BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The present invention relates to a yarn winding device adapted to wind a yarn while
traversing.
2. Description of the Related Art
[0002] Conventionally, there is known a yarn winding device in which a winding bobbin is
rotatably supported by a cradle, and adapted to wind a yarn around an outer peripheral
surface of the bobbin to form a package. This type of yarn winding device includes
a yarn winding device having a configuration of changing a winding-angle according
to an increase in a wound diameter of the package, as illustrated in Japanese Unexamined
Patent Publication No.
2007-204191.
[0003] The yarn winding device disclosed in Japanese Unexamined Patent Publication No.
2007-204191 includes a package diameter sensor adapted to detect a package diameter, a traverse
device, and a traverse control section adapted to control the traverse device. The
traverse control section changes a traverse speed (changes the winding-angle) according
to the detected package diameter to prevent a bulge, and the like. In Japanese Unexamined
Patent Publication No.
2007-204191, a shape of the package is not particularly mentioned, but a cheese-shaped package
is illustrated in the drawing.
[0004] As described above, in the yarn winding device, a control for changing a winding
method according to the change in the package diameter (according to advancement in
an winding operation) may be carried out. However, in a cone winding package, a package
diameter differs depending on a position in a winding width direction. Therefore,
in the cone winding package, a control for changing the winding method according to
the change in the package diameter of an end region at a larger-diameter side is normally
carried out.
[0005] Japanese Unexamined Patent Publication No.
3-288769 discloses a configuration in which a yarn layer is divided into an outermost layer
section and an inner layer section based a wound thickness of the package (thickness
of the yarn layer) rather than the package diameter, and a control is carried out
so that a winding-angle when winding the outermost layer section and a winding-angle
when winding the inner layer section become a predetermined ratio. Instead of directly
detecting the thickness of the yarn layer, the yarn winding device estimates the thickness
of the yarn layer according to an elapsed time and changes the winding-angle according
to the estimated value.
[0006] When carrying out a control to suppress the bulge, trial winding of the package may
be carried out before the winding operation to determine a set value necessary for
the control. In this case, an operator simply winds a yarn around a bobbin without
carrying out the control to suppress the bulge to form a trial wound package, actually
examines how the bulge appears in the trial wound package, and then determines a winding-angle
pattern showing how to change the winding-angle accompanying an increase in the wound
thickness of the package. Since how the bulge appears can be predicted from a type
of yarn and a winding condition from an empirical value, the operator may set a prediction
value to determine the winding-angle pattern. Then, the winding operation is carried
out in accordance with the determined winding-angle pattern.
[0007] In the cone winding package, a larger bulge tends to occur on a smaller-diameter
side than a larger-diameter side. Therefore, when determining the above winding-angle
pattern, the winding-angle is desirably defined with respect to a package diameter
on the smaller-diameter side. However, as described above, in the yarn winding device
adapted to wind a yarn into the cone winding package, a package diameter on the larger-diameter
side and the set value are generally associated. Thus, in the conventional yarn winding
device, the winding-angle is required to be defined with respect to the package diameter
on the larger-diameter side while looking at the bulge on the smaller-diameter side
of the package, which may confuse the operator and lead to a setting mistake.
[0008] The yarn winding device of Japanese Unexamined Patent Publication No.
3-288769 determines the wound thickness of the package based on the elapsed time, and thus
cannot respond to a case in which the winding operation is interrupted by yarn joining
and the like. Furthermore, Japanese Unexamined Patent Publication No.
3-288769 describes, in the section of Industrial Application, as being a technique related
to a cheese-shaped or conical package but contents disclosed in embodiments and the
like relate only to the cheese-shaped package and the disclosure is not made on the
conical package.
[0009] EP 1 321 412 A2 discloses a method for forming a wound package of a conical cheese on rotor spinning
machines, wherein a crossing angle in end zones located adjacent ends of the wound
package is increased in respect to a central zone.
BRIEF SUMMARY OF THE INVENTION
[0010] It is an object of the present invention to provide a yarn winding device capable
of effectively suppressing an occurrence of a bulge and the like by changing a winding-angle
and forming a cone winding package of a desired shape, the yarn winding device having
a configuration in which a setting mistake of the winding-angle is less likely to
occur.
[0011] According to an aspect of the present invention, a yarn winding device includes a
winding section, a winding-angle pattern storage section, and a winding control section.
The winding section is adapted to wind a yarn around a conical winding bobbin to form
a conical package. The winding-angle pattern storage section is adapted to store a
winding-angle pattern that associates a thickness of a yarn layer of the package with
a winding-angle. The winding control section is adapted to control the winding section
so as to wind the yarn with the winding-angle determined in accordance with the winding-angle
pattern stored in the winding-angle pattern storage section.
[0012] Since the thickness of the yarn layer of the package does not differ according to
the position in the winding width direction of the package, after trial winding when
determining the winding-angle pattern, the winding-angle pattern can be determined
by simply referencing, for example, the thickness of the yarn layer on the smaller-diameter
side and the package shape on the smaller-diameter side (the larger-diameter side
does not need to be referenced). Therefore, the setting mistake of the winding-angle
pattern can be reduced. Furthermore, the thickness of the yarn layer can be acquired
by simply measuring a distance from an outer peripheral surface of the winding bobbin
. Thus, as compared to the package diameter, the thickness of the yarn layer can be
easily acquired as a highly accurate value. Therefore, by creating the winding-angle
pattern using the thickness of the yarn layer and winding the yarn in accordance with
the relevant winding-angle pattern, the winding-angle can be controlled at satisfactory
accuracy.
[0013] In the above yarn winding device, the winding-angle pattern storage section is preferably
adapted to associate and store the thickness of the yarn layer at any position in
a winding width direction of the package with the winding-angle.
[0014] Accordingly, the winding-angle can be set in association with the thickness of the
yarn layer at any position in the winding width direction of the package (e.g., end
region at the larger-diameter side, end region at the smaller-diameter side, central
part, or the like), and the winding-angle can be accurately controlled according to
various conditions and demands.
[0015] In the above yarn winding device, the winding-angle pattern storage section is preferably
adapted to associate and store the thickness of the yarn layer at a position located
within an end region at a smaller-diameter side in the winding width direction of
the package with the winding-angle.
[0016] Accordingly, the winding-angle pattern can be set using the thickness of the yarn
layer on the smaller-diameter side of the package where the bulge is likely to occur,
and the occurrence of the bulge can be accurately suppressed.
[0017] The above yarn winding device preferably includes an operation section adapted to
be operated for an input of the winding-angle pattern. The winding-angle pattern storage
section is adapted to store the winding-angle pattern that is input via the operation
section.
[0018] Accordingly, the winding section can carry out the winding operation of the package
in accordance with the winding-angle pattern determined through an experience of the
operator, for example.
[0019] The above yarn winding device preferably includes an operation section and a calculation
section. The operation section is adapted to be operated for an input of a thickness
of a yarn layer of a fully-wound package, a default value of the winding-angle, and
an adjusting value for determining a changing amount of the winding-angle. The calculation
section is adapted to calculate the winding-angle pattern in accordance with values
input via the operation section. The winding-angle pattern storage section is adapted
to store the winding-angle pattern calculated by the calculation section.
[0020] Accordingly, while saving work load of the operator to determine and input the winding-angle
pattern, the winding section can carry out the winding operation of the package in
accordance with the appropriate winding-angle pattern calculated by the minimal input
content.
[0021] The above yarn winding device preferably includes a display section adapted to display
the winding-angle pattern stored in the winding-angle pattern storage section. Accordingly,
the operator can appropriately check the set winding-angle pattern.
[0022] In the above yarn winding device, the winding section preferably includes a package
driving section, a traverse section, and a driving section. The package driving section
is adapted to rotationally drive the package. The traverse section is adapted to traverse
the yarn to be wound into the package. The traverse driving section is provided independently
from the package driving section and adapted to drive the traverse section.
[0023] Accordingly, the yarn winding device can drive the traverse section independently
from a rotation of the package, and the control for changing the winding-angle can
be easily carry out.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024]
FIG. 1 is a front view of an automatic winder according to one embodiment of the present
invention;
FIG. 2 is a front view and a block diagram of a winder unit;
FIG. 3 is a schematic side view of a traverse device;
FIG. 4 is a schematic front view of the traverse device;
FIG. 5 is a schematic view illustrating a cross-sectional shape of a package obtained
by trial winding;
FIG. 6A is a diagram illustrating a winding-angle pattern, and FIG. 6B is a diagram
illustrating an input content for causing a calculation section to calculate the winding-angle
pattern; and
FIG. 7 is a graph illustrating a setting example of the winding-angle with respect
to a yarn layer thickness.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0025] Embodiments of the invention will be hereinafter described. First, an overall configuration
of an automatic winder (yarn winding device) 1 according to an embodiment will be
described with reference to FIG. 1. FIG. 1 is a front view of the automatic winder
1 according to one embodiment of the present invention. Herein, "upstream" and "downstream"
respectively refer to upstream and downstream in a travelling direction of a yarn
at the time of yarn winding.
[0026] As illustrated in FIG. 1, the automatic winder (yarn winding device) 1 includes a
plurality of winder units 10 arranged in line, an automatic doffing device 80, and
a main control device 90.
[0027] Each winder unit 10 is configured to wind a yarn 20 unwound from a yarn supplying
bobbin 21 while traversing the yarn 20 to form a package 30.
[0028] When the package 30 is fully wound in one of the winder units 10, the automatic doffing
device 80 travels to a position of the relevant winder unit 10 to collect the fully-wound
package 30 and supply an empty winding bobbin.
[0029] The main control device 90 includes an operation section 91 and a display section
92. The operation section 91 enables an operator to input a predetermined set value
or select an appropriate control method to carry out setting with respect to each
winder unit 10. The display section 92 may display winding status of the yarn 20 in
each winder unit 10, content of trouble that occurred, and the like.
[0030] Next, a description will be made on a detailed configuration of the winder unit 10
with reference to FIG. 2. FIG. 2 is a front view and a block diagram of the winder
unit 10.
[0031] As illustrated in FIG. 2, each winder unit 10 includes a winding unit main body 16,
and a unit control section 50.
[0032] The unit control section 50 includes, for example, a Central Processing Unit (CPU),
and a Read Only Memory (ROM). The ROM stores a program for controlling each component
of the winding unit main body 16. The CPU executes the program stored in the ROM.
The unit control section 50 includes a calculation section 71, a winding-angle pattern
storage section 72, and a winding control section 73. The detailed configuration thereof
will be described later.
[0033] The winding unit main body 16 is configured with a yarn-unwinding assisting device
12, a tension applying device 13, a splicer device 14, a yarn length detecting sensor
61, a clearer (yarn quality measuring equipment) 15, and a winding section 17 arranged
in this order from the yarn supplying bobbin 21 along a yarn travelling path between
the yarn supplying bobbin 21 and the winding bobbin (winding tube) 22.
[0034] The yarn-unwinding assisting device 12 causes a regulation member 40 to make contact
with a balloon formed at an upper part of the yarn supplying bobbin 21 when the yarn
20 unwound from the yarn supplying bobbin 21 is swung around, and controls the balloon
to an appropriate size to assist the unwinding of the yarn 20. A sensor (not illustrated)
for detecting a chase portion of the yarn supplying bobbin 21 is arranged in proximity
to the regulation member 40. When this sensor detects lowering of the chase portion,
the yarn-unwinding assisting device 12 can lower the regulation member 40 by an air
cylinder (not illustrated), for example, following thereto.
[0035] The tension applying device 13 applies a predetermined tension on the travelling
yarn 20. The tension applying device 13 may be a gate-type in which movable comb teeth
37 are arranged with respect to fixed comb teeth 36. The movable comb teeth 37 are
swung by a rotary solenoid 38 or the like, so as to be in a meshed state or a released
state with respect to the fixed comb teeth 36. The tension applying device 13 applies
a predetermined tension on the yarn 20 to be wound, thus improving quality of the
package 30. A disc-type tension applying device 13, for example, may be adopted instead
of the gate-type tension applying device described above.
[0036] The splicer device 14 joins a lower yarn from the yarn supplying bobbin 21 and an
upper yarn from the package 30 after a yarn cut when the clearer 15 detects a yarn
defect and cuts the yarn 20 with a cutter 39, or after a yarn breakage while unwinding
the yarn 20 from the yarn supplying bobbin 21. Such a yarn joining device adapted
to join the upper yarn and the lower yarn may be a mechanical type or a type that
uses fluid such as compressed air.
[0037] The yarn length detecting sensor 61 detects a yarn length of the yarn 20 wound into
the package 30 in a non-contacting manner. The yarn length detecting sensor 61 detects
an amount of hairiness of the yarn 20 to calculate a movement amount of the yarn 20,
and detects the yarn length. Specifically, although not illustrated, the yarn length
detecting sensor 61 includes a plurality of optical hairiness detecting sections having
a light receiving element and a light source along a yarn travelling direction. The
yarn length detecting sensor 61 detects a travelling length of the yarn 20 in accordance
with a change in an output signal of the hairiness detecting sections located at different
positions in the yarn travelling direction.
[0038] The clearer 15 includes a clearer head 49 provided with a sensor (not illustrated)
for detecting a thickness of the yarn 20, and an analyzer 53 for processing a yarn
thickness signal from the sensor. The clearer 15 detects a yarn defect such as slub
by monitoring the yarn thickness signal from the sensor. The cutter 39 is provided
in proximity to the clearer head 49, and immediately cuts the yarn 20 when the clearer
15 detects the yarn defect. The analyzer 53 may be arranged in the unit control section
50.
[0039] A lower yarn guiding pipe 25 for catching the lower yarn from the yarn supplying
bobbin 21 and guiding the lower yarn to the splicer device 14, and an upper yarn guiding
pipe 26 for catching the upper yarn from the package 30 and guiding the upper yarn
to the splicer device 14 are respectively arranged below and above the splicer device
14. The lower yarn guiding pipe 25 and the upper yarn guiding pipe 26 can respectively
swing with shafts 33 and 35 as a center. A suction port 32 is formed at a distal end
of the lower yarn guiding pipe 25. A suction mouth 34 is arranged at a distal end
of the upper yarn guiding pipe 26. An appropriate negative pressure source (not illustrated)
is connected to the lower yarn guiding pipe 25 and the upper yarn guiding pipe 26.
Accordingly, a suction flow is generated at the suction port 32 and the suction mouth
34 to suck and catch yarn ends of the upper yarn and the lower yarn with the upper
yarn guiding pipe 26 and the lower yarn guiding pipe 25.
[0040] The winding unit main body 16 includes a cradle 23 adapted to removably support the
winding bobbin (paper tube or core tube) 22, and a contact roller 29 adapted to be
driven and rotated when brought into contact with a peripheral surface of the winding
bobbin 22 or a peripheral surface of the package 30. The winding unit main body 16
also includes an arm-type traverse device 27 in proximity to the cradle 23 to traverse
the yarn 20 with respect to the surface of the package 30, so that the yarn 20 can
be wound into the package 30 while being traversed with the traverse device 27.
[0041] The winding section 17 includes a cradle 23, a package driving motor (package driving
section) 41, and the traverse device 27.
[0042] The cradle 23 includes a smaller-diameter-side supporting arm 23a for supporting
a smaller-diameter side of the conical (tapered) winding bobbin 22, and a larger-diameter-side
supporting arm 23b for supporting a larger-diameter side of the winding bobbin 22.
The cradle 23 grips the conical winding bobbin 22 with the smaller-diameter-side supporting
arm 23a and the larger-diameter-side supporting arm 23b to rotatably support the conical
winding bobbin 22.
[0043] The cradle 23 can swing with a swing shaft 48 as the center. An increase in a yarn
layer diameter of the package 30 accompanying the winding of the yarn 20 around the
winding bobbin 22 can be absorbed by the swinging of the cradle 23. In other words,
even if the yarn layer diameter of the package 30 changes due to the winding of the
yarn 20, the surface of the package 30 can be appropriately made in contact with the
surface of the contact roller 29. By winding the yarn 20 around the conical winding
bobbin 22, the cradle 23 and the traverse device 27 can form the conical package 30
as illustrated in FIG. 2.
[0044] A package driving motor 41 such as a servo motor is attached to the cradle 23. When
the winding bobbin 22 is rotationally driven by the package driving motor 41, the
yarn 20 is wound around the surface of the winding bobbin 22 (or the surface of the
package 30). A motor shaft of the package driving motor 41 is coupled with the winding
bobbin 22 so as to be relatively non-rotatable when the winding bobbin 22 is supported
by the cradle 23 (so-called direct drive type). An operation of the package driving
motor 41 is controlled by the unit control section 50. A package-driving-motor control
section which is independent from the unit control section 50 may be provided, and
the operation of the package driving motor 41 may be controlled by the package-driving-motor
control section.
[0045] Next, the traverse device 27 will be described. The traverse device 27 includes a
traverse arm (traverse section) 28, a traverse-arm driving motor (traverse driving
section) 45, and a yarn guiding member 52. FIG. 3 and FIG. 4 are respectively a schematic
side view and a front view of the traverse device 27.
[0046] The traverse arm 28 is configured as an elongate arm adapted to swing about a supporting
axis. A traverse guide 11 is connected to a distal end of the traverse arm 28. The
traverse guide 11 is a hook-shape adapted to engage the yarn 20. A basal end of the
traverse arm 28 is fixed to a drive shaft 45a of the traverse-arm driving motor 45.
The traverse-arm driving motor 45 is provided to drive the traverse arm 28 and is
configured by a servo motor. Instead of the servo motor, the traverse-arm driving
motor 45 may be an appropriate motor such as a brushless DC motor, a stepping motor,
or a voice coil motor.
[0047] The traverse device 27 drives the traverse-arm driving motor 45 with the yarn 20
engaged to the traverse guide 11 to reciprocate the traverse arm 28 as illustrated
with an arrow in FIG. 4. As a result, the traverse guide 11 is reciprocated to the
left and the right (winding width direction of the package 30) and the yarn 20 is
traversed with respect to the surface of the package 30 in the left and right direction.
Accordingly, the yarn 20 can be wound around the winding bobbin 22 while being traversed
at a predetermined speed and to a predetermined winding width to form the yarn layer
on the outer peripheral surface of the winding bobbin 22 at a desired density.
[0048] An operation of the traverse-arm driving motor 45 is controlled by the winding control
section 73. However, the operation of the traverse-arm driving motor 45 may be controlled
by the unit control section 50, or a dedicated traverse control section may be provided
for control. The yarn guiding member 52 is arranged upstream of the traverse guide
11 in the yarn travelling direction. The yarn guiding member 52 bends the yarn path
of the yarn 20 located upstream of the yarn guiding member 52 in the yarn travelling
direction towards the contact roller 29 to guide the yarn 20 so as to be caught by
the traverse guide 11.
[0049] As illustrated in FIG. 3, the drive shaft 45a of the traverse-arm driving motor 45
is arranged to form an angle close to parallel with respect to the yarn path of the
yarn 20 located upstream of the yarn guiding member 52 (extended line of the drive
shaft 45a and the yarn path of the yarn 20 form an acute angle) when seen in a direction
of a line connecting one end side and the other end side of a traverse stroke. When
seen in the direction of the line connecting one end side and the other end side of
the traverse stroke, a virtual line connecting a basal end of the traverse arm 28
and the traverse guide 11 is arranged to be substantially orthogonal to the extended
line of the yarn path of the yarn 20 located upstream of the yarn guiding member 52.
The yarn path of the yarn 20 is substantially perpendicular to an installation surface
of the winder unit 10 (horizontal surface in the present embodiment). Therefore, in
the automatic winder 1 of the present embodiment, the traverse guide 11 reciprocates
within a plane substantially parallel to the installation surface of the winder unit
10 (horizontal surface in the present embodiment).
[0050] The processes carried out by the automatic winder 1 to suppress the occurrence of
bulge will now be described with reference to FIG. 4 to FIG. 7. FIG. 5 is a schematic
diagram illustrating a cross-sectional shape of the package 30 obtained by trial winding.
FIG. 6A is a diagram illustrating a winding-angle pattern and FIG. 6B is a diagram
illustrating an input content for causing the calculation section 71 to calculate
the winding-angle pattern. FIG. 7 is a graph illustrating a set example of a winding-angle
with respect to a yarn layer thickness.
[0051] When winding the yarn 20 with a new winding condition, firstly, trial winding is
carried out to check an occurrence degree of the bulge. In such trial winding, a process
for suppressing the occurrence of the bulge, to be described later, is not performed.
[0052] As illustrated with a solid line in FIG. 5, the package 30 having a shape in which
the side surface is bulged out is formed by the trial winding. Such bulging of the
side surface is hereinafter referred to as the bulge. The bulge occurs when the yarn
20 of an intermediate layer of the package 30 is compressed by a tightening force
of the yarn 20 on an outer diameter side and a repulsion force from the winding bobbin
22, thus running out from an end face of the package 30. The running-out amount depends
on the distance (thickness of the yarn layer) from the surface of the winding bobbin
22. In the case of the conical package 30, the bulge is known to significantly appear
(influence of the bulge is large) on the smaller-diameter side than the larger-diameter
side.
[0053] Next, the operator measures the shape of the package 30 obtained by the trial winding,
and determines the winding-angle pattern in accordance with the measurement result.
The winding-angle pattern indicates how to change the winding-angle (see a winding-angle
θ illustrated in FIG. 4) in accordance with the advancement of the winding of the
package 30. In the present embodiment, the winding-angle is an inclination angle of
the yarn 20 on the package 30 with respect to a perpendicular line with respect to
an axis of the winding bobbin 22. However, an intersecting angle of the yarn 20 and
the yarn 20 may be adopted for the winding-angle. In this case, however, a numerical
value of the winding-angle is different from the numerical value of the angle illustrated
in the present embodiment.
[0054] Conventionally, when forming the conical package 30, the winding-angle pattern that
associates the package diameter on the larger-diameter side with the winding-angle
is used. In such a conventional winding-angle pattern, in order to effectively suppress
the occurrence of the bulge on the smaller-diameter side in which the influence of
the bulge is large, the winding-angle needs to be defined with respect to the package
diameter on the larger-diameter side while looking at the degree of bulge appearing
on the smaller-diameter side in the trial wound package. Therefore, a work load of
conversion is cumbersome, and a setting mistake also increases. Furthermore, when
measuring the package diameter on the larger-diameter side, a projecting end or the
like of the winding bobbin 22 may become an obstacle in an accurate measurement. If
the package end on the larger-diameter side changes according to the yarn layer such
as in taper winding, the package diameter differs depending on a measurement position
(the same applies to the smaller-diameter side of the package 30).
[0055] In the present embodiment, the winding-angle pattern that associates the thickness
of the yarn layer with the winding-angle is used. Since the thickness of the yarn
layer does not differ according to the position in the winding width direction, the
winding-angle pattern can be determined by simply referencing the thickness of the
yarn layer on the smaller-diameter side and the package shape on the smaller-diameter
side (thickness of the yarn layer on the larger-diameter side of the package 30 and
the package shape on the larger-diameter side do not need to be referenced). The thickness
of the yarn layer of the package 30 can be easily obtained by measuring the distance
from the outer peripheral surface of the winding bobbin 22. Therefore, the operator
places a ruler on a side surface of the yarn layer of the trially wound package 30
(in particular, side surface on the smaller-diameter side of the package 30) with
the ruler directed perpendicular to the outer peripheral surface of the winding bobbin
22 to examine where or how many mm from the surface of the winding bobbin 22, the
running-out (bulge) of the yarn layer of about how many mm is appearing. The operator
can directly designate the winding-angle pattern in accordance with the examined result.
Therefore, the direct designation can be made at the time of the setting of the winding-angle
pattern, and the occurrence of the setting mistake as described above can be prevented.
[0056] In the present embodiment, the winding-angle pattern can be set through roughly two
methods. A first setting method is a method in which the operator determines the winding-angle
pattern in accordance with a comparison result of the thickness of the yarn layer
and the bulge shape, and manually inputs the determined winding-angle pattern (e.g.,
content illustrated in FIG. 6A) using the operation section 91. The input winding-angle
pattern is stored in the winding-angle pattern storage section 72 of each winder unit
10.
[0057] In the second setting method, firstly, in accordance with the comparison result of
the thickness of the yarn layer and the bulge shape, the operator determines a final
yarn layer thickness, which is a thickness of the yarn layer of the fully-wound package
30, a default value of the winding-angle to be set, and a winding-angle adjusting
value, which is a value for determining a changing amount of the winding-angle (see
FIG. 6B). The operator inputs the determined value by operating the operation section
91. The input content is output to the calculation section 71 of each winder unit
10. From the above three input values, the calculation section 71 can automatically
generate the winding-angle pattern (content as illustrated in FIG. 6A) for suppressing
the bulge through calculation. The parameters corresponding to the yarn layer thicknesses
of 20 mm and 70 mm in FIG. 6A are calculated by appropriately using a relational expression
or the like obtained theoretically or empirically and stored in the calculation section
71 in advance. The created winding-angle pattern is stored in the winding-angle pattern
storage section 72 of each winder unit 10.
[0058] The winding-angle pattern is set in the above manner. The operator operates the operation
section 91 to display the set winding-angle pattern on the display section 92 in a
form of a table as illustrated in FIG. 6A or display the set winding-angle pattern
in a form of a graph as illustrated in FIG. 7. Accordingly, the operator can appropriately
check the set winding-angle pattern.
[0059] The winding control section 73 controls the winding section 17 to wind the yarn 20
in accordance with the winding-angle pattern stored in the winding-angle pattern storage
section 72. A description will be made on the control carried out by the winding control
section 73 in accordance with the winding-angle pattern illustrated in FIG. 7. The
winding control section 73 first controls the traverse device 27 (specifically, the
traverse-arm driving motor 45) such that the winding-angle is 12.5 degrees (a default
value of the winding-angle) to wind the yarn 20 by the winding section 17.
[0060] In accordance with the yarn length detected by the yarn length detecting sensor 61
and the type (yarn count or the like) of the yarn 20 set in the main control device
90 or the like in advance, the winding control section 73 obtains the thickness of
the yarn layer of the package 30 at a predetermined interval during the winding of
the yarn 20. The winding control section 73 controls the traverse device 27 so that
the winding-angle becomes greater as the thickness of the yarn layer increases. After
the obtained thickness of the yarn layer becomes 20 mm, the winding control section
73 stops the control for increasing the winding-angle, and controls the traverse device
27 so that the winding-angle is maintained at 14.5 degrees.
[0061] After the obtained thickness of the yarn layer becomes 70 mm, the winding control
section 73 controls the traverse device 27 such that the winding-angle becomes smaller
as the thickness of the yarn layer increases. According to such a control, the winder
unit 10 can form the package 30 in which the occurrence of the bulge is effectively
suppressed.
[0062] Generally, if the traverse section and the package are independently drivable, from
the viewpoint of winding control, various settings and controls are sometimes desirably
carried out using the package diameter at the central part in the winding width direction
of the package. If the package is conical as described above, various settings and
controls are generally carried out using the package diameter on the larger-diameter
side. Therefore, as in the present embodiment, if the traverse arm 28 and the package
30 are independently drivable and the package 30 is conical, it is difficult to determine
the package diameter of which position in the winding width direction of the package
30 is to be used to carry out the control, and the operator may get confused. In the
present embodiment, since the control is carried out using the thickness of the yarn
layer of which value does not change according to the position in the winding width
direction of the package 30, the confusion of the operator can be prevented.
[0063] As described above, the automatic winder 1 of the present embodiment includes the
winding section 17, the winding-angle pattern storage section 72, and the winding
control section 73. The winding section 17 winds the yarn 20 around the winding bobbin
22 to form the conical package 30. The winding-angle pattern storage section 72 stores
the winding-angle pattern that associates the thickness of the yarn layer of the package
30 with the winding-angle. The winding control section 73 controls the winding section
17 so that the yarn 20 is wound at the winding-angle determined in accordance with
the winding-angle pattern stored in the winding-angle pattern storage section 72.
[0064] Accordingly, since the thickness of the yarn layer does not differ according to the
position in the winding width direction, after the trial winding in determining the
winding-angle pattern, the winding-angle pattern can be determined by simply referencing,
for example, the thickness of the yarn layer on the smaller-diameter side and the
package shape on the smaller-diameter side (the larger-diameter side does not need
to be referenced). Therefore, the setting mistake of the winding-angle pattern can
be reduced. Furthermore, the thickness of the yarn layer can be acquired by simply
measuring the distance from the outer peripheral surface of the winding bobbin 22.
Thus, the thickness of the yarn layer can be easily acquired as a highly accurate
value compared to the package diameter. Therefore, by creating the winding-angle pattern
using the thickness of the yarn layer and winding the yarn 20 in accordance with the
winding-angle pattern, the winding-angle can be controlled at satisfactory accuracy.
[0065] In the automatic winder 1 of the present embodiment, the winding-angle pattern storage
section 72 associates and stores the thickness of the yarn layer at a position located
within an end region at a smaller-diameter side in the winding width direction of
the package 30 with the winding-angle. Accordingly, the winding-angle pattern can
be set using the thickness of the yarn layer on the smaller-diameter side where the
bulge easily occurs, and the occurrence of the bulge can be accurately suppressed.
[0066] The automatic winder 1 of the present embodiment includes an operation section 91
adapted to be operated for an input of the winding-angle pattern. The winding-angle
pattern storage section 72 stores the winding-angle pattern that is input via the
operation section 91. Accordingly, the automatic winder 1 can carry out the winding
operation of the package 30 in accordance with the winding-angle pattern determined
through the experience of the operator, for example.
[0067] The automatic winder 1 of the present embodiment includes the operation section 91
and the calculation section 71. The operation section 91 is adapted to be operated
for an input of a thickness of a yarn layer of a fully-wound package, a default value
of the winding-angle, and an adjusting value for determining a changing amount of
the winding-angle. The calculation section 71 is adapted to calculate the winding-angle
pattern in accordance with values input via the operation section 91. The winding-angle
pattern storage section 72 is adapted to store the winding-angle pattern calculated
by the calculation section 71.
[0068] Accordingly, while saving the work load of the operator to determine and input the
winding-angle pattern, the winding section 17 can carry out the winding operation
of the package 30 in accordance with the appropriate winding-angle pattern calculated
by the minimal input content.
[0069] The automatic winder 1 of the present embodiment includes a display section 92 adapted
to display the winding-angle pattern stored in the winding-angle pattern storage section
72. Accordingly, the operator can appropriately check the set winding-angle pattern.
[0070] In the automatic winder 1 of the present embodiment, the winding section 17 includes
the package driving motor 41, the traverse arm 28, and the traverse arm driving motor
45. The package driving motor 41 is adapted to rotationally drive the package 30.
The traverse arm 28 is adapted traverse the yarn 20 to be wound into the package 30.
The traverse arm driving motor 45 is provided independently from the package driving
motor 41 and is adapted to drive the traverse arm 28. Accordingly, the automatic winder
1 can drive the traverse arm 28 independently from the rotation of the package 30,
and the control of changing the winding-angle can be easily carried out.
[0071] The preferred embodiments of the present invention have been described above, but
the above configurations may be modified as below.
[0072] The operation section 91 and the display section 92 are not limited to the configuration
of being arranged in the main control device 90, and may be arranged for every winder
unit 10. The calculation section 71 and the winding-angle pattern storage section
72 are not limited to the configuration of being arranged for every winder unit 10,
and may be arranged in the main control device 90.
[0073] In the embodiment described above, the thickness of the yarn layer of the package
30 is calculated in accordance with the yarn length detected by the yarn length detecting
sensor 61, and the winding condition set in the main control device 90. Alternatively,
for example, by storing in advance the relationship (obtained empirically) of the
length of the yarn 20 to be wound into the package 30 and the thickness of the yarn
layer of the package 30, such calculation may be omitted.
[0074] As the configuration of obtaining the thickness of the yarn layer of the package
30, an angle sensor for detecting an angle of the cradle 23 (swing angle about the
swing shaft 48) may be used. The angle sensor includes a rotary encoder, for example,
and transmits an angle signal corresponding to the angle of the cradle 23 to the unit
control section 50. Since the angle of the cradle 23 changes accompanying the increase
in the wound diameter of the package 30, the package diameter can be detected by detecting
the angle with the angle sensor. The thickness of the yarn layer of the package 30
can be calculated by subtracting the diameter of the winding bobbin 22 from the detected
package diameter. As the method of detecting the package diameter, an appropriate
configuration such as a method using an analog sensor or an absolute type sensor may
be used other than the angle sensor.
[0075] As the configuration for obtaining the thickness of the yarn layer of the package
30, a timer capable of measuring the elapsed time can be used. In this case, a temporal
change in the thickness of the yarn layer is defined in advance through calculation
or empirical value in accordance with the winding condition. Then, the thickness of
the yarn layer is obtained in accordance with the defined value and the measured elapsed
time. The timer can measure the elapsed time, while taking into consideration the
time the winding was interrupted by yarn cut or yarn breakage.
[0076] In addition, the thickness of the yarn layer of the package 30 can be obtained using
the travelling length of the yarn 20 detected by the yarn length detecting sensor
61. Specifically, the winding-angle can be calculated in accordance with the yarn
travelling speed calculated from the yarn travelling length detected by the yarn length
detecting sensor 61, and the traverse speed. Then, the package diameter is calculated
in accordance with the winding-angle, the peripheral speed of the package 30, and
the number of rotations of the package 30. By subtracting the diameter of the winding
bobbin 22 from the calculated package diameter, the thickness of the yarn layer can
be obtained.
[0077] An example of a general cone winding package has been described in the above embodiments
by way of example, but the present invention can also be applied to a cone winding
package of which an end surface is tapered.
[0078] In place of the arm-type traverse device as described above, the traverse device
27 may be a belt-type traverse device adapted to reciprocate the traverse guide to
left and right by belt drive, a rotary-type traverse device using a rotary blade,
or a rod-type traverse device adapted to reciprocate a rod to which a traverse guide
is attached.
[0079] As described above, the traverse device 27 is not limited to a configuration of reciprocating
the traverse arm 28 within a substantially horizontal plane with respect to the installation
surface of the winder unit 10. For example, as in Japanese Unexamined Patent Publication
No.
2007-204191, a configuration (conventional configuration) may be adopted in which the longitudinal
direction of the traverse arm is substantially perpendicular to the installation surface
of the winder unit.
[0080] The package driving motor 41 is not limited to a servo motor, and may be various
types of motors such as a step motor or an induction motor, The contact roller 29
may be driven with an appropriate driving device and the package 30 may be rotated
accompanying the rotation of the contact roller 29.
[0081] In the embodiments described above, the winding-angle pattern that associates the
thickness of the yarn layer of the end region at the smaller-diameter side with the
winding-angle is used. However, instead of the thickness of the yarn layer on the
smaller-diameter side, for example, the winding-angle pattern may be used that associates
the winding-angle with the thickness of the yarn layer at an arbitrary position in
the winding width direction of the package 30 such as the thickness of the yarn layer
on the larger-diameter side or the thickness of the yarn layer at the central part
in the winding width direction. Instead of being set to a broken-line shape as in
FIG. 7, the winding-angle pattern may be set with an appropriate curve such as a polynomial
curve.
[0082] The present invention is not limited to the automatic winder, and may be applied
to other yarn winding devices such as a re-winding machine, a fine spinning machine
(e.g., an air-jet spinning machine, an open-end spinning machine, or the like).
1. Eine Garnwickelvorrichtung, die folgende Merkmale aufweist:
einen Wickelabschnitt (17), der angepasst ist, um ein Garn (20) um eine konische Wickelspule
(22) zu wickeln, um einen konischen Wickelkörper (30) zu bilden;
dadurch gekennzeichnet, dass dieselbe ferner folgende Merkmale aufweist:
einen Wickelwinkelmusterspeicherabschnitt (72), der angepasst ist, um ein Wickelwinkelmuster
zu speichern, das eine Dicke einer Garnschicht des Garnkörpers (30) einem Wickelwinkel
zuordnet; und
einen Wickelsteuerabschnitt (73), der angepasst ist, um den Wickelabschnitt (17) zu
steuern, um das Garn (20) mit dem Wickelwinkel zu wickeln, der gemäß dem Wickelwinkelmuster
bestimmt wird, das in dem Wickelwinkelmusterspeicherabschnitt (72) gespeichert ist.
2. Die Garnwickelvorrichtung gemäß Anspruch 1, bei der der Wickelwinkelmusterspeicherabschnitt
(72) angepasst ist, um die Dicke der Garnschicht an jeder Position in einer Wickelbreiterichtung
des Garnkörpers (30) dem Wickelwinkel zuzuordnen und zu speichern.
3. Die Garnwickelvorrichtung gemäß Anspruch 2, bei der der Wickelwinkelmusterspeicherabschnitt
(72) angepasst ist, um die Dicke der Garnschicht an einer Position, die innerhalb
einer Endregion an einer Seite mit kleinerem Durchmesser in der Wicklelbreiterichtung
des Garnkörpers (30) angeordnet ist, dem Wickelwinkel zuzuordnen und zu speichern.
4. Die Garnwickelvorrichtung gemäß einem der Ansprüche 1 bis 3, die ferner einen Betriebsabschnitt
(91) aufweist, der angepasst ist, um für eine Eingabe des Wickelwinkelmusters angepasst
zu sein, wobei der Wickelwinkelmusterspeicherabschnitt (72) angepasst ist, um das
Wickelwinkelmuster zu speichern, das über den Betriebsabschnitt (91) eingegeben wird.
5. Die Garnwickelvorrichtung gemäß einem der Ansprüche 1 bis 3, die ferner folgende Merkmale
aufweist:
einen Betriebsabschnitt (91), der angepasst ist, um für eine Eingabe einer Dicke einer
Garnschicht eines vollständig gewickelten Garnkörpers (30), eines Vorgabewerts des
Wickelwinkels und eines Einstellwerts zum Bestimmen eines Änderungsbetrags des Wickelwinkels
betrieben zu werden; und
einen Berechnungsabschnitt (71), der angepasst ist, um das Wickelwinkelmuster gemäß
Werten zu berechnen, die über den Betriebsabschnitt (91) eingegeben werden,
wobei der Wickelwinkelmusterspeicherabschnitt (72) angepasst ist, um das durch den
Berechnungsabschnitt (71) berechnete Wickelwinkelmuster zu speichern.
6. Die Garnwickelvorrichtung gemäß einem der Ansprüche 1 bis 5, die ferner einen Anzeigeabschnitt
(92) aufweist, der angepasst ist, um das Wickelwinkelmuster anzuzeigen, das in dem
Wickelwinkelmusterspeicherabschnitt (72) gespeichert ist.
7. Die Garnwickelvorrichtung gemäß einem der Ansprüche 1 bis 6, bei der der Wickelabschnitt
(17) folgende Merkmale umfasst:
einen Garnkörperantriebsabschnitt (41), der angepasst ist, um den Garnkörper (30)
drehend anzutreiben;
einen Traversierabschnitt (28), der angepasst ist, um das Garn (20), das in den Garnkörper
(30) gewickelt werden soll, zu traversieren; und
einen Traversierantriebsabschnitt (45), der unabhängig von dem Garnkörperantriebsabschnitt
(41) vorgesehen ist und angepasst ist, um den Traversierabschnitt (28) abzutreiben.