TECHNICAL FIELD
[0001] The present invention relates to a management system applied to a fine spinning winder.
BACKGROUND ART
[0002] Conventionally known is a fine spinning winder including a spinning frame for spinning
a yarn and winding the yarn on a bobbin, an automatic winder for unwinding the spun
yarn from the bobbin to form a package having a predetermined length, and a bobbin
transport mechanism for automatically transporting the bobbin by a tray from a fine
spinning unit of the spinning frame to a rewinding unit of the automatic winder. In
this type of fine spinning winder, a textile machine management system is sometimes
applied, whereby recording means for recording information is attached to the tray
and bobbin information is managed based on the information recorded on the recording
means. By using such a management system, in a case where, for example, a yarn of
lower quality than a set level is detected, a fine spinning unit having wound the
yarn on the bobbin can be promptly identified based on the information recorded on
the recording means. A fine spinning winder using such a fine spinning winder management
system is disclosed in, for example, Patent Documents 1 and 2.
PRIOR-ART DOCUMENTS
PATENT DOCUMENTS
[0003]
Patent Document 1: Japanese Patent Application Laid-Open No. 2003-176081
Patent Document 2: Japanese Patent Application Laid-Open No. 62-41329 (1987)
SUMMARY OF INVENTION
PROBLEMS TO BE SOLVED BY THE INVENTION
[0005] In the above-described fine spinning winder, there is sometimes a desire to know
how fluff is occurring in a spun yarn on a unit basis of the bobbin, in order to use
it as a reference for recognizing an operating situation of the fine spinning unit.
It is therefore conceivable to use a fluff detection function of a clearer that is
provided in the rewinding unit of the automatic winder.
[0006] Here, fluffing (the amount of fluff) in the spun yarn that is unwound from the bobbin
has a certain variation tendency relative to the length of the unwound yarn, such
as being small immediately after the start of the unwinding but gradually increasing
as the amount of remaining yarn approaches zero. However, in a case of detecting the
fluff by the clearer, the above-mentioned variation cannot be considered. Therefore,
the amount of occurrence of fluff cannot be properly analyzed on a unit basis of the
bobbin.
[0007] Therefore, a conventional fine spinning winder adopts a method in which one of the
bobbins wound with the yarns by the fine spinning units of the spinning frame is picked
up as a sample, and the yarn is unwound up to a certain length that is predefined,
and then the amount of fluff is measured by an analyzer that is provided independently
of the fine spinning winder. As a result, data concerning the amount of fluff in the
yarn capable of being compared with another bobbin can be obtained. Therefore, a tendency
of each bobbin can be grasped, such as a tendency that a certain bobbin has a larger
amount of fluff than other bobbins. However, the spinning frame often includes a large
number of fine spinning units, and it is quite troublesome to pick up a sample and
analyze the sample by the analyzer for all of the fine spinning units. On the other
hand, if an interval at which the sample is picked up for a quality inspection is
increased, detection of a failure of the fine spinning unit may be delayed depending
on a timing of picking up the sample, which undesirably causes decrease in production
efficiency.
[0008] The present invention is made in view of the circumstances described above, and an
object of the present invention is to provide a management system for a fine spinning
winder, which enables a tendency of occurrence of fluff in a yarn spun by a fine spinning
unit to be automatically analyzed on a unit basis of a bobbin.
MEANS FOR SOLVING THE PROBLEMS AND EFFECTS THEREOF
[0009] The problem to be solved by the present invention is as described above, and next,
means for solving the problem and effects thereof will be described.
[0010] In a first aspect of the present invention, in a management system for managing a
fine spinning winder including a spinning frame, an automatic winder, and a bobbin
transport mechanism, the following configuration is provided. The spinning frame includes
a plurality of fine spinning units for winding spun yarns on bobbins. The automatic
winder includes a rewinding unit for unwinding the yarn from the bobbin to form a
package. The bobbin transport mechanism transports, to the rewinding unit, a transporter
on which the bobbin wound with the yarn by the spinning frame is set. The transporter
has a data recording section configured to record information for identifying the
fine spinning unit that has wound the yarn on the bobbin set on this transporter.
The rewinding unit includes a fluff detection part, a yarn length calculation section,
and a data reading part. The fluff detection part detects the amount of fluff in the
yarn. The yarn length calculation section calculates the length of the unwound yarn
indicating the length of the yarn unwound from the bobbin. The data reading part reads
the information from the data recording section corresponding to the bobbin on which
a rewinding operation is performed. The automatic winder includes a quality inspection
section for recording the amount of fluff together with the length of the unwound
yarn obtained when the fluff detection part detected this amount of fluff, and performing
a quality inspection, on a unit basis of the bobbin, on the yarn spun by the fine
spinning unit.
[0011] Accordingly, the fine spinning unit having performed the spinning can be identified
based on the information in the data recording section. Therefore, the quality of
the yarn produced by the fine spinning unit can be examined on a unit basis of the
bobbin. Additionally, the quality inspection can be automatically performed concurrently
with the rewinding operation in a production line. This provides laborsaving for the
quality inspection operation. Moreover, since the amount of fluff is recorded in association
with the yarn length, a tendency of occurrence of fluff that indicates a portion of
the yarn where a large amount of fluff occurs can be accurately recognized, which
enables the fluff to be detected and handled efficiently.
[0012] In the management system, it is preferable that the fine spinning unit is configured
as a ring spinning unit having a traveler.
[0013] Accordingly, since the tendency of occurrence of fluff can be accurately recognized
on a unit basis of the bobbin, increase in the amount of fluff throughout the yarn,
which is caused by degradation of the traveler due to abrasion, can also be detected
easily.
[0014] It is preferable that the management system is configured as follows. That is, the
fine spinning winder includes notification means configured to identify the fine spinning
unit requiring maintenance, and to make notification. The management system monitors,
on a unit basis of the bobbin, a tendency of occurrence of fluff in the yarn produced
by the same fine spinning unit, and if the tendency of occurrence of fluff exhibits
a change that satisfies a determination condition as compared with a previous tendency
of occurrence of fluff, the notification means makes notification.
[0015] Accordingly, since a change in the tendency of occurrence of fluff is monitored on
a unit basis of the bobbin, a change in the amount of fluff caused by a failure of
the fine spinning unit while a system is running can be detected on a unit basis of
the bobbin, and an operator can be notified of the fine spinning unit requiring maintenance.
This allows the operator to promptly handle the failure of the fine spinning unit,
thus effectively suppressing deterioration in quality of the yarn rewound into the
package. Moreover, a component part is replaced at a timing when the component part
actually reaches the end of its lifetime and causes a failure. Therefore, the replacement
of only the minimum number of component parts is required, and thus costs can be reduced
efficiently.
[0016] It is preferable that the management system for the fine spinning winder is configured
as follows. That is, if the rewinding operation is interrupted halfway, the management
system records unwound yarn length information indicating the length of the unwound
yarn obtained at a time when the interruption occurs. Additionally, when performing
the rewinding operation again using the bobbin on which the rewinding operation has
been interrupted halfway, the management system refers to the unwound yarn length
information corresponding to this bobbin, and records the amount of fluff in association
with the length of the unwound yarn including consideration for this unwound yarn
length information.
[0017] Accordingly, even when the bobbin on which the rewinding operation has been interrupted
is transported again to the rewinding unit, the amount of fluff is recorded based
on the length of the unwound yarn including consideration for the length of the already
unwound yarn. Therefore, a portion where the fluff is detected can be accurately identified.
[0018] In the management system, it is preferable that the rewinding unit includes a fluff
suppression device that is controlled based on a tendency of occurrence of fluff on
a unit basis of the bobbin.
[0019] Accordingly, fluff is suppressed in accordance with the tendency of occurrence thereof,
and therefore the quality of the yarn rewound into the package can be kept more uniform.
[0020] In a second aspect of the present invention, a fine spinning winder to which the
management system is applied is provided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021]
FIG. 1 is a schematic plan view showing a tray transport path provided in a fine spinning
winder according to one embodiment of the present invention, as seen from the top
side thereof.
FIG. 2 contains a schematic front elevational view and a block diagram showing a fine
spinning winder.
FIG. 3 is a perspective view showing external appearances of a bobbin and a tray.
FIG. 4 is a side view showing a configuration of a fine spinning unit.
FIG. 5 is a side view showing a configuration of a rewinding unit.
FIG. 6 is an explanatory diagram for explaining trend data used for a quality inspection.
FIG. 7 is a side view showing a configuration of a rewinding unit according to a modification.
EMBODIMENT FOR CARRYING OUT THE INVENTION
[0022] Next, an embodiment of the invention will be described. FIG. 1 is a schematic plan
view showing a fine spinning winder 1 according to one embodiment of the present invention,
as seen from the top side thereof. FIG. 2 contains a schematic front elevational view
and a block diagram showing the fine spinning winder 1.
[0023] As shown in FIG. 1, the fine spinning winder 1 has a tray transport path 90 for transporting
a tray (transporter) 50 on which a bobbin 23 is set. A spinning frame 2, a winder
3, and an automatic bobbin feed system (bobbin transport mechanism) 6 are arranged
in the tray transport path 90. The tray transport path 90 connects the spinning frame
2 and the winder 3 to each other, and is configured as a loop, so that the bobbin
23 (tray 50) circulates through the tray transport path 90. Although FIG. 1 shows
only one bobbin 23 and one tray 50, actually a plurality of trays 50 are transported
along the tray transport path 90.
[0024] In the following description, regarding a flow of the tray 50 through the tray transport
path 90, an upstream side and a downstream side with respect to a direction of transport
of the tray 50 may be simply referred to as "upstream side" and "downstream side",
respectively.
[0025] Firstly, configurations of the tray 50 and the bobbin 23 transported in the tray
transport path 90 will be briefly described with reference to FIG. 3. FIG. 3 is a
perspective view showing external appearances of the tray 50 and the bobbin 23 used
in the fine spinning winder 1 of this embodiment.
[0026] As shown in the left part of FIG. 3, the tray 50 includes a base portion 50a having
a substantially circular disc shape, and a bobbin insertion portion 50b having a rod-like
shape and protruding from the base portion 50a in a vertical direction. The tray 50
moves along the tray transport path 90 while a side of the tray 50 at which the insertion
portion 50b protrudes faces upward.
[0027] As shown in the middle part of FIG. 3, the bobbin 23 is shaped into a long and thin
cylinder, and allows the insertion portion 50b to be inserted therein. Thereby, the
bobbin 23 is set on the tray 50 with a longitudinal direction of the bobbin 23 extending
in the vertical direction, and can be transported along the tray transport path 90.
[0028] In the following description, a bobbin (bobbin shown in the right part of FIG. 3)
on which a yarn is wound will be sometimes referred to as "actual bobbin". A bobbin
in a state where no yarn is wound thereon (in a state shown in the middle part of
FIG. 3) will be sometimes referred to as "empty bobbin" or "bobbin that is empty"
for the purpose of especially emphasizing such a state.
[0029] In the fine spinning winder 1 of this embodiment, a management system (textile machine
management system) is applied which manages information of the bobbin 23 set on the
tray 50 by using a technique of RFID (Radio Frequency IDentification: individual identification
based on a radio wave). More specifically, in each tray 50, an RF tag (data recording
section) 60 in which appropriate information can be written is arranged within the
base portion 50a. By writing information concerning the bobbin 23 into the RF tag
60 (of each tray 50), a status of the bobbin 23 is managed.
[0030] Next, each configuration of the fine spinning winder 1 will be described along the
tray transport path 90. The tray transport path 90 includes an actual bobbin introduction
path 91, an actual bobbin transport path 92, a returned bobbin transport path 93,
a bobbin waiting loop 94, a bobbin supply path 95, an empty bobbin transport path
96, an empty bobbin return path 97, a defective bobbin waiting path 98, and a replaced
bobbin return path 99.
[0031] The actual bobbin introduction path 91 connects the spinning frame 2 and the automatic
bobbin feed system 6 to each other, and transports the tray 50 having the bobbin 23
placed thereon from the spinning frame 2 to the automatic bobbin feed system 6. Hereinafter,
the spinning frame 2 will be described.
[0032] As shown in FIG. 2, the spinning frame 2 includes a large number of fine spinning
units 32 arranged in parallel with one another, and a controller 19 configured to
collectively control the large number of fine spinning units 32. The spinning frame
2 also includes a doffing device (not shown) for doffing the bobbin 23 (actual bobbin)
on which the yarn has been wound by the fine spinning unit 32.
[0033] Next, a detailed description will be given to the fine spinning unit 32 with reference
to FIG. 4. As shown in FIG. 4, the fine spinning unit 32 of this embodiment is for
spinning a sliver or a rove having been generated in a prior step by imparting twist
thereto. More specifically, the spinning frame 2 is configured as a ring spinning
frame, and the fine spinning unit 32 is configured as a ring spinning unit including
a drafting mechanism 101 and a twist imparting mechanism 102.
[0034] The drafting mechanism 101 has a plurality of drafting rollers, and the drafting
rollers include top rollers 103 and bottom rollers 104. The top rollers 103 have three
drafting rollers, namely, a back roller 103a, a middle roller 103b having an apron
belt 105 mounted thereon, and a front roller 103c. On the other hand, the bottom rollers
104 have three drafting rollers, namely, a back bottom roller 104a, a middle bottom
roller 104b having an apron belt 105 mounted thereon, and a front bottom roller 104c.
As shown in FIG. 4, the top roller 103 and the bottom roller 104 are arranged so as
to be opposed to each other across a path of travel of the sliver or the rove, and
are configured to nip the sliver or the rove with predetermined pressure. An output
shaft of a driving source (not shown) is connected to each of the bottom rollers 104,
so that the bottom rollers 104 can be driven at different speeds. By the driving of
the bottom rollers 104, the sliver or the rove is, while being drawn, fed to the twist
imparting mechanism 102.
[0035] The twist imparting mechanism 102 includes a spindle shaft 111, a ring rail 112,
a ring 113, and a traveler 114. The spindle shaft 111 is for rotating the bobbin 23
that is set on the spindle shaft 111. The ring rail 112 is connected to a driver (not
shown), and movable in the longitudinal direction of the bobbin 23. The ring 113 is
fixed to the ring rail 112, and has a flange portion for the traveler 114 to be mounted
thereon. The traveler 114 is supported on the flange portion of the ring 113, and
movable in a circumferential direction of the ring 113.
[0036] To perform the fine spinning in the fine spinning unit 32 configured as described
above, firstly, the yarn (sliver or rove having been drawn) fed from the drafting
mechanism 101 is inserted into a gap between the traveler 114 and the ring 113, and
an end portion of the yarn is fixed to the empty bobbin 23 by an appropriate method.
In this state, the spindle shaft 111 rotates the bobbin 23, and thereby the yarn being
wound on the bobbin 23 drags the traveler 114, so that the traveler 114 moves in the
circumferential direction. As a result, the rotation of the traveler 114 is delayed
behind the rotation of the bobbin 23, and twist is imparted to the yarn due to a difference
in the number of rotations thus caused. The twisted yarn is sequentially wound on
the bobbin 23. When a preset length of the yarn is wound on the bobbin 23, the rotation
of the spindle shaft 111 is stopped, to terminate the winding.
[0037] The spinning frame 2 of this embodiment is of so-called simultaneous doffing type.
In the spinning frame 2 of this type, a large number of bobbins 23 transported from
the automatic bobbin feed system 6 through the empty bobbin return path 97 which will
be described later are stocked while being arranged in a line, and when a predetermined
timing comes, the large number of bobbins 23 are simultaneously set on the spindle
shafts 111 of the fine spinning units 32, and yarns are simultaneously wound thereon.
When the winding of the yarns is completed, the doffing device simultaneously doffs
all the bobbins 23 (actual bobbins). Then, bobbins 23 that are empty are pulled away
from the trays 50. having the empty bobbins 23 placed thereon, which are waiting in
appropriate positions. Then, the bobbins 23 (actual bobbins) are inserted into the
trays 50. Then, the pulled bobbins 23 that are empty are set on the spindle shafts
111, and the spinning frame 2 winds yarns thereon. The bobbins 23 doffed by the spinning
frame 2 and placed on the trays. 50 are transported through the actual bobbin introduction
path 91, and thereby introduced into the automatic bobbin feed system 6.
[0038] The automatic bobbin feed system 6 receives the trays 50 having the bobbins 23 (actual
bobbins) placed thereon from the spinning frame 2, and then writes appropriate information
into the RF tags 60 of the trays 50. A pick finding device 7 finds pick of the bobbins
23, and then the trays 50 are supplied to the winder 3 side. Hereinafter, a detailed
description will be given.
[0039] As shown in FIG. 1, an RF writer (data writing part) 4 is arranged at the downstream
side of the spinning frame 2 in the actual bobbin introduction path 91. The RF writer
4 writes, for example, information identifying the fine spinning unit 32 that has
spun the yarn on the bobbin 23, into the RF tag 60. When the tray 50 transported in
the actual bobbin introduction path 91 passes through a writing position of the RF
writer 4, the information identifying the fine spinning unit 32 that has wound the
yarn on the bobbin 23 placed on this tray 50 is recorded on the RF tag 60 by the RF
writer 4.
[0040] The fine spinning units 32 are arranged side by side in a longitudinal direction
of the spinning frame 2. The bobbins 23 doffed by the simultaneous doffing are mounted
on the trays 50, and then transported in the actual bobbin introduction path 91 in
the same order as the order in which the fine spinning units 32 are arranged. Accordingly,
by counting the order in which the bobbins 23 are introduced into the actual bobbin
introduction path 91, the fine spinning unit 32 that has spun the yarn on the bobbin
23 can be identified. For example, in the first tray 50 that has passed through a
reading position of the RF writer 4 after the simultaneous doffing was performed,
a station number No.1 of the fine spinning unit 32 arranged most downstream is stored
in the RF tag 60. In the next transported tray 50, the station number No. 2 of the
fine spinning unit 32 adjacent upstream to the fine spinning unit 32 having the station
number No. 1 is stored in the RF tag 60. In the subsequent trays newly transported,
in the same manner, the station numbers No. 3, No. 4, ... are sequentially stored
in the RF tags 60. As a result, the information (station number) identifying the fine
spinning unit 32 that has wound the yarn on the bobbin 23 placed on the tray 50 is
stored in the RF tag 60 of this tray 50 passing through the writing position of the
RF writer 4.
[0041] The RF writer 4 of this embodiment is configured to write doffing information as
well as the station number described above. Here, the doffing information means information
indicating a timing of performing the doffing, such as time when the simultaneous
doffing was performed or how many number of times the doffing was.
[0042] The reason why the doffing information (such as clock time when the doffing was performed)
as well as the station number is recorded on the RF tag 60 is as follows. That is,
in the automatic bobbin feed system 6 and the winder 3 (the downstream side of the
spinning frame 2), there may be the trays 50 in which the same station number is stored
in the RF tags 60. For example, this occurs in a case where, before a rewinding operation
on the bobbin 23 that has been fed to the winder 3 side in the previous doffing is
not completed, the next doffing is performed so that a new group of bobbins 23 are
introduced into the automatic bobbin feed system 6. In such a case, if the doffing
information mentioned above is stored in the RF tag 60, the doffing information is
referred to so that the bobbins 23 having the same station number can be distinctively
recognized as different bobbins 23. The RF writer 4 of this embodiment can also store,
in the RF tag 60, not only the above-described information but also a lot number,
a number of the spinning frame 2 (a number given to each spinning frame 2 in a case
where a plurality of spinning frames 2 are provided), and the like. In the following
description, the information (the station number and the doffing information) identifying
the bobbin 23 which is stored in the RF tag 60 may be referred to as bobbin information.
[0043] A downstream end portion of the actual bobbin introduction path 91 is connected to
an upstream end portion of the actual bobbin transport path 92. The actual bobbin
transport path 92 connects the automatic bobbin feed system 6 and the winder 3 to
each other. The tray 50 in which predetermined information is written in the RF tag
60 thereof by the RF writer 4 is transported to the winder 3 along the actual bobbin
transport path 92.
[0044] The automatic bobbin feed system 6 includes the pick finding device 7. The pick finding
device 7 is arranged on the above-described actual bobbin transport path 92 and at
the upstream side of the winder 3. The pick finding device 7 finds pick of the bobbin
23 in order to make it easy for the winder 3 to catch the yarn of the bobbin 23. A
brief description will be given. The pick finding device 7 applies a suction flow
to the bobbin 23 placed on the tray 50 transported in the actual bobbin transport
path 92, and thereby unwinds the yarn from a surface of the bobbin 23. An end of the
unwound yarn is inserted into the inside of the bobbin 23 having the cylindrical shape.
This makes it easy that the end of the yarn of the bobbin 23 is caught by the winder
3 arranged at the downstream side of the pick finding device 7.
[0045] The pick finding device 7 does not always succeed in the pick-finding, and may sometimes
fail. In this case, the tray 50 having placed thereon the bobbin 23 for which the
pick-finding has been failed is sent out to the returned bobbin transport path 93.
The returned bobbin transport path 93 diverges from the actual bobbin transport path
92 immediately downstream of the pick finding device 7, and is curved in a loop so
as to be connected to the upstream end portion of the actual bobbin transport path
92. Such a configuration enables the bobbin 23 for which the pick-finding has been
failed to be transported along the returned bobbin transport path 93 and thereby returned
to the upstream side of the pick finding device 7 again. Thus, even if the pick-finding
has been failed, a pick-finding process by the pick finding device 7 is automatically
performed again. Therefore, it is not necessary that each time an error in the pick-finding
occurs, an operator deals with it.
[0046] Next, the winder 3 will be described. As shown in FIGS. 1 and 2, the winder 3 includes
a plurality of rewinding units 31, RF readers (data reading part) 5 arranged in the
respective rewinding units 31, and a machine controller 11 serving as a controller.
The winder 3 also includes a clearer control box (CCB) 12 to which a clearer (fluff
detection part) 15 of the rewinding unit 31 which will be described later is connected.
[0047] As shown in FIG. 1, in the winder 3, a plurality of bobbin supply paths 95 diverging
from the actual bobbin transport path 92 are provided. The plurality of bobbin supply
paths 95 are provided corresponding to the plurality of rewinding units 31 of the
winder 3. The plurality of bobbin supply paths 95 allow the bobbins 23 transported
in the actual bobbin transport path 92 to be distributed to the rewinding units 31.
A specific description will be given as follows.
[0048] Each bobbin supply path 95 has a predetermined length, and is configured such that
a plurality of bobbins 23 can be arranged and stocked in the bobbin supply path 95.
A guide member (not shown) or the like is arranged at an upstream end portion of each
bobbin supply path 95, so that the bobbin 23 transported in the actual bobbin transport
path 92 can be introduced into the bobbin supply path 95 by the guide member in the
course of nature. If there is not a space in the bobbin supply path 95 for introduction
of the bobbin 23 (if a maximum number of bobbins 23 are stocked), introduction of
the new bobbin 23 into the bobbin supply path 95 is blocked by the bobbins existing
in this bobbin supply path 95. At this time, the bobbin 23 blocked from being introduced
into the bobbin supply path 95 is transported to the downstream side in the actual
bobbin transport path 92, and introduced into another bobbin supply path 95 having
a space. In this manner, the bobbins 23 fed from the spinning frame 2 can be distributed
to the rewinding units 31.
[0049] On the other hand, if there is no bobbin supply path 95 having a space that allows
the bobbin 23 to be introduced therein, the bobbin 23 is introduced into the bobbin
waiting loop 94, and transported in the bobbin waiting loop 94. The bobbin waiting
loop 94 diverges from a most downstream portion of the actual bobbin transport path
92, and is connected to a portion of the actual bobbin transport path 92 located at
the upstream side of a position where the most upstream bobbin supply path 95 is diverged
from the actual bobbin transport path 92. Accordingly, the bobbin 23 keeps circulating
through a loop path made up of the bobbin waiting loop 94 and the actual bobbin transport
path 92, until a space that allows a bobbin to be stocked therein is made in any bobbin
supply path 95.
[0050] Next, a configuration of the rewinding unit 31 will be described in detail with reference
to FIG. 5. As shown in FIG. 5, the rewinding unit 31 is for rewinding the yarn from
the actual bobbin onto a rewinding bobbin 22 to thereby form a package 30. The rewinding
unit 31 includes a rewinding drum (traverse drum) 24 for traversing the yarn and for
driving the rewinding bobbin 22. In the rewinding unit 31 of this embodiment, in a
path of travel of the yarn between the rewinding drum 24 and the bobbin 23 set in
an appropriate position for an unwinding operation to be performed thereon, a tension
applying device 13, a yarn piecing device 14, and a clearer (yarn quality measuring
instrument) 15 are arranged in the mentioned order from the bobbin 23 side.
[0051] The tension applying device 13 applies a predetermined tension to the traveling yarn.
As the tension applying device 13, a gate type one is adopted in which a movable comb
is arranged relative to a fixed comb. The movable comb is rotatable by a rotary solenoid
such that the combs can be brought into an engaged state or a disengaged state. The
tension of the yarn to be rewound is controlled by the tension applying device 13,
and thereby the quality of the package 30 can be improved.
[0052] For example, at a time of yarn cutting that is performed by the clearer 15 upon detection
of a yarn defect, or at a time of yarn breakage during unwinding of the yarn from
the bobbin 23, the yarn piecing device 14 pieces a lower yarn of the bobbin 23 to
an upper yarn of the package 30. Examples of the yarn piecing device 14 include a
mechanical one, and one using a fluid such as a compressed air. A lower yarn guide
pipe 25 for guiding the lower yarn of the bobbin 23 by sucking and catching the lower
yarn and an upper yarn guide pipe 26 for guiding the upper yarn of the package 30
by sucking and catching the upper yarn are provided at the lower and upper sides of
the yarn piecing device 14, respectively.
[0053] The clearer 15 is for detecting a defect and the amount of fluff in the yarn by detecting
a diameter of the yarn using an appropriate sensor. The clearer 15 can also function
as a sensor for simply detecting presence or absence of the yarn. Cutting means is
provided near the clearer 15, so that if the clearer 15 detects a defect in the yarn,
the defect can be removed.
[0054] The yarn unwound from the bobbin 23 is rewound on the rewinding bobbin 22 that is
arranged at the downstream side of the yarn piecing device 14. The rewinding bobbin
22 is driven by rotational driving of the rewinding drum 24 that is opposed to the
rewinding bobbin 22. A rotation sensor (not shown) is mounted to the rewinding drum
24. Each time the rewinding drum 24 is rotated through a predetermined angle, the
rotation sensor outputs a rotation pulse signal to a unit control section (yarn length
calculation section) 10. The rewinding unit 31 of this embodiment measures the number
of pulses per a time period, thereby calculating a speed of rotation of the rewinding
drum 24.
[0055] In the above-described configuration, the bobbin 23 transported in the bobbin supply
path 95 is set in an appropriate position (rewinding position) in the rewinding unit
31, and then the rewinding drum 24 is driven, so that the yarn unwound from the bobbin
23 is rewound on the rewinding bobbin 22, to form the package 30 having a predetermined
length.
[0056] An RF reader 5 is arranged in the bobbin supply path 95 so as to read the RF tag
60 of the tray 50 on which the bobbin 23 whose yarn is rewound by the rewinding unit
31 is placed. Information read by the RF reader 5 is transmitted to the machine controller
11.
[0057] As shown in FIG. 2, the machine controller 11 includes a display (notification means)
16 serving as display means, and input keys 17 serving as operation means. The display
16 is for displaying a status of each rewinding unit 31. The input keys 17 allow the
operator to set rewinding conditions and the like.
[0058] As described above, the bobbin information (the station number and the doffing information)
read by the RF reader is inputted into the machine controller 11. Therefore, which
of the fine spinning units 32 has wound the yarn on the bobbin 23 whose yarn is currently
rewound by the rewinding unit 31 can be identified.
[0059] The CCB 12 performs a determination process for determining, for example, whether
or not a yarn defect is occurring, based on information transmitted from the clearer
15. As shown in FIG. 2, the CCB 12 has a display 18 serving as display means, so that
various information, such as information concerning a yarn defect and information
generated based on a yarn defect, can be displayed on the display 18. The CCB 12 is
electrically connected to the machine controller 11, and communicates various information
with the machine controller 11.
[0060] As shown in FIG. 5, the bobbin supply path 95 is laid under the rewinding unit 31.
The bobbin 23 supplied to the rewinding unit 31 is transported to the above-mentioned
rewinding position by this bobbin supply path 95. During the rewinding of the yarn,
the bobbin 23 is stopped in the rewinding position, and therefore the transport of
the tray 50 by the bobbin supply path 95 is temporarily stopped.
[0061] As described above, the bobbin supply path 95 is configured such that a plurality
of bobbins 23 can be stocked therein. As shown in FIG. 5, the stocked bobbins 23 are
arranged in a line on the bobbin supply path 95. The most downstream one of the bobbins
23 in the bobbin supply path 95 is an object of yarn rewinding performed by the rewinding
unit 31. In FIG. 5, the position of the rightmost one of the plurality of bobbins
is the above-mentioned rewinding position.
[0062] The unwinding of the yarn from the bobbin 23 is performed with the bobbin 23 being
placed on the tray 50, as shown in FIG. 5. If the yarn of the bobbin 23 runs out and
the bobbin 23 becomes empty, the bobbin supply path 95 transports the tray 50. Thereby,
the bobbin 23 that is empty is fed to the downstream side while being placed on the
tray 50, and discharged into the empty bobbin transport path 96 (which will be described
later).
[0063] Along with the bobbin 23 that is empty and placed in the rewinding position being
fed to the downstream side, each bobbin 23 stocked in the bobbin supply path 95 is
also fed to the downstream side. As a result, a new bobbin 23 is set in the rewinding
position, and the yarn is unwound from the new bobbin 23. Thus, the rewinding can
be restarted. By discharging the empty bobbin 23 from the bobbin supply path 95, a
new space allowing the bobbin 23 to be stocked therein is made in the bobbin supply
path 95. Thus, the bobbin supply path 95 is replenished with the bobbin 23 transported
in the actual bobbin transport path 92.
[0064] As shown in FIG. 1, a downstream end portion of each of the plurality of bobbin supply
paths 95 joins the empty bobbin transport path 96. The empty bobbin transport path
96 connects the winder 3 and the automatic bobbin feed system 6 to each other. The
empty bobbin 23 discharged from each rewinding unit 31 is transported through the
empty bobbin transport path 96, and thereby returned to the automatic bobbin feed
system 6.
[0065] In the automatic bobbin feed system 6, the empty bobbin transport path 96 is connected
to a middle of the returned bobbin transport path 93. In the returned bobbin transport
path 93, the empty bobbin return path 97 diverges therefrom at a position downstream
of a position where the empty bobbin transport path 96 is connected to the returned
bobbin transport path 93. The empty bobbin returned to the automatic bobbin feed system
6 through the empty bobbin transport path 96 passes through a part of the returned
bobbin transport path 93, and then is introduced into the empty bobbin return path
97 by a path switching mechanism (not shown) which will be described later. The empty
bobbin return path 97 connects the automatic bobbin feed system 6 and the spinning
frame 2 to each other. In the automatic bobbin feed system 6, the bobbin 23 that is
empty is transported in the empty bobbin return path 97, and thereby the bobbin 23
that is empty is returned to the spinning frame 2.
[0066] As described above, due to the loop-shaped tray transport path 90 that connects the
spinning frame 2 and the winder 3 to each other, the bobbin 23 can circulate between
the spinning frame 2 and the winder 3.
[0067] Actually, bobbins transported in the empty bobbin transport path 96 include not only
the empty bobbins, but the actual bobbins and defective bobbins are randomly mixed
therein. Therefore, a configuration is required that sorts and appropriately processes
the empty bobbin, the actual bobbin, and the defective bobbin that are mixed in transport.
In the following, this point will be described in detail.
[0068] Firstly, a description will be given to a case where the actual bobbin (bobbin on
which the yarn remains) is transported in the empty bobbin transport path 96. For
example, if yarn breakage occurs during rewinding of the yarn in the rewinding unit
31, the yarn piecing device 14 performs yarn piecing. At this time, the rewinding
unit 31 causes a suction flow to occur in a distal end portion of the lower yarn guide
pipe 25, thereby sucking and catching an end of the yarn of the bobbin 23, then guiding
the end of the yarn to the yarn piecing device 14. Then, the yarn piecing device 14
pieces the yarn to the upper yarn.
[0069] However, in a case where the end of the yarn of the bobbin 23 cannot be sucked and
caught by the lower yarn guide pipe 25, for example, in a case where the end of the
yarn is wrapped around the bobbin 23 or in a case where the yarn is broken at a position
near the bobbin 23, the lower yarn guide pipe 25 cannot catch the end of the yarn,
and therefore the yarn piecing device 14 cannot perform the yarn piecing. In such
a case, the rewinding unit 31 abandons catching the end of the yarn of the bobbin
23, and discharges the bobbin 23 whose yarn end could not be caught, to the empty
bobbin transport path 96. Simultaneously with this, the stocked bobbin 23 is transported
in the bobbin supply path 95 toward the downstream side, and set in the rewinding
position. Since this new bobbin 23 has been subjected to the pick-finding in the pick
finding device 7, an end of the yarn can be easily caught, so that the yarn piecing
can be performed. In this manner, even if the end of the yarn cannot be caught at
the time of yarn breakage, the bobbin 23 whose yarn end could not be caught is discharged,
and instead, a new bobbin 23 can be set, thereby enabling the yarn piecing and restarting
the rewinding.
[0070] On the other hand, the bobbin 23 whose yarn end could not be caught is transported
in the empty bobbin transport path 96. In the empty bobbin transport path 96, as described
above, the empty bobbins sent out from the other rewinding units 31 are also transported.
Accordingly, the bobbin 23 whose yarn end could not be caught is transported together
with the empty bobbins in the empty bobbin transport path 96, and then introduced
into the returned bobbin transport path 93.
[0071] As shown in FIG. 1, in the returned bobbin transport path 93, an empty bobbin determination
device 8 is provided at a position upstream of the position where the empty bobbin
return path 97 diverges from the returned bobbin transport path 93. The empty bobbin
determination device 8 inspects whether or not the bobbin 23 being transported in
the returned bobbin transport path 93 is an empty bobbin, by using an appropriate
sensor. Additionally, a path switching mechanism (not shown) is provided at the position
where the empty bobbin return path 97 diverges from the returned bobbin transport
path 93. The path switching mechanism sends out a bobbin 23 to the empty bobbin return
path 97 side if the empty bobbin determination device 8 determines that the bobbin
23 is an empty bobbin, and keeps a bobbin 23 transported in the returned bobbin transport
path 93 if the empty bobbin determination device 8 determines that the bobbin 23 is
not an empty bobbin.
[0072] In the above-described configuration, only the empty bobbin can be returned to the
spinning frame 2. The bobbin 23 (bobbin on which the yarn remains) determined to be
not an empty bobbin by the empty bobbin determination device 8 is transported in the
returned bobbin transport path 93. Then, a remaining yarn amount detection device
(not shown) measures the amount of remaining yarn. In the bobbin 23 for which it is
determined that the amount of remaining yarn is extremely small, the extremely small
amount of remaining yarn is removed by a remaining yarn processing device (not shown).
The bobbin 23 having a sufficient amount of remaining yarn is subjected to the pick-finding
process in the pick finding device 7. In this manner, even if the end of the yarn
of the bobbin 23 could not be caught in the rewinding unit 31, the bobbin 23 is subjected
to the pick-finding in the pick finding device 7, and thereby the rewinding unit 31
can perform unwinding again.
[0073] Next, a description will be given to a case where a defective bobbin (bobbin from
which a defective yarn is rewound) is transported in the empty bobbin transport path
96.
[0074] In the fine spinning unit 32, if damage, abrasion, or the like, occurs in the apron
belt 105 for example, the yarn manufactured by the fine spinning unit 32 may have
a non-uniform diameter. Additionally, there is a tendency that the amount of fluff
in the yarn increases as the traveler 114 is abraded away. In a description given
below, it is considered that a yarn having a non-uniform diameter and a yarn having
a large amount of fluff is a defective yarn of low commercial value, and a bobbin
23 having such a defective yarn wound thereon may be referred to as "defective bobbin".
It is desired that the rewinding unit 31 automatically detects and removes the defective
bobbin, in order to prevent the defective yarn to be mixed into the package 30.
[0075] In this embodiment, therefore, the diameter and the fluff of the yarn unwound from
the bobbin 23 are detected by the clearer 15, as described above. In this embodiment,
if the magnitude of variation in the yarn diameter or the amount of fluff, which is
detected by the clearer 15 of the rewinding unit 31, is beyond a predetermined allowable
range, it is determined that the bobbin on which the rewinding unit 31 currently performs
rewinding is a defective bobbin.
[0076] If a defective bobbin is detected, the rewinding unit 31 does not unwind the yarn
any longer, and discharges the defective bobbin as it is (with the yarn left thereon)
to the empty bobbin transport path 96, and then starts unwinding the yarn from another
bobbin 23 stocked in the bobbin supply path 95. This can prevent the yarn having a
non-uniform diameter or the yarn having a large amount of fluff from being mixed into
the package 30.
[0077] Here, if the defective bobbin sent out from the rewinding unit 31 into the empty
bobbin transport path 96 was introduced into the returned bobbin transport path 93,
the empty bobbin determination device 8 would determine that this defective bobbin
is not an empty bobbin (because the yarn remains on this defective bobbin), and this
defective bobbin would be supplied through the pick finding device 7 to the winder
3 again. Therefore, the automatic bobbin feed system 6 is configured such that when
the defective bobbin is transported in the empty bobbin transport path 96, the defective
bobbin is not introduced into the returned bobbin transport path 93 and escaped into
the defective bobbin waiting path 98.
[0078] A specific description is as follows. If a defective bobbin is detected in a certain
rewinding unit 31, the machine controller 11 stores information indicating the detection
of the defective bobbin in the certain rewinding unit 31. As described above, while
the yarn is rewound from the bobbin 23 in the rewinding unit 31, the information (including
the information for identifying the bobbin 23) recorded on the RF tag 60 of the tray
50 having this bobbin 23 mounted thereon is read by the RF reader 5, and the information
is inputted to the machine controller 11. If a defective bobbin is detected in the
rewinding unit 31; the machine controller 11 stores the information indicating the
detection in association with the bobbin information of the bobbin 23 (the defective
bobbin described above) on which the rewinding unit 31 currently performs rewinding.
As a result, information indicating which bobbin 23 is a defective bobbin is stored
in the machine controller 11.
[0079] On the other hand, as shown in FIG. 1, the defective bobbin waiting path 98 diverges
from the empty bobbin transport path 96 at a position upstream of the position where
the empty bobbin transport path 96 joins the returned bobbin transport path 93. Additionally,
in the empty bobbin transport path 96, an RF reader 9 is arranged at a position upstream
of the position where the defective bobbin waiting path 98 diverges from the empty
bobbin transport path 96. The RF reader 9 reads a storage content of the RF tag 60
of the tray 50 that is transported in the empty bobbin transport path 96, and transmits
the storage content to the machine controller 11. Moreover, a path switching mechanism
(not shown) is provided at the position where the defective bobbin waiting path 98
diverges from the empty bobbin transport path 96. The path switching mechanism is
controllable by the machine controller 11.
[0080] The machine controller 11 checks the information transmitted from the RF reader 9
against the information stored in the machine controller 11 itself (the information
indicating which bobbin 23 is a defective bobbin), and thereby determines whether
or not the bobbin 23 placed on the tray 50 that is passing through the position of
the RF reader 9 is a defective bobbin. This path switching mechanism sends out a bobbin
23 to the defective bobbin waiting path 98 side if the machine controller 11 determines
that the bobbin 23 is a defective bobbin, and keeps a bobbin 23 transported in the
empty bobbin transport path 96 if the machine controller 11 determines that the bobbin
23 is not a defective bobbin.
[0081] The defective bobbin waiting path 98 has a certain length, and a downstream end portion
of the defective bobbin waiting path 98 is a closed end. Therefore, a plurality of
trays 50 having defective bobbins placed thereon can wait in the defective bobbin
waiting path 98.
[0082] When the trays 50 having the defective bobbins placed thereon are reserved to a certain
extent in the defective bobbin waiting path 98, the operator removes the defective
bobbins from the trays 50, and replaces them with empty bobbins. Then, the operator
performs an appropriate operation, to thereby drive the defective bobbin waiting path
98 in reverse. As a result, the trays 50 reserved in the defective bobbin waiting
path 98, on which the replacing empty bobbins are placed, are introduced into the
replaced bobbin return path 99.
[0083] As shown in FIG. 1, the replaced bobbin return path 99 diverges from a middle of
the defective bobbin waiting path 98, and is connected to the empty bobbin return
path 97. The tray 50 on which the defective bobbin has been replaced with the empty
bobbin is introduced through the replaced bobbin return path 99 into the empty bobbin
return path 97, and then returned to the spinning frame 2.
[0084] As described above, in the fine spinning winder 1 of this embodiment, even if the
empty bobbin, the actual bobbin, and the defective bobbin are mixed, the bobbin 23
can be appropriately transferred between the spinning frame 2 and the winder 3 without
stopping the transport of the tray 50.
[0085] Next, a quality inspection function of a management system applied to the fine spinning
winder 1 will be described with reference to FIG. 6. FIG. 6 is an explanatory diagram
for explaining trend data that is used for a quality inspection. The upper part of
FIG. 6 shows graphs of the trend data. The lower part of FIG. 6 is a schematic diagram
of the bobbin 23, expressing decrease in the amount of remaining yarn corresponding
to the length of the unwound yarn in the trend data. The quality inspection function
of this embodiment is a function for examining whether or not the quality of the yarn
wound on the actual bobbin is maintained within a certain quality-assured range. The
quality-assured range herein means such a range that the amount of fluff throughout
the yarn wound on one bobbin is equal to or less than a predetermined value. A likelihood
of departing from the quality-assured range means a likelihood that the amount of
fluff would be equal to or more than the predetermined value. This predetermined value
is set to be a value smaller than the value of the amount of fluff that serves as
a reference when the clearer 15 determines the defective bobbin.
[0086] In this embodiment, the quality inspection is performed by chronologically comparing
trend data that indicates a tendency of occurrence of an amount of fluff in the yarn
wound on the actual bobbin. As shown in FIG. 6, the trend data is data indicating
the relationship between an amount of fluff and the length of the unwound yarn obtained
when this amount of fluff was detected. Here, the length of the unwound yarn is the
length of the yarn unwound from the actual bobbin (the length of the yarn rewound
from the actual bobbin into the package 30). The length of the unwound yarn is calculated
based on the number of rotations of the rewinding drum. A method for calculating the
length of the unwound yarn will be described later.
[0087] For each rewinding unit 31, information indicating the length of the unwound yarn
is transmitted and inputted from the unit control section 10 to the machine controller
11. Additionally, for each rewinding unit 31, information indicating the amount of
fluff is inputted from the clearer 15 to the CCB 12 at appropriate intervals. The
machine controller 11 and the CCB 12 exchange the information indicating the length
of the unwound yarn and the information indicating the amount of fluff, and thus generate
the trend data on a unit basis of the bobbin. That is, a process of making correspondence
between the information indicating the amount of fluff and the information indicating
the length of the unwound yarn obtained when this amount of fluff was detected is
sequentially performed from the start to the end of unwinding for the bobbin 23. Thereby,
the trend data for one bobbin is generated. The generated trend data is stored in
the machine controller 11 in chronological order with respect to each fine spinning
unit 32 (according to the station number) identified based on the bobbin information
in the RF tag 60.
[0088] In the machine controller 11, a determination condition is preliminarily set. Based
on this determination condition, whether or not there is a likelihood that the newly
stored trend data would depart from the quality-assured range is determined. To be
more specific, when newly stored trend data is stored, the machine controller 11 compares
the trend data with previous trend data, and if the new trend data exhibits a change
that satisfies the determination condition, determines that there is a likelihood
of departing from the quality-assured range. The determination condition is appropriately
set in accordance with the number of yarn and the type of yarn. In this embodiment,
operator can change the determination condition by operating the input keys 17 of
the machine controller 11.
[0089] Here, the traveler 114 provided in the fine spinning unit 32 is a component part
requiring periodic replacement, because degradation is caused by abrasion. If the
traveler 114 is not replaced at an appropriate timing, as shown in FIG. 6, the amount
of fluff may increase throughout the yarn due to degradation caused by abrasion of
the traveler 114 (current trend data as compared with previous trend data). Conventionally,
it has been difficult that such a change in which the fluff gradually increases over
a long period is detected solely by the clearer 15. However, in the configuration
of this embodiment, a tendency of increase of fluff over a long period as described
above can be detected, by setting the above-mentioned determination condition so as
to detect a change in which the amount of fluff throughout the yarn increases in the
current trend data as compared with the previous trend data.
[0090] The determination condition may be set in consideration of a portion of the bobbin
23 where the yarn is wound based on the length of the unwound yarn. For example, as
shown in FIG. 6, the amount of fluff in the yarn wound on the bobbin 23 exhibits a
relatively high value in the vicinity of the end of the unwinding operation of the
bobbin 23. Considering this, the determination condition may be set such that, for
example, if the amount of fluff rapidly increases at a timing near the end of the
unwinding operation, it is determined that there is a likelihood of departing from
the quality-assured range even though an amount of change in the other portions is
small.
[0091] If the newly generated trend data exhibits a change that satisfies the determination
condition, the machine controller 11 displays on the display 16 information (for example,
the station number mentioned above) that allows identification of the fine spinning
unit 32 requiring maintenance. Alternatively, this display can be made on the display
18 of the CCB 12. The machine controller 11 of this embodiment can cause the trend
data stored in the machine controller 11 to be displayed on the display 16 in the
form of a graph, for example, with respect to each fine spinning unit 32. This configuration
allows the operator to intuitively recognize a change in the tendency of occurrence
of fluff by the visual sense.
[0092] Processes of generating and storing the trend data are performed by a quality inspection
section provided in the winder 3. Either of the machine controller 11 and the CCB
12 functions as the quality inspection section. A configuration of the quality inspection
section can be appropriately changed depending on circumstances.
[0093] Next, a method for calculating the length of the unwound yarn will be described.
As described above, the rotation sensor mounted to the rewinding drum 24 inputs the
rotation pulse signal to the unit control section 10 (see FIG. 5). The unit control
section 10 counts the rotation pulse signal, and based on a count value, calculates
the length of the unwound yarn. This count value is reset at a timing when a new actual
bobbin on which the rewinding operation is not yet performed is transported or at
a timing when the yarn is entirely unwound from the actual bobbin, and the counting
is started based on a timing of unwinding the yarn from a new actual bobbin. In this
embodiment, the length of the yarn wound on the bobbin 23 by the fine spinning unit
32 is preliminarily stored as a set yarn length, and this information is used for
various determination processes.
[0094] Next, a description will be given to calculation of the length of the unwound yarn
in a case where the rewinding operation is interrupted. As described above, the bobbin
23 whose yarn could not be sucked and caught by the lower yarn guide pipe 25 due to
occurrence of yarn breakage during the rewinding operation is once discharged from
the rewinding position into the empty bobbin transport path 96. At this time, the
machine controller 11 stores unwound yarn length information indicating the length
of the unwound yarn obtained at a time when the rewinding operation is stopped, in
association with the bobbin information of the bobbin 23 that has performed this unwinding
operation.
[0095] The machine controller 11 obtains the bobbin information of the bobbin 23 newly transported
to the rewinding unit 31, and then refers to the stored bobbin information to determine
whether or not the bobbin 23 is a bobbin on which the rewinding operation has been
interrupted. If the bobbin 23 is the bobbin 23 on which the rewinding operation has
been interrupted, the unwound yarn length information stored in association with this
bobbin 23 is referred to. Then, a value obtained based on the unwound yarn length
information is added to the count value, to calculate the length of the unwound yarn.
The length of the unwound yarn calculated in this manner includes consideration for
the length of the already unwound yarn, and therefore is substantially coincident
with the length of the yarn actually unwound from the bobbin 23. Thus, the trend data
can be accurately generated.
[0096] In the above-described configuration, the spun yarn wound on the bobbin 23 in the
fine spinning unit 32 is unwound in the rewinding unit 31, and with it, the trend
data is generated. The generated trend data is distinguished according to the station
number of each fine spinning unit that is identified based on the bobbin information
stored in the RF tag 60, and is chronologically stored. If, as a result of the comparison
between the newly generated trend data and the previous trend data of the same fine
spinning unit 32, the newly generated trend data exhibits a change that satisfies
the determination condition, the machine controller 11 determines that there is a
likelihood that the quality of the actual bobbin would depart from the quality-assured
range. Then, the information identifying the fine spinning unit 32 having produced
the actual bobbin that is likely to depart from the quality-assured range is displayed
on the display 16 of the machine controller 11, to notify the operator of the necessity
of maintenance of this fine spinning unit 32.
[0097] As described above, the fine spinning winder 1 of this embodiment includes the spinning
frame 2, the winder 3, and the automatic bobbin feed system 6. The spinning frame
2 includes the plurality of fine spinning units 32 that wind the spun yarns on the
bobbins 23. The winder 3 includes the plurality of rewinding units 31 that unwind
the yarns from the bobbins 23 to form the packages 30. The automatic bobbin feed system
6 transports, to the rewinding unit 31, the tray 50 on which the bobbin 23 wound with
the yarn by the spinning frame 2 is set. The tray 50 has the RF tag 60 capable of
recording thereon the information for identifying the fine spinning unit 32 that has
wound the yarn on the bobbin 23 set on this tray 50. The rewinding unit 31 includes
the clearer 15, the unit control section 10, and the RF reader 5. The clearer 15 detects
the amount of fluff in the yarn. The unit control section 10 calculates the unwound
yarn length that indicates the length of the yarn unwound from the bobbin 23. The
RF reader 5 reads the information from the RF tag 60 corresponding to the bobbin 23
on which the rewinding operation is being performed. The winder 3 includes the quality
inspection section (the machine controller 11 or the CCB 12) for recording the amount
of fluff together with the unwound yarn length obtained when the clearer 15 detected
this amount of fluff, and performing the quality inspection, on a unit basis of the
bobbin 23, on the yarn spun by the fine spinning unit 32.
[0098] Accordingly, the fine spinning unit 32 having performed the spinning can be identified
based on the information in the RF tag 60. Therefore, the quality of the yarn produced
by the fine spinning unit 32 can be examined on a unit basis of the bobbin 23. Additionally,
the quality inspection can be automatically performed concurrently with the rewinding
operation in a production line. This provides laborsaving for the quality inspection
operation. Moreover, since the amount of fluff is recorded in association with the
yarn length, the tendency of occurrence of fluff that indicates a portion of the yarn
where a large amount of fluff occurs can be accurately recognized, which enables the
fluff to be detected and handled efficiently.
[0099] In the fine spinning winder 1 of this embodiment, the fine spinning unit 32 is configured
as a ring spinning unit having the traveler 114.
[0100] Accordingly, since the tendency of occurrence of fluff can be accurately recognized
on a unit basis of the bobbin 23, increase in the amount of fluff throughout the yarn,
which is caused by degradation of the traveler 114 due to abrasion, can also be detected
easily.
[0101] The fine spinning winder 1 of this embodiment is configured as follows. That is,
the fine spinning winder 1 includes the display 16 of the machine controller 11, and
the display 16 is configured to make notification about the fine spinning unit 32
that has been identified as the one requiring maintenance. The management system monitors,
on a unit basis of the bobbin 23, the tendency of occurrence of fluff in the yarn
produced by the same fine spinning unit 32. If the tendency of occurrence of fluff
exhibits a change that satisfies the determination condition as compared with the
previous tendency of occurrence of fluff, the management system causes the display
16 to display the information identifying the fine spinning unit 32, for the notification
to the operator.
[0102] Accordingly, since a change in the tendency of occurrence of fluff is monitored on
a unit basis of the bobbin 23, a change in the amount of fluff caused by a failure
of the fine spinning unit 32 while a system is running can be detected on a unit basis
of the bobbin, and the operator can be notified of the fine spinning unit 32 requiring
maintenance. This allows the operator to promptly handle the failure of the fine spinning
unit 32, thus effectively suppressing deterioration in quality of the yarn rewound
into the package. Moreover, a component part is replaced at a timing when the component
part actually reaches the end of its lifetime and causes a failure. Therefore, the
replacement of only the minimum number of component parts is required, and thus costs
can be reduced efficiently. Furthermore, by analyzing the tendency of occurrence of
fluff (trend data) in each fine spinning unit 32, it is also possible to recognize
time for simultaneous replacement of the travelers 114.
[0103] The management system applied to the fine spinning winder 1 of this embodiment is
configured as follows. That is, if the rewinding operation is interrupted halfway,
the management system records the unwound yarn length information indicating the length
of the unwound yarn obtained at a time when the interruption occurs. When performing
the rewinding operation again using the bobbin 23 on which the rewinding operation
has been interrupted halfway, the management system refers to the aforementioned unwound
yarn length information corresponding to the bobbin 23, and records the amount of
fluff in association with the length of the unwound yarn including consideration for
this unwound yarn length information.
[0104] Accordingly, even when the bobbin 23 on which the rewinding operation has been interrupted
is transported again to the rewinding unit 31, the amount of fluff is recorded based
on the length of the unwound yarn including consideration for the length of the already
rewound yarn. Therefore, a portion where the fluff is detected can be accurately identified.
[0105] While the fine spinning winder 1 according to one embodiment of the present invention
has been described above, the configuration of the fine spinning winder 1 can be appropriately
modified depending on circumstances, as long as the management system of the present
invention is applied thereto. In a possible modification, for example, the rewinding
unit 31 of the winder 3 may include a fluff suppression device. Next, a modification
in which a rewinding unit 231 includes a fluff suppression device 201 will be described
with reference to FIG. 7. FIG. 7 is a side view showing a configuration of the rewinding
unit 231 according to the modification. Since the modification which will be described
below is identical to the above-described embodiment except that a rewinding unit
includes a fluff suppression device, the identical parts will not be described.
[0106] As shown in FIG. 7, in the rewinding unit 231, the fluff suppression device 201 is
provided above the tension applying device 13 (downstream thereof in a yarn travel
direction). The fluff suppression device 201 of this modification includes swirling
flow generation means (not shown in the drawing) for generating a swirling flow. The
swirling flow generated by the swirling flow generation means serves to suppress fluff.
As shown in FIG. 7, the yarn unwound from the bobbin 23 goes through the swirling
flow, and then is rewound into the package 30.
[0107] The fluff suppression device 201 of this modification is configured to adjust the
flow rate of the swirling flow and also to control a timing of generation of the swirling
flow. The fluff suppression device 201 is controlled so as to apply the swirling flow
in accordance with the trend data. To be specific, the intensity of the swirling flow
generated by the fluff suppression device 201 varies based on the trend data. A control
is made such that an enhanced fluff suppression effect can be exerted to a portion
having a large amount of fluff. A method for controlling the fluff suppression device
201 may be appropriately modified depending on circumstances. For example, in consideration
of the fact that the amount of fluff increases immediately before the amount of remaining
yarn reaches zero after a progress of the unwinding, the control may be made so as
to operate the fluff suppression device 201 at such a timing.
[0108] As shown above, in the management system according to the modification, the rewinding
unit 231 includes the fluff suppression device 201 that is controlled based on the
tendency of occurrence of fluff on a unit basis of the bobbin 23.
[0109] Accordingly, fluff is suppressed in accordance with the tendency of occurrence thereof,
and therefore the quality of the yarn rewound into the package 30 can be kept more
uniform.
[0110] Although the embodiment of the present invention has been described above, the above-described
configuration may be modified as follows.
[0111] Although in the embodiment described above, the station number and the doffing information
are stored in the RF tag 60 so that the fine spinning unit is identified, this configuration
may be appropriately modified depending on circumstances. For example, a unique identification
number may be given to the tray 50, so that the bobbin 23 is identified based on the
identification number.
[0112] In a possible configuration, the rewinding unit 31 according to the embodiment described
above may further include an RF writer (data writing part), so that when the rewinding
operation is interrupted, this RF writer stores the unwound yarn length information
in the RF tag 60. In this case, the RF reader 5 reads the RF tag 60 of the tray 50
transported again, and the length of the unwound yarn is calculated with reference
to the unwound yarn length information stored therein.
[0113] The notification means for notifying the operator of the necessity of maintenance
may be appropriately modified. For example, in a possible configuration, a warning
light serving as the notification means may be arranged for each fine spinning unit
32, and if the quality inspection function determines that maintenance is necessary,
the warning light is operated (turned on) to thereby give notification to the operator.
[0114] Although the modification adopts the fluff suppression device that utilizes the swirling
flow, this configuration may be appropriately modified depending on circumstances.
For example, adoptable is a fluff suppression device having a configuration in which
a plurality of friction discs are rotated to thereby impart temporary twist to a spun
yarn traveling between the discs, so that fluff is drawn into fibers, thus implementing
a fluff laying process.
DESCRIPTION OF THE REFERENCE NUMERALS
[0115]
- 1
- fine spinning winder
- 2
- spinning frame
- 3
- winder (automatic winder)
- 4
- RF writer
- 5
- RF reader (data reading part)
- 6
- automatic bobbin feed system (bobbin transport mechanism)
- 11
- machine controller
- 15
- clearer (fluff detection part)
- 16
- display (notification means)
- 23
- bobbin
- 31
- rewinding unit
- 32
- fine spinning unit
- 50
- tray (transporter)
- 60
- RF tag (data recording section)