by the rotation of the bobbin 44 and extends, together
with the relative stresses, up to the point at which the sliver 10 of the yarn 34
is released by the final drafting cylinders 28 and 30.
[0022] In order to wind the yarn 34 thus twisted on the bobbin 44 in a regular manner, as
the bobbin progressively forms, it is necessary to distribute it on the bobbin 44
at different heights, continuously changing the level of the rotating small ring 38
borne by the ring-rail 42, continuously moved in accordance with the arrow E in two
directions, and modulating the deposition so to continuously lift the average travel
point of the arrow E itself. The deposit of the yarn 34 on the bobbin 44 generally
starts in the lower part of the bobbin 44 and rises upward in overlapped layers with
conical progression, layers obtained with a series of slow, ascending movements of
the ring-rail 42 following by sudden and slightly shorter descending movements. The
object of such bobbin 44 winding mode is essentially that of giving a tapered shape
to the bobbin 44 itself, such that it results compact, so that it does not break up
during its unwinding, and so that the yarn 34 is unwound, substantially unwinding
layer-by-layer from its upper conical part.
[0023] Once the winding of the yarn 34 on the bobbin 44 has completed, it is doffed from
the relative bobbin carrier spindle and is then deposited on one of the pins 50 of
a suitable peg/plate support 52 (figure 2), belonging to a transport system which
acts as a carrier of the full bobbins 44 and empty tubes 46 from and towards the single
winding stations 8 belonging to the winding unit 4 of the integrated yarn-winder machine
according to the present invention.
[0024] Each winder station 8, schematically shown in figure 2, is therefore capable of drawing
a single bobbin 44 replete with yarn 34, for unwinding such yarn 34, and sending it
to an unwinder group which comprises thread guide members 54, a yarn presence detector
or sensor 56 and a yarn tensioner 58, generally composed of a pair of facing plates
which press the unwinding yarn 34 between them with regulated and controlled pressure.
Along the ascending path of the yarn 34, a yarn tail junction device 60 is present,
currently called "splicer", to which the yarn tails of the yarn 34 are brought when
they may have been cut by an accidental breaking or by the intervention of the so-called
clearer 62 which is situated immediately downstream of the splicer 60; such yarn tails
are spliced by means of an air suction system 64 and 66 movable between an operative
position and a rest position.
[0025] The clearer 62 is a device of mechanical, electronic or optical type, capable of
detecting size defects (both transverse and length) of the yarn 34. The clearer 62
then commands the cutting of the yarn 34 every time that its detected size does not
come within the range of the acceptable sizes of the yarn 34 itself, on the basis
of its calibration. The member which cuts the yarn 34 can be incorporated in the same
clearer 62, or as shown for example in figure 2 it can be separated and made in the
form of scissors 68 placed between the sensor 56 of the yarn 34 and the yarn tensioner
58.
[0026] Following a breakage, or a cutting of the yarn 34 commanded by the clearer 62, the
sensor 56 of the yarn 34 signals the absence of the yarn 34 to the governing unit
70 of the winding station 8. The governing unit 70 in fact comprises, among other
functions, a drive and control program for the re-attachment process by means of the
splicer device 60, with the connections shown as an example with dashed lines in figure
2.
[0027] The yarn 34 is then collected in a package 72, which is driven into rotation at predetermined
and substantially constant speed by a roller 74, on which a package carrier arm 76
is supported in an abutting manner. The rotating package 72 draws the yarn 34, unwinding
it at high speed from the bobbin 44 kept stopped on the positioning pin 50 of the
relative peg/plate support 52.
[0028] According to the invention, with particular reference to figure 3, the integrated
yarn-winder machine comprises a single master management and control group 78 containing
all the command equipment and service devices adapted to simultaneously ensure the
functioning of the spinning unit 2 and the winding unit 4 present on the machine itself,
of the service modules 100 dedicated to the spinning stations 6, situated along the
sides of the spinning unit 2, of one or more service modules 101, 102, 103 dedicated
to the winding stations 8, situated along the sides of the winding unit 4.
[0029] The service module 100, for example, is dedicated to the motion transmission to the
command of the drafting units 12, for the interlock of the spinning stations 6, respectively
in the case of short or long spinning unit 2. The service module 101 is dedicated
to the physical connection between the spinning unit 2 and the winding unit 4. The
service module 102 is dedicated to the station for the search of the bobbin 44 yarns.
The service module 103 is dedicated to storing and sending the cones on which the
packages 72 are wound to the winding stations 8. Other modules can also be provided,
dedicated to different objects for interlocking the spinning unit 2 and the winding
unit 4.
[0030] More precisely, the management and control master group 78 or control head, which
can be arranged at one of the two heads or free ends of the integrated yarn-winder
machine, or preferably in intermediate position between the spinning unit 2 and the
winding unit 4, as shown in figure 3, is provided with a single electrical drive and
control panel 80, operatively connected to the different control and service motors
of the spinning unit 2 and to the different control and service motors of the winding
unit 4.
[0031] The management and control group 78 moreover comprises a single electronic processor
84, provided with an electrical and electronic logic interface unit for the setting
and sending of functioning data to the command and control devices of the spinning
unit 2, of the winding unit 4 and of the service modules 100, 101, 102 and 103, and
of a single software packet, with consequent improved management and programming simplicity
with respect to the separate control heads of the spinning frames and winders according
to the
prior art.
[0032] Also present on the management and control group 78 is a centralised suction unit
86 with two reduced pressure stages connected in series with each other, composed
of a first stage with high flow rate and average reduced pressure, set to collect
and capture the fibres, yarns and dust coming from the spinning unit 2 by means of
a suction and capture channel 94, and by a second stage with low flow rate and strongly
reduced pressure for the suction of the yarn tails of the bobbins 44 and the packages
72 in the individual winding stations 8 and for the search of the yarns of the bobbins
44 in the service module 102, by means of a suction and capture channel 95.
[0033] The two reduced pressure stages of the centralised suction unit 86 (figure 5) are
respectively constituted by two electro-suction devices 91 and 92 connected together
in series. In detail, the first stage is constituted by an electro-suction device
92 with high flow rate and mildly reduced pressure, connected upstream of an attenuation
chamber 93, or air inflow plenum chamber, in turn connected upstream with the channel
94 coming from the spinning unit 2. The second stage is constituted by an electro-suction
device 91 with low flow rate and average reduced pressure, connected with suction
to the channel 95, and with discharge to the aforesaid reduced pressure plenum chamber
93 of the first stage. Such connection in series allows the second stage to advantageously
exploit the existing reduced pressure at its discharge, due to the plenum chamber
93 of the first stage, in order to further reduce the suction pressure at its inlet.
[0034] Such solution thus allows making a first stage with low flow rate and strongly reduced
pressure without having to use an electro-suction device of larger size and power.
However, by exploiting the reduced pressure at the discharge, as said, it allows using
an electro-suction device 92 of smaller diameter, therefore with smaller losses and
energy dissipations, obtaining advantages in terms of space reduction and lower energy
absorption.
[0035] The centralised suction unit 86 is provided with a single technological air discharge
point, by means of air or underground channelling, in such a manner simplifying the
general plan of the factory where the integrated yarn-winder machine is installed.
[0036] As shown in figure 4, the integrated yarn-winder machine according to the present
invention is provided with a single travelling cleaning device 88, placed above the
spinning 2 and winding 4 units and the management and control group 78, for the cleaning
and collection of dust and yarns from all the components of the machine itself.
[0037] A single drawing and collection point is provided for the waste and lint coming from
the reduced pressure filtration tank connected with the centralised electro-suction
unit 86, while the discharge of the lint and dust coming from the travelling cleaning
device 88 is cyclically carried out in the dust and yarn collection tank of the strongly
reduced pressure suction device.
[0038] The integrated yarn-winder machine according to the present invention is also provided
with a single common transport system, provided with a plurality of motorised control
units 90, capable both of transferring the bobbins 44 replete with yarn 34 from the
spinning unit 2 to the winding unit 4, and to bring back the empty tubes 46 from the
winding unit 4 to the spinning unit 2, by means of moving the relative peg/plate supports
52 along a single continuous path (not shown) which extends around the spinning unit
2 and the winding unit 4.
[0039] The management and control group 78 is finally provided with a single interface for
the possible insertion or interposition, between the spinning unit 2 and the winding
unit 4, of a continuous vapour treatment system (not shown) of the bobbins 44.
[0040] In order to facilitate the control of the integrated yarn-winder machine by the operators,
the service modules 100, 101, 102 and 103, situated along the sides of the spinning
unit 2 and/or winding unit 4, may be provided with control interfaces and/or command
interfaces operatively connected with the management and control group 78.
[0041] It is thus seen that the integrated yarn-winder machine according to the present
invention achieves the above-mentioned object, obtaining a series of advantages including
the following:
- cost savings on the electrical control parts, on the suction and mechanical structure
parts (which are integrally formed) of the machine;
- reduction of the electrical consumptions due to the centralised suction unit with
two reduced pressure stages placed in series;
- reduction of the energy consumptions of the electrical and electronic parts due to
the single electrical control and command panel, and to a single electronic processor;
- reduction of the overall machine bulk, with the possibility of increasing the number
of spinning spindles and/or winding heads given the same occupied land space;
- machine management ergonomics, which encloses the components to be managed by the
operators in a single allocation.
[0042] The integrated yarn-winder machine of the present invention thus conceived is in
any case susceptible to numerous modifications and variants, all falling within the
same inventive concept; moreover, all details can be substituted by technically equivalent
elements while the shapes and sizes can be of any type according to technical needs.
[0043] The protective scope of the invention is therefore defined by the attached claims.
1. Yarn-winder machine comprising a spinning unit (2), provided with a plurality of spinning
stations (6) each capable of achieving the winding of a yarn (34), obtained starting
from a sliver (10), on a bobbin (44), a winding unit (4), provided with a plurality
of winding stations (8) each capable of unwinding said yarn (34) from said bobbin
(44) and re-winding it on a package (72), and means for the transport of said bobbins
(44) replete with yarn (34) from said spinning stations (6) towards said winding stations
(8) and for the transport of the empty tubes (46) from said winding stations (8) towards
said spinning stations (6), characterised in that it comprises a management and control master group (78) containing all the control
equipment and service devices adapted to simultaneously ensure the functioning of
said spinning unit (2), of said winding unit (4) and of one or more service modules
(100, 101, 102, 103) operatively connected with said spinning unit (2) and/or said
winding unit (4).
2. Yarn-winder machine according to claim 1, characterised in that said management and control group (78) is provided with a single electrical drive
and control panel (80), operatively connected with the different command and service
motors of the spinning unit (2) and to the different command and service motors of
the winding unit (4).
3. Yarn-winder machine according to claim 2, characterised in that said management and control group (78) comprise a single electronic processor (84),
provided with a single software packet and a single electrical and electronic interlocking
logic unit for setting and sending the functioning data to the command and control
devices of the spinning unit (2), of the winding unit (4) and of said service modules
(100, 101, 102, 103).
4. Yarn-winder machine according to claim 1, characterised in that, on said management and control group (78), a single centralised suction unit (86)
is present.
5. Yarn-winder machine according to claim 4, characterised in that said centralised suction unit (86) is of the type with two reduced-pressure stages
connected in series with each other, wherein the first stage is with high flow rate
and average reduced pressure, set for collecting and capturing the fibres, yarns and
dust coming from the spinning unit (2) by means of a first suction and capture channel
(94), and the second stage is with low flow rate and strongly reduced pressure, for
the suction of the yarn tails of said bobbins (44) and of said packages (72) in the
single winding stations (8) and for the search of the yarns of said bobbins (44) in
one of said service modules (102) by means of a second suction and capture channel
(95).
6. Yarn-winder machine according to claim 5, characterised in that said first stage is composed of an electro-suction device (92) with high flow rate
and mildly reduced pressure, connected upstream of an attenuation chamber (93) in
turn connected upstream with said first suction and capture channel (94).
7. Yarn-winder machine according to claim 6, characterised in that said second stage is composed of an electro-suction device (91) with low flow rate
and average reduced pressure, connected with suction to said second suction and capture
channel (95) and with discharge to said attenuation chamber (93) of said first stage,
said electro-suction device (91) generating at its inlet, into said second suction
and capture channel (95), strongly reduced pressure due to the direct discharge of
the air directly into said reduced pressure attenuation chamber (93).
8. Yarn-winder machine according to claim 1, characterised in that it is provided with a single travelling cleaning device (88), placed above the spinning
units (2) and winding units (4) and said management and control group (78), for the
cleaning and collection of dust and yarns from all the components of said yarn-winder
machine.
9. Yarn-winder machine according to claim 1, characterised in that said means for the transport of said bobbins (44) replete with yarn (34) from the
spinning stations (6) towards the winding stations (8) and for the transport of said
empty tubes (46) from the winding stations (8) towards the spinning stations (6) are
provided with a single motorised command unit (90) for moving peg/plate supports (52)
of said bobbins (44) and said tubes (46) along a continuous path which is extended
around the spinning unit (2) and the winding unit (4).
10. Yarn-winder machine according to claim 1, characterised in that said management and control group (78) is provided with a single interfacing for
the insertion, between the spinning unit (2) and the winding unit (4), of a continuous
vapour treatment system of said bobbins (44).
11. Yarn-winder machine according to any one of the claims 1 - 10, characterised in that said management and control group (78) is arranged in intermediate position between
the spinning unit (2) and the winding unit (4).
12. Yarn-winder machine according to claim 11, characterised in that said one or more service modules (100) dedicated to the spinning stations (6), situated
along the sides of the spinning unit (2), and said one or more service modules (101,
102, 103) dedicated to the winding stations (8), situated along the sides of the winding
unit (4), are provided with control and/or command interfaces that are operatively
connected with said management and control group (78) for facilitating the control
of said yarn-winder machine by the operators.