BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The present invention mainly relates to a yarn winding machine that winds a yarn
around a winding bobbin while traversing the yarn.
2. Description of the Related Art
[0002] A yarn winding machine that includes a traverse device for traversing a yarn has
been conventionally known. The traverse device includes a yarn guide, a traverse arm,
and a driving device. The yarn guide makes contact with a yarn to traverse the yarn.
The traverse arm supports the yarn guide. The driving device drives the traverse arm.
By reciprocating (i.e., by swinging) the traverse arm by the driving device, a yarn
can be wound into a package while being traversed.
[0003] Winding a yarn in the above-described method may cause a phenomenon (i.e., a bulge
winding) in which a package is formed with lateral sides of the package being bulged.
A yarn in inter-layers of the package is compressed by tightening force of yarn on
an outer diameter portion of the package and repulsion force generated from a winding
tube. Then, the yarn protrudes from end faces of the package, which causes such a
phenomenon.
[0004] Japanese Unexamined Patent Application Publication No.
H09-71367 discloses a yarn winding method for preventing occurrence of such a bulge winding.
In such a yarn winding method, a winding width can be narrowed by winding a yarn with
a winding angle increased to a greater angle, which makes it possible to prevent occurrence
of the bulge winding.
[0005] However, when the yarn is wound with the winding angle increased to a greater angle,
the traverse device is required to operate rapidly for rapidly traversing the yarn.
Accordingly, a major load acts upon the driving device for performing a traversing
operation, causing an increase in power consumption. Further, when winding the yarn
at a high speed, in case the winding angle is increased, performance limitation of
the driving device may be exceeded. Consequently, there were cases in which the above-described
method could not be used.
SUMMARY OF THE INVENTION
[0006] It is an object of the present invention to provide a yarn winding machine having
a simple structure capable of preventing occurrence of a bulge winding.
[0007] This object is achieved by a yarn winding machine according to claim 1, and by a
method according to claim 8.
[0008] According to a first aspect of the present invention, the yarn winding machine includes
a yarn traversing device, a correction width setting section, and a control section.
The yarn traversing device traverses a yarn to be wound into a package. The correction
width setting section sets an end correction width for correcting a predetermined
target traverse width dependent on or in accordance with a predicted package winding
diameter (e.g. a respective end correction width is associated with a respective package
winding diameter). The control section controls the yarn traversing device so as to
traverse the yarn under a traverse width determined in accordance with the end correction
width that has been set by the correction width setting section.
[0009] That is, the size of a bulge which occurs on a lateral side of the package when the
package has been fully wound depends on a distance from a central axis of a winding
tube or a distance from the surface of the winding tube. Each of these distances is
regarded as the predicted package winding diameter, and the traverse width of the
yarn traversing device is narrowed in accordance with an appropriate end correction
width associated with the predicted package winding diameter. Since a width to be
corrected from an edge of the package can be set, occurrence of a bulge winding can
be prevented, for example. Further, occurrence of a bulge winding or the like has
been conventionally prevented by increasing a traversing speed to increase a winding
angle; however, in the above-described structure, it is not necessary to increase
a traversing speed. Accordingly, load acting on the driving source of the yarn traversing
device can be reduced, and energy consumption of the yarn winding machine can be reduced.
[0010] The yarn winding machine includes a standard diameter setting section and a package
diameter acquiring section. The standard diameter setting section sets the predicted
package winding diameter as a standard diameter. The package diameter acquiring section
acquires a package diameter, which is a wound diameter of the package. When the package
diameter acquired by the package diameter acquiring section is the standard diameter,
the control section controls the yarn traversing device so as to traverse the yarn
under a traverse width determined in accordance with the end correction width that
has been set dependent on or in accordance with the standard diameter (e.g. one end
correction width is associated with the standard diameter).
[0011] Accordingly, the package diameter can be acquired with great accuracy in real-time
by the package diameter acquiring section. Then, when the package diameter which is
kept being acquired becomes equal to the preset standard diameter, the traverse width
of the yarn traversing device is narrowed in accordance with the end correction width
associated with such a standard diameter. Consequently, occurrence of a bulge winding
can be prevented effectively.
[0012] The yarn winding machine further includes a correction width calculating section.
The correction width calculating section can calculate an end correction width for
a package diameter other than the set standard diameter in accordance with the set
standard diameter and the end correction width associated with such a standard diameter.
When a package diameter acquired by the package diameter acquiring section is a package
diameter other than the set standard diameter, the control section controls the yarn
traversing device so as to traverse the yarn under a traverse width determined in
accordance with the end correction width calculated by the correction width calculating
section. Accordingly, just by setting a certain number of standard diameters and end
correction widths associated with such standard diameters, the yarn traversing device
can be controlled in accordance with appropriate end correction widths for an entire
range of the package diameter that changes from start of a winding operation until
an end of the winding operation.
[0013] In the yarn winding machine, the standard diameter setting section includes a smaller-diameter
portion standard diameter setting section and a larger-diameter portion standard diameter
setting section. The smaller-diameter portion standard diameter setting section sets
a standard diameter of a smaller-diameter portion of a cone winding package. The larger-diameter
portion standard diameter setting section sets a standard diameter of a larger-diameter
portion of the cone winding package. The correction width setting section includes
a smaller-diameter portion correction width setting section and a larger-diameter
portion correction width setting section. The smaller-diameter portion correction
width setting section sets an end correction width of the smaller-diameter portion
of the cone winding package dependent on or in accordance with the standard diameter
set by the smaller-diameter portion standard diameter setting section (e.g. one end
correction width is associated with the standard diameter set by the smaller-diameter
portion standard diameter setting section) . The larger-diameter portion correction
width setting section sets an end correction width dependent on or in accordance with
the standard diameter set by the larger-diameter portion standard diameter setting
section (e.g. one end correction width is associated with the standard diameter set
by the larger-diameter portion standard diameter setting section).
[0014] That is, in the cone winding package, differences in changes of winding density or
the like cause differences between the shape of a bulge winding which occurs on a
lateral side of the larger-diameter portion and the shape of a bulge winding which
occurs on a lateral side of the smaller-diameter portion. According to the above-described
structure, a different end correction width can be set for each of the smaller-diameter
portion and the larger-diameter portion; therefore, even in the cone winding package,
occurrence of a bulge winding or the like can be prevented effectively.
[0015] In the yarn winding machine, in accordance with the larger-diameter portion standard
diameter set by the larger-diameter portion standard diameter setting section and
the end correction width of the larger-diameter portion set by the larger-diameter
portion correction width setting section, the smaller-diameter portion standard diameter
setting section automatically sets the standard diameter of the smaller-diameter portion
and the smaller-diameter portion correction width setting section automatically sets
the end correction width of the smaller-diameter portion. Accordingly, just by setting
the standard diameter and the end correction width for the larger-diameter portion,
the standard diameter and the end correction width for the smaller-diameter portion
are automatically set. As a result, time and effort for setting a standard diameter
and an end correction width can be reduced.
[0016] In the yarn winding machine, in accordance with the smaller-diameter portion standard
diameter set by the smaller-diameter portion standard diameter setting section and
the end correction width of the smaller-diameter portion set by the smaller-diameter
portion correction width setting section, the larger-diameter portion standard diameter
setting section automatically sets the standard diameter of the larger-diameter portion
and the larger-diameter portion correction width setting section automatically sets
the end correction width of the larger-diameter portion. Accordingly, just by setting
the standard diameter and the end correction width for the smaller-diameter portion,
the standard diameter and the end correction width for the larger-diameter portion
are automatically set. As a result, time and effort for setting a standard diameter
and an end correction width can be reduced.
[0017] The yarn winding machine includes a winding tube supporting section and a winding
tube angle setting section. The winding tube supporting section rotatably supports
a winding tube around which the yarn is wound to form the package. The winding tube
angle setting section sets an angle of the winding tube to be supported by the winding
tube supporting section. The standard diameter setting section sets the standard diameter
in accordance with the angle of the winding tube set by the winding tube angle setting
section. The correction width setting section sets the end correction width in accordance
with the angle of the winding tube set by the winding tube angle setting section.
[0018] That is, since change of the angle of the winding tube causes the shape of the package
to change, the size of a bulge which occurs on a lateral side of the package also
changes. According to the above-described structure, the standard diameter and the
end correction width are set in accordance with the angle of the winding tube; therefore,
occurrence of a bulge winding or the like can be prevented effectively.
[0019] According to a second aspect of the present invention, a yarn winding method includes
a setting step, a package diameter acquiring step, and a controlling step. The setting
step is a step of setting a standard diameter and an end correction width, which corrects
a predetermined target traverse width, with respect to a package, and storing the
set standard diameter and the end correction width. The package diameter acquiring
step is a step of acquiring a package diameter, which is a wound diameter of the package.
The controlling step is a step of controlling a yarn traversing device, which traverses
a yarn, in accordance with an end correction width associated with the acquired package
diameter.
[0020] That is, the size of a bulge which occurs on a lateral side of the package when the
package is fully wound depends on a distance from a central axis of the winding tube
or a distance from the surface of the winding tube. According to the above-described
method, a traverse width of the yarn traversing device is narrowed in accordance with
an appropriate end correction width associated with the package diameter which gradually
increases during a winding operation, which makes it possible to form the package
while preventing occurrence of a bulge winding or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021]
Fig. 1 is a schematic view illustrating an automatic winder according to an embodiment
of the present invention.
Fig. 2 is a block diagram illustrating a main structure of the automatic winder.
Fig. 3 is a schematic view and a block diagram illustrating a schematic structure
of a winder unit.
Fig. 4 is a schematic view illustrating a structure of a traverse device.
Fig. 5 is a schematic view illustrating a cross-sectional shape of a package of when
a bulge winding occurs.
Fig. 6 is a flowchart illustrating an example of a process that prevents occurrence
of the bulge winding.
Fig. 7 is a graph illustrating an example of setting of a standard diameter and an
end correction width.
Fig. 8 is a block diagram illustrating a main structure of an automatic winder according
to a first variation.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0022] Next, an embodiment of the present invention will be described. First, by referring
to Fig. 1 and Fig. 2, a description will be made on an overall structure of an automatic
winder 1 according to the present embodiment. As illustrated in Fig. 1, the automatic
winder (a yarn winding machine) 1 includes a plurality of winder units 10 which are
arranged next to one another, an automatic doffing device 60, and a machine setting
device 90 as main components.
[0023] Each of the winder units 10 winds a yarn 20, which is unwound from a yarn supplying
bobbin 21, into a package 30 while traversing the yarn 20 by a traverse device (a
yarn traversing device) 27.
[0024] When the package 30 is fully wound in a winder unit 10, the automatic doffing device
60 travels to the position of the such a winder unit 10. Then, the automatic doffing
device 60 collects the fully-wound package 30 and supplies an empty bobbin to the
winder unit 10. A machine controlling section 94 illustrated in Fig. 1 and Fig. 2
performs a control operation relating to the entire automatic winder 1 including the
automatic doffing device 60.
[0025] The machine setting device 90 includes a setting section 91 and a display section
92 as main components. An operator operates the setting section 91 to input a prescribed
setting value or to choose an appropriate control method. Accordingly, the setting
section 91 can carry out setting for each of the winder units 10. The display section
92 is configured capable of displaying a yarn winding state in the each of the winder
units 10, troubles generated in the each of the winder units 10, or the like.
[0026] Next, by referring to Fig. 3, the structure of each of the winder units 10 will be
described specifically. Each of the winder units 10 includes a winding unit main body
16 and a unit control section 50 as main components.
[0027] For example, the unit control section 50 includes a Central Processing Unit (CPU),
a Random Access Memory (RAM), a Read Only Memory (ROM), an Input-Output (I/O) port,
and a communication port. A program for controlling each structure of the winding
unit main body 16 is recorded in the ROM. Various components of the winding unit main
body 16 (which will be described later) and the machine setting device 90 are connected
to the I/O port and the communication port. Accordingly, the unit control section
50 is configured capable of communicating control information.
[0028] The winding unit main body 16 includes a yarn unwinding assisting device 12, a tension
applying device 13, a splicer device 14, and a clearer (a yarn quality measuring device)
15, which are arranged along a yarn travelling path between the yarn supplying bobbin
21 and a contact roller 29 and in this order from a yarn supplying bobbin 21 side.
[0029] The yarn unwinding assisting device 12 includes a restricting member 40 covering
a core tube of the yarn supplying bobbin 21. The yarn unwinding assisting device 12
lowers the restricting member 40 accompanying unwinding of the yarn from the yarn
supplying bobbin 21 in order to assist unwinding of the yarn from the yarn supplying
bobbin 21. The restricting member 40 makes contact with a balloon formed in an upper
portion of the yarn supplying bobbin 21, which has been formed by rotation and centrifugal
forth of the yarn unwound from the yarn supplying bobbin 21, and appropriately adjusts
the size of such a balloon in order to assist unwinding of the yarn. In the vicinity
of the restricting member 40, a sensor (not illustrated in the drawings) for detecting
a chase portion of the yarn supplying bobbin 21 is provided. When the sensor detects
lowering of the chase portion, the restricting member 40 is lowered by an air cylinder
(not illustrated in the drawings), for example, accompanying the lowering of the chase
portion.
[0030] The tension applying device 13 applies predetermined tension to the travelling yarn
20. The tension applying device 13 may be a gate-typed device in which movable comb
teeth are arranged with respect to fixed comb teeth. The movable comb teeth can be
operated by a rotary solenoid so that the movable comb teeth and the fixed comb teeth
can be engaged with or disengaged from one another.
[0031] When a yarn is cut after the clearer 15 detects a yarn defect, or when a yarn breakage
occurs while the yarn is being unwound from the yarn supplying bobbin 21, or the like,
the splicer device 14 splices a lower yarn from a yarn supplying bobbin 21 side and
an upper yarn from a package 30 side. A yarn splicing device that splices the upper
yarn and the lower yarn may be a mechanical device, a device using fluid such as compressed
air, or the like.
[0032] The clearer 15 includes a clearer head 49 and an analyzer 52. The clearer head 49
includes a sensor (not illustrated in the drawings) which detects the thickness of
the yarn 20. The analyzer 52 processes a yarn thickness signal transmitted from such
a sensor. The clearer 15 monitors the yarn thickness signal transmitted from the sensor
in order to detect a yarn defect such as a slub. A cutter 39 is arranged in the vicinity
of the clearer head 49. The cutter 39 cuts the yarn 20 immediately after the clearer
15 detects a yarn defect.
[0033] A lower yarn guiding pipe 25 is provided below the splicer device 14 to catch and
guide the lower yarn from the yarn supplying bobbin 21 to the splicer device 14. An
upper yarn guiding pipe 25 is provided above the splicer device 14 to catch and guide
the upper yarn from the package 30 to splicer device 14. The lower yarn guiding pipe
25 can swing around a shaft 33. The upper yarn guiding pipe 26 can swing around a
shaft 35. A suction opening 32 is formed at a tip end of the lower yarn guiding pipe
25. A suction mouth 34 is provided at a tip end of the upper yarn guiding pipe 26.
Appropriate negative-pressure sources are connected to the lower yarn guiding pipe
25 and the upper yarn guiding pipe 26, respectively. The winder unit 10 is configured
such that suction airflow is generated at the suction opening 32 and the suction mouth
24 in order to suck and catch yarn ends of the upper yarn and the lower yarn.
[0034] The winding unit main body 16 includes a cradle (a winding tube supporting section)
23 and the contact roller 29. The cradle 23 removably supports a winding bobbin (a
winding tube) 22. The contact roller 29 can rotate while making contact with the surface
of the winding bobbin 22 or the surface of the package 30. The winding unit main body
16 includes the arm-typed traverse device 27 for traversing the yarn 20. The traverse
device 27 is located in the vicinity of the cradle 23. In the winding unit main body
16, the yarn 20 can be wound into the package 30 while being traversed by the traverse
device 27.
[0035] The cradle 23 can swing around a swing shaft 48. An increase in a diameter of yarn
layers accompanying winding of the yarn 20 around the winding bobbin 22 is absorbed
by swinging of the cradle 23. As illustrated in Fig. 3, the cradle 23 and the traverse
device 27 can form a cone-shaped package 30.
[0036] A package driving motor 41 is attached to a portion where the cradle 23 grips and
supports the winding bobbin 22. The winder unit 10 winds the yarn 20 into the package
30 by rotating the winding bobbin 22 by the package driving motor 41. When the winding
bobbin 22 is supported by the cradle 23, a motor shaft of the package driving motor
41 is connected to the winding bobbin 22 such that the motor shaft cannot relatively
rotate with respect to the winding bobbin 22 (i.e., a direct drive system). The operation
of the package driving motor 41 is controlled by a package driving control section
42. The package driving control section 42 controls the package driving motor 41 to
operate and stop by receiving an operation signal from the unit control section 50.
[0037] An angle sensor (a package diameter acquiring section) 44 for detecting an angle
(a swing angle) of the cradle 23 is attached to the swing shaft 48. The angle sensor
44 is formed of a rotary encoder, for example. The angle sensor 44 transmits an angular
signal corresponding to the angle of the cradle 23 to the unit control section 50.
The angle of the cradle 23 changes accompanying an increase in the winding diameter
of the package 30. Accordingly, by detecting the swing angle of the cradle 23 by the
angle sensor 44, a package diameter of the package 30 can be detected.
[0038] Next, by referring to Fig. 3 and Fig. 4, the traverse device 27 will be described
in details. The traverse device 27 includes a traverse arm 28, a yarn guide 24, and
a traverse driving motor 45 as main components. The traverse arm 28 is formed as a
tapered arm capable swinging. The yarn guide 24 is connected to a tip end of the traverse
arm 28 and is formed in a hook shape. The traverse driving motor 45 drives the traverse
arm 28. The traverse driving motor 45 is a servomotor, for example. A base portion
of the traverse arm 28 is fixed to a tip end of an output shaft 65 of the traverse
driving motor 45.
[0039] As illustrated in Fig. 3, the operation of the traverse driving motor 45 is controlled
by a traverse control section 46. The traverse control section 46 includes a hardware
device provided with a dedicated microprocessor or the like. The traverse control
section 46 controls the traverse driving motor 45 to operate and stop by receiving
signals from the unit control section 50. A storing section 71 and a correction width
calculating section 72 of the traverse control section 46 will be described later.
[0040] The output shaft 62 of the traverse driving motor 45 is rotated forward and backward.
Accordingly, the traverse arm 28 is reciprocated in a direction of the length of the
package 30. Thus, the yarn guide 24 supported at a tip end of the traverse arm 28
is reciprocatedin a circular trajectory.
[0041] As a traverse stroke TS indicating a range of the yarn 20 traversed by the yarn guide
24, a target traverse stroke is predetermined according to a shape of a package 30
to be formed and set in the unit control section 50.
[0042] Next, by referring to Fig. 2 through Fig. 7, a description will be made on a process
to be performed by the winding unit 10 for preventing occurrence of a bulge winding.
As illustrated in Fig. 5, a bulge winding is a phenomenon in which a lateral side
of a package bulges. A yarn in inter-layers of the package is compressed by tightening
force of yarn on an inner diameter side and an outer diameter side of the package,
and then the yarn protrudes from an end face of the package. The amount of protrusion
depends on a distance from a central axis of a winding bobbin 22 or a distance from
the surface of the winding bobbin 22.
[0043] Accordingly, in the winder unit 10, the distance from the central axis of the winding
bobbin 22 is referred to as a predicted bulge occurrence diameter (i.e., a predicted
package winding diameter), and the following processes are performed in accordance
with a relation between the predicted bulge occurrence diameter and the amount of
yarn protrusion in order to prevent the shape of the package 30 from deteriorating.
[0044] Before starting winding of the yarn 20, an operator performs various inputting and
setting works to the winder unit 10 by operating the setting section 91 provided in
the machine setting device 90.
[0045] The setting section 91 is a section for setting an end correction width which is
a value to be used when correcting the traverse width (i. e. , the traverse stroke
TS) of the traverse device 27. More specifically, the end correction width is a value
indicating how inward the traverse stroke TS is corrected from an edge of a package
with respect the predetermined target traverse stroke.
[0046] The end correction width set by the setting section 91 is transmitted to the traverse
control section 46 via the unit control section 50. Interpolation processing relating
to the end correction width is carried out by the correction width calculating section
72 of the traverse control section 46. Then, the result of such processing is stored
in the storing section 71. Further, such processing carried out by the correction
width calculating section 72 will be described later.
[0047] As illustrated in Fig. 2, the setting section 91 includes a standard diameter setting
section 81 and a correction width setting section 85. The standard diameter setting
section 81 includes a larger-diameter portion standard diameter.setting section 82
and a smaller-diameter portion standard diameter setting section 83. The correction
width setting section 85 includes a larger-diameter portion correction width setting
section 86 and a smaller-diameter portion correction width setting section 87. In
a cone winding package, a larger-diameter portion indicates an end portion with a
larger diameter (i.e., the right-hand side in Fig. 5). Meanwhile, in the cone winding
package, a smaller-diameter portion indicates an end portion with a smaller diameter
(i.e., the left side in Fig. 5).
[0048] First, the operator carries out setting for the larger-diameter portion. The operator
operates the setting section 91 to input a predicted package winding diameter which
is a standard diameter of the larger-diameter portion as a larger-diameter portion
standard diameter and further to input an end correction width value associated with
such a larger-diameter portion standard diameter. By inputting such values, a larger-diameter
portion standard diameter is set by the larger-diameter portion standard diameter
setting section 82, and an end correction width associated with such a larger-diameter
portion standard diameter is set by the larger-diameter portion correction width setting
section 86 (step S101).
[0049] The operator also carries out the above-described operation for the smaller-diameter
portion. By carrying out such an operation, a smaller-diameter portion standard diameter
is set by the smaller-diameter portion standard diameter setting section 83, and an
end correction width associated with such a smaller-diameter portion standard diameter
is set by the smaller-diameter portion correction width setting section 87 (step S102).
[0050] As described above, since the end correction width is a value indicating how inward
the traverse stroke TS is corrected from an edge of the package, the operator can
directly set a width to be corrected from the package edge.
[0051] In the above described embodiment, the setting for the larger-diameter portion is
carried out, and then the setting for the smaller-diameter portion is carried out.
However, the setting for the smaller-diameter portion may be carried out first, and
then the setting for the larger-diameter portion may be carried out.
[0052] Black circles in Fig. 7 indicate examples of the standard diameters and the end correction
widths set in the above-described manner. The longitudinal axis in Fig. 7 indicates
a package diameter in the center of an axial direction of a package. The horizontal
axis in Fig. 7 indicates an end correction width. In the example, four larger-diameter
portion standard diameters and four smaller-diameter portion standard diameters are
set, and an end correction width for each of all the standard diameters are set. Specifically,
as four larger-diameter portion standard diameters, a winding tube diameter, 100 mm,
150 mm, and a fully-wound diameter are set. Meanwhile, as respective end correction
widths associated with the four larger-diameter portion standard diameters, 0 mm,
1.0 mm, 0.7 mm, and 0 mm are set. In the same manner, as four smaller-diameter portion
standard diameters, the winding tube diameter, 120 mm, 170 mm, and the fully-wound
diameter are set. Meanwhile, as respective end correction widths associated with the
four smaller-diameter portion standard diameters, 0 mm, 2.0 mm, 1.5 mm, and 0 mm are
set. These numerical values just indicate an example; therefore, different values
may be appropriately set depending on a package to be wound.
[0053] The line graph illustrated in Fig. 7 is displayed in a display section 92 of the
machine setting device 90, for example. Accordingly, the operator can visually confirm
settings for a standard diameter and an end correction width. Further, by confirming
the line graph, the operator can intuitively imagine the shape of a package to be
formed through processing carried out in the present embodiment. Therefore, a package
can be easily formed in a shape demanded by the operator. Further, the operator can
select whether or not to display a line graph such as the line graph illustrated in
Fig. 7.
[0054] The standard diameters set as described above (i.e., the four standard diameters
set per each of the larger-diameter portion and the smaller-diameter portion) and
the respective end correction widths associated with such standard diameters are transmitted
to the correction width calculating section 72. The correction width calculating section
72 is a section for approximating an end correction width for wound diameters other
than such standard diameters. That is, although respective end correction widths are
set for the above-described set standard diameters, end correction widths are not
set for values other than the above-described set standard diameters. Therefore, by
carrying out interpolation processing, such an end correction width that has not been
set is determined (step S103).
[0055] As an example of the interpolation processing, a method (so-called a linear interpolation)
may be adopted in which a line graph such as the line graph illustrated in Fig. 7
is made by connecting dots each indicating a relation between a standard diameter
and an end correction width (i.e., four dots for each of the larger-diameter portion
and the smaller-diameter portion) with a straight line. An end correction width can
be determined for values other than the set standard diameters by such a line graph.
End correction widths can be consecutively determined for the package diameter that
changes from the winding start until the winding end. Further, instead of using the
method for making the line graph, the present embodiment may also adopt a method for
calculating an approximation function by an approximation method such as a least-squares
method. The relation between standard diameters and end correction widths determined
as described above is stored in the storing section 71.
[0056] Next, the operator appropriately operates the setting section 91 of the machine setting
device 90 and each of the winder units 10 to start a winding operation of the yarn
20 (step S104). During the winding operation of the yarn 20, a package diameter is
acquired by the angle sensor 44 as described above, and the acquired package diameter
is transmitted to the unit control section 50 (step S105).
[0057] The correction width calculating section 72 determines an end correction width for
the acquired package diameter in accordance with contents stored in the storing section
71. The traverse control section 46 calculates a value by subtracting such an end
correction width from the preset target traverse stroke. The traverse control section
46 controls the traverse device 27 (especially the traverse driving motor 45) such
that the calculated value becomes equal to the actual traverse stroke TS (step S106).
[0058] For example, during the winding operation, suppose that a result detected by the
angle sensor 44 indicates that the package diameter is 150 mm. In such case, it can
be determined from the line graph in Fig. 7 that the end correction width of the larger-diameter
portion and the end correction width of the smaller-diameter portion are respectively
0.7 mm and 1.7 mm. The traverse device 27 is controlled such that the preset traverse
stroke TS is shortened by 0.7 mm from the larger-diameter edge and shortened 1.7 mm
from the smaller-diameter edge.
[0059] When the traverse stroke TS is narrowed, the narrowed traverse stroke TS balances
with a bulge of the package 30 that would occur due to the tightening force of the
yarn 20. Therefore, the package 30 can be formed in an appropriate shape as illustrated
by the alternate long and double-short dashed line in Fig. 5.
[0060] The unit control section 50 detects whether or not the package 30 is fully wound
(step S107) . The unit control section 50 performs the above-described control operations
(steps S105 and S106) until the package 30 is fully wound. When the package 30 is
fully wound, a winding operation ends (step S108).
[0061] Occurrence of a bulge winding has been conventionally prevented by increasing a traversing
speed and increasing a winding angle. Accordingly, there were cases where a winding
angle of a package which has been formed results being different from a winding angle
intended by an operator. That is, there were cases where winding density of the package
which has been formed results being different from winding density intended by the
operator.
[0062] Meanwhile, in the present embodiment, the traverse stroke TS of the traverse device
27 is narrowed in accordance with an appropriate end correction width. The winder
unit 10 according to the present embodiment does not increase a traversing speed in
order to prevent occurrence of a bulge winding. Accordingly, a winding angle of a
package which has been formed does not change contrary to the intention of the operator.
That is, in the present embodiment, it is possible to prevent occurrence of a bulge
winding and also form a package with winding density intended by the operator.
[0063] As described above, the automatic winder 1 according to the present embodiment includes
the traverse device 27, the correction width setting section 85, and the traverse
control section 46. The traverse device 27 traverses a yarn to be wound into the package
30. The correction width setting section 85 sets the end correction width for correcting
the predetermined target traverse stroke by associating with the predicted bulge occurrence
diameter. The traverse control section 46 controls the traverse device 27 so as to
traverse the yarn under the traverse stroke TS determined in accordance with the end
correction width that has been set by the correction width setting section 85.
[0064] That is, the size of a bulge which occurs on a lateral side of the package 30 when
the package 30 has been formed depends on a distance from a central axis of the winding
bobbin 22 or a distance from the surface of the winding bobbin 22 (i.e., depends on
the predicted bulge occurrence diameter). Accordingly, since the traverse stroke TS
of the traverse device 27 is narrowed in accordance with an appropriate end correction
width associated with the predicted bulge occurrence diameter, occurrence of a bulge
winding can be prevented.
[0065] The automatic winder 1 according to the present embodiment includes the standard
diameter setting section 81, the correction width setting section 85, and the angle
sensor 44. The standard diameter setting section 81 sets the predicted bulge occurrence
diameter as the standard diameter. The angle sensor 44 acquires the package diameter,
which is a wound diameter of the package 30. When the package diameter acquired by
the angle sensor 44 is the standard diameter, the traverse control section 46 controls
the traverse device 27 so as to traverse the yarn under the traverse stroke TS determined
in accordance with an end correction width that has been set by being associated with
such a standard diameter.
[0066] Accordingly, the package diameter can be acquired with great accuracy in real-time
by the angle sensor 44. When the package diameter which is kept being acquired becomes
equal to the preset standard diameter, the traverse stroke TS of the traverse device
27 is narrowed in accordance with the end correction width associated with such a
standard diameter. Consequently, occurrence of a bulge winding can be prevented effectively.
[0067] The automatic winder 1 according to the present embodiment includes the correction
width calculating section 72. The correction width calculating section 72 can calculate
an end correction width for a package diameter other than the set standard diameter
in accordance with the set standard diameter and an end correction width associated
with such a standard diameter. When the package diameter acquired by the angle sensor
44 is a package diameter other than the set standard diameter, the traverse control
section 46 controls the traverse device 27 so as to traverse the yarn under the traverse
stroke TS determined in accordance with the end correction width calculated by the
correction width calculating section 72.
[0068] Accordingly, just by setting a certain number of standard diameters and end correction
widths associated with such standard diameters, the correction width calculating section
72 can form a line graph capable of obtaining end correction widths for package diameters
other than the standard diameter. By controlling the traverse device 27 in accordance
with the line graph, an appropriate end correction width can be applied to an entire
range of the package diameter that changes during from start of a winding operation
until and end of the winding operation. Consequently, occurrence of a bulge winding
can be prevented effectively. Further, since an operator is not required to set an
end correction width for every single package diameter, the operator can easily perform
a setting operation.
[0069] In the automatic winder 1 according to the present embodiment, the standard diameter
setting section 81 includes the smaller-diameter portion standard diameter setting
section 83 and the larger-diameter portion standard diameter setting section 82. The
smaller-diameter portion standard diameter setting section 83 sets the standard diameter
of the smaller-diameter portion of the cone winding package. The larger-diameter portion
standard diameter setting section 82 sets the standard diameter of the larger-diameter
portion of the cone winding package. The correction width setting section 85 includes
the smaller-diameter portion correction width setting section 87 and the larger-diameter
portion correction width setting section 86. The smaller-diameter portion correction
width setting section 87 sets the end correction width of the smaller-diameter portion
of the cone winding package by associating with the standard diameter of the smaller-diameter
portion. The larger-diameter portion correction width setting section 86 sets the
end correction width of the larger-diameter portion of the cone winding package by
associating with the standard diameter of the larger-diameter portion.
[0070] That is, in the cone winding package, differences in changes of winding density or
the like cause differences between a shape of a bulge winding which occurs on a lateral
side of the larger-diameter portion of the cone winding package and a shape of a bulge
winding which occurs on a lateral side of the smaller-diameter portion. According
to the above-described structure, a different end correction width can be set for
each of the smaller-diameter portion and the larger-diameter portion; therefore, even
in the cone winding package, occurrence of a bulge winding can be prevented effectively.
[0071] Next, by referring to Fig. 8, a first variation of the above-described embodiment
will be described. In the following description on the variations of the above-described
embodiment, like reference numerals are used in the drawings for elements that are
the same or similar to those of the above-described embodiment, and description thereof
is omitted.
[0072] In the first variation, a setting section 91 of a machine setting device 90 includes
a winding tube angle setting section 89 capable of setting an angle of a winding bobbin
22. By setting the angle of the winding bobbin 22 in the winding tube angle setting
section 89, a standard diameter and an end correction width associated with such an
angle are set with respect to each of winding units 10. Further, the angle of the
winding bobbin 22 indicates an angle formed by a central axis of the winding bobbin
22 and an outline of the winding bobbin 22 when the winding bobbin 22 is seen from
a lateral side. General automatic winders normally use winding bobbins 22 with an
angle of 3.30 degrees or an angle of 5.57 degrees.
[0073] In the first variation, the correction width calculating section 72 is not provided.
This is because when the winding tube angle setting section 89 sets the standard diameter
and the end correction width, a relation is not discretely set but is consecutively
set.
[0074] As described above, the automatic winder 1 according to the first variation includes
the cradle 23 and the winding tube angle setting section 89. The cradle 23 rotatably
supports the winding bobbin 22 around which a yarn is wound to form a package 30.
The winding tube angle setting section 89 can set the angle of the winding bobbin
22. A standard diameter setting section 81 sets the standard diameter in accordance
with the angle of the winding bobbin 22 set by the winding tube angle setting section
89. A correction width setting section 85 sets the end correction width in accordance
with the angle of the winding bobbin 22 set by the winding tube angle setting section
89.
[0075] That is, change of the angle of the winding bobbin 22 causes the shape of the package
30 to change. Consequently, the size of a bulge which is occurs on a lateral side
of the package 30 also changes. According to the above-described structure, the standard
diameter and the end correction width are set in accordance with the angle of the
winding bobbin 22; therefore, occurrence of a bulge winding can be prevented effectively.
[0076] Next, a second variation will be described. An automatic winder according to the
second variation includes a correction width calculating section 72 that automatically
calculates a standard diameter and an end correction width for a smaller-diameter
portion when a standard diameter and an end correction width with respect to a larger-diameter
portion are set. Various methods can be used as such a calculating method. For example,
a method can be used in which a predicted bulge of a package is calculated in accordance
with the ratio between a larger diameter and a smaller diameter and the size of such
a bulge is set as an end correction width.
[0077] As described above, in an automatic winder 1 according to the second variation, in
accordance with the standard diameter of the larger-diameter portion set by the larger-diameter
portion standard diameter setting section 82 and the end correction width of the larger-diameter
portion set by the larger-diameter portion correction width setting section 86, the
smaller-diameter portion standard diameter setting section 83 automatically sets the
standard diameter of the smaller-diameter portion, and the smaller-diameter portion
correction width setting section 87 automatically sets the end correction width of
the smaller-diameter portion. Accordingly, just by setting the standard diameter and
the end correction width with respect to the larger-diameter portion, the standard
diameter and the end correction width with respect to the smaller-diameter portion
can be automatically set. As a result, time and effort for setting a standard diameter
and an end correction width can be reduced.
[0078] Next, a third variation will be described. In an automatic winder 1 according to
the third variation, in accordance with a standard diameter of a smaller-diameter
portion set by the smaller-diameter portion standard diameter setting section 83 and
an end correction width of the smaller-diameter portion set by the smaller-diameter
portion correction width setting section 87, the larger-diameter portion standard
diameter setting section 82 automatically sets a standard diameter of a larger-diameter
portion, and the larger-diameter portion correction width setting section 86 automatically
sets an end correction width of the larger-diameter portion. Accordingly, just by
setting the standard diameter and the end correction width with respect to the smaller-diameter
portion, the standard diameter and the end correction width with respect to the larger-diameter
portion can be automatically set. As a result, time and effort for setting a standard
diameter and an end correction width can be reduced.
[0079] While a preferred embodiment and variations of the present invention have been described,
the above-described structures can be further modified as follows.
[0080] In the above-described embodiment, the end correction width is set so as to be associated
with the predicted bulge occurrence diameter. However, the end correction width may
be set to be associated with a predicted package winding diameter other than the predicted
bulge occurrence diameter. Accordingly, also for purposes than prevention of bulge
winding, when the operator sets a width to be corrected from an edge of a package,
the operator can intuitively carry out the setting.
[0081] In the above-described embodiment, the operator manually sets a standard diameter
and an end correction width. However, such a structure may be replaced with a structure
in which the standard diameter and the end correction width are automatically set
according to package information that has been set by the machine setting device 90
or the like.
[0082] In the above-described embodiment, an end correction width is changed according to
the package diameter acquired by the angle sensor 44. However, for example, such a
structure may be replaced with a structure in which the end correction width is changed
according to a period of time that has elapsed from the start of a winding operation.
In such a case, by setting a relation between the period of time that has elapsed
and the end correction width in accordance with a relation between the predicted bulge
occurrence diameter and the end correction width, it possible to eliminate the necessity
for setting a standard diameter.
[0083] The winder unit 10 can form packages of various shapes (such as a cheese-shaped package
and a tapered package) other than a cone-shaped package.
[0084] In the winder unit 10 according to the above-described embodiment and variations,
a yarn is traversed by the arm-type traverse device 27. However, such a structure
can be replaced with a traverse device that is driven and reciprocated by a belt.
[0085] In the above-described embodiment and variations, the package driving control section
42 and the traverse control section 46 are described as components that are provided
separately from the unit control section 50. However, such a structure can be replaced
with a structure in which the unit control section 50 includes at least one of the
package driving control section 42 and the traverse control section 46.
[0086] In the above-described embodiment and variations, the package driving motor 41 drives
the package 30. However, such a structure can be replaced with a structure in which
an appropriate driving device drives the contact roller 29 so as to drive and rotate
the package 30.
[0087] In the above-described embodiment and variations, the angle sensor 44 acquires a
package diameter. However, such a structure can be replaced with a structure in which
the package diameter is calculated by detecting a rotational speed of the contact
roller 29.
[0088] In the above-described embodiment and variations, the angle sensor 44 is formed as
a rotary encoder. However, the angle sensor 44 can be replaced with an analog-type
sensor such as a potentiometer.
[0089] In the above-described embodiment and variations, the traverse driving motor 45 is
formed as a servomotor. However, the servomotor can be replaced with an appropriate
driving device such as a step motor and a voice coil motor.
[0090] In the above-described embodiment and variations, the machine setting device 90 includes
the setting section 91 for setting a standard diameter, an end correction width, an
angle of the winding tube, or the like. Alternatively, each of the winder units 10
may include the setting section 91. However, it is advantageous for the machine setting
device 90 to include the setting section 91 since the setting for a plurality of winder
units can be carried out at once.
[0091] In the above-described embodiment and variations, a distance that is twice as long
as a distance from a center portion of the winding bobbin 22 in an axial direction
to the surface of a package is set as a standard diameter. However, in place of such
a distance, a distance (a yarn layer length) from the surface of the winding bobbin
22 to the surface of the package can be set as the standard diameter.
[0092] The above-described embodiment and variations are not limited to an automatic winder,
and can also be applied widely to a yarn winding machine in which a yarn is wound
while being traversed by the traverse device.
1. A yarn winding machine, comprising:
a yarn traversing device (27) adapted to traverse a yarn to be wound into a package,
a correction width setting section (85) adapted to set an end correction width for
correcting a predetermined target traverse width dependent on a predicted package
winding diameter, and
a control section (46) adapted to control the yarn traversing device (27) so as to
traverse the yarn under a traverse width determined in accordance with the end correction
width that has been set by the correction width setting section (85).
2. The yarn winding machine according to claim 1, further comprising:
a standard diameter setting section (81) adapted to set the predicted package winding
diameter as a standard diameter, and
a package diameter acquiring section (44) adapted to acquire a package diameter, which
is a wound diameter of the package,
wherein, when the package diameter acquired by the package diameter acquiring section
(44) is the standard diameter, the control section (46) is adapted to control the
yarn traversing device (27) so as to traverse the yarn under a traverse width determined
in accordance with the end correction width that has been set dependent on the standard
diameter.
3. The yarn winding machine according to claim 2, further comprising:
a correction width calculating section (72) adapted to calculate an end correction
width for a package diameter other than the set standard diameter in accordance with
the set standard diameter and the end correction width associated with such standard
diameter,
wherein, when a package diameter acquired by the package diameter acquiring section
(44) is a package diameter other than the set standard diameter, the control section
(46) is adapted to control the yarn traversing device (27) so as to traverse the yarn
under a traverse width determined in accordance with the end correction width calculated
by the correction width calculating section (72).
4. The yarn winding machine according to claim 2 or claim 3, wherein
the standard diameter setting section (81) includes:
a smaller-diameter portion standard diameter setting section (83) adapted to set a
standard diameter of a smaller-diameter portion of a cone winding package, and
a larger-diameter portion standard diameter setting section (82) adapted to set a
standard diameter of a larger-diameter portion of the cone winding package, and the
correction width setting section (85) includes:
a smaller-diameter portion correction width setting section (87) adapted to set an
end correction width of the smaller-diameter portion of the cone winding package dependent
on the standard diameter set by the smaller-diameter portion standard diameter setting
section (83), and
a larger-diameter portion correction width setting section (86) adapted to set an
end correction width of the larger-diameter portion of the cone winding package dependent
on the standard diameter set by the larger-diameter portion standard diameter setting
section (82).
5. The yarn winding machine according to claim 4, wherein, in accordance with the larger-diameter
portion standard diameter set by the larger-diameter portion standard diameter setting
section (82) and the end correction width of the larger-diameter portion set by the
larger-diameter portion correction width setting section (86), the smaller-diameter
portion standard diameter setting section (83) is adapted to automatically set the
standard diameter of the smaller-diameter portion and the smaller-diameter portion
correction width setting section (87) is adapted to automatically set the end correction
width of the smaller-diameter portion.
6. The yarn winding machine according to claim 4, wherein, in accordance with the smaller-diameter
portion standard diameter set by the smaller-diameter portion standard diameter setting
section (83) and the end correction width of the smaller-diameter portion set by the
smaller-diameter portion correction width setting section (87), the larger-diameter
portion standard diameter setting section (82) is adapted to automatically set the
standard diameter of the larger-diameter portion and the larger-diameter portion correction
width setting section (86) is adapted to automatically set the end correction width
of the larger-diameter portion.
7. The yarn winding machine according to claim 2, further comprising:
a winding tube supporting section (23) adapted to rotatably support a winding tube
around which the yarn is wound to form the package, and
a winding tube angle setting section (89) adapted to set an angle of the winding tube
to be supported by the winding tube supporting section (23),
wherein the standard diameter setting section (81) is adapted to set the standard
diameter in accordance with the angle of the winding tube set by the winding tube
angle setting section (89), and
the correction width setting section (85) is adapted to set the end correction width
in accordance with the angle of the winding tube set by the winding tube angle setting
section (89).
8. A yarn winding method comprising:
a setting step (S101, S102) of setting a standard diameter and an end correction width,
which corrects a predetermined target traverse width, with respect to a package, and
storing the set standard diameter and the end correction width,
a package diameter acquiring step (S105) of acquiring a package diameter, which is
a wound diameter of the package, and
a controlling step (S106) of controlling a yarn traversing device (27), which traverses
a yarn, in accordance with an end correction width associated with the acquired package
diameter.