AUTOMATIC WINDER, YARN WINDING SYSTEM, AND YARN WINDING METHOD

Abstract

 An automatic winder 4 includes an acquisition unit 45 configured to acquire information related to quality of yarn 14 travelling from a yarn supply bobbin 11 toward a package 15 and a controller 41 configured to control a winding speed at which yarn 14 is wound from the yarn supply bobbin 11. The controller 41 controls the winding speed, based on a quality index of yarn based on the information related to quality acquired by the acquisition unit 45 and a preset index threshold range related to quality of yarn 14, such that the quality index falls within an index threshold range.

Description

Technical Field

[0001] The present invention relates to an automatic winder, a yarn winding system, and a yarn winding method.

Background Art

[0002] Conventionally, a yarn winding system is known, which includes a spinning frame having a plurality of spinning units to form yarn supply bobbins and an automatic winder having a plurality of winder units to wind yarn from the yarn supply bobbins to form packages (for example, see Patent Literature 1).

Citation List

Patent Literature

[0003] [Patent Literature 1] Japanese Examined Patent Publication No. H6-76177

Summary of Invention

Technical Problem

[0004] In the yarn winding system as described above, the optimization of operation of the automatic winder has been desired in view of improving production efficiency and/or working quality. In a yarn winding system, as an example of the optimization of operation control, the yarn winding speed in the automatic winder may be changed according to the processing status of forming a yarn supply bobbin in the spinning frame. With this configuration, in the yarn winding system, the winding speed of the automatic winder can be controlled appropriately based on the processing status of forming a yarn supply bobbin in the spinning frame (for example, the supply timing of a yarn supply bobbin transferred from the spinning frame to the automatic winder) . Here, in the automatic winder, when the yarn winding speed is changed, for example, the amount of hairiness may change to cause a change in yarn quality. It is undesirable that the yarn quality changes in the middle of forming a package.

[0005] An aspect of the present invention aims to provide an automatic winder, a yarn winding system, and a yarn winding method that can reduce changes in yarn quality in the middle of forming a package.

Solution to Problem

[0006] An automatic winder according to an aspect of the present invention winds yarn from a yarn supply bobbin to form a package. The automatic winder includes an acquisition unit configured to acquire information related to quality of the yarn travelling from the yarn supply bobbin toward the package and a controller configured to control a winding speed at which the yarn is wound from the yarn supply bobbin. The controller controls the winding speed, based on a quality index of the yarn based on the information related to quality acquired by the acquisition unit and a preset index threshold range related to quality of the yarn, such that the quality index falls within the index threshold range.

[0007] The automatic winder according to an aspect of the present invention includes an acquisition unit configured to acquire information related to quality of the yarn. In the automatic winder, the controller controls the winding speed, based on a quality index of the yarn based on the information related to quality acquired by the acquisition unit and a preset index threshold range related to quality of the yarn, such that the quality index falls within the index threshold range. In the automatic winder with this configuration, yarn is wound such that the quality of yarn is within a certain range. In the automatic winder, therefore, changes in yarn quality in the middle of forming a package can be reduced.

[0008] In an embodiment, the acquisition unit may acquire at least information about hairiness of the yarn. The winding speed affects, in particular, the amount of hairiness of yarn. The amount of hairiness has a large effect on the yarn quality. In the automatic winder, therefore, at least information about hairiness is acquired by the acquisition unit as the information related to quality, and the winding speed is controlled such that the quality index falls within the index threshold range, whereby changes in yarn quality in the middle of forming a package can be reduced appropriately.

[0009] In an embodiment, the acquisition unit may acquire information about a defect of the yarn. A defect of yarn has a large effect on yarn quality. In the automatic winder, therefore, information about a detect of yarn is acquired by the acquisition unit as the information related to quality, and the winding speed is controlled such that the quality index falls within the index threshold range, whereby changes in yarn quality in the middle of forming a package can be reduced appropriately.

[0010] In an embodiment, the automatic winder may further include a receiver configured to receive spinning information transmitted from a spinning frame configured to form the yarn supply bobbin. The spinning information includes information about a processing status of forming the yarn supply bobbin. The controller may set a target value of the winding speed based on the spinning information received by the receiver and may change the winding speed toward the target value such that the quality index falls within the index threshold range. When the winding speed of the automatic winder is controlled based on a processing status of forming a yarn supply bobbin in the spinning frame, the yarn quality may change with a change in winding speed. Thus, when the winding speed of the automatic winder is controlled based on a processing status of forming a yarn supply bobbin in the spinning frame, controlling the winding speed such that the quality index falls within the index threshold range is particularly effective in reducing changes in yarn quality in the middle of forming a package.

[0011] In an embodiment, the automatic winder may further include an input unit configured to accept input of an upper limit value and a lower limit value of the winding speed. The controller may control the winding speed within a range of the upper limit value and the lower limit value. In this configuration, the winding speed is set within a range of the upper limit value and the lower limit value. This configuration can prevent control unintended by the operator.

[0012] In an embodiment, the controller may calculate a margin based on the quality index and the index threshold range and may calculate the amount of change in the winding speed based on the margin to control the winding speed in accordance with the amount of change in the winding speed. In this configuration, since the amount of change in winding speed is calculated in accordance with the margin and the winding speed is controlled in accordance with the amount of change, the winding speed can be controlled such that the quality index falls within the index threshold range.

[0013] In an embodiment, the controller may increase the amount of change in the winding speed as the margin is higher and may reduce the amount of change in the winding speed as the margin is lower. The degree of margin is high when the difference between the quality index and the index threshold is large, and the degree of margin is small when the difference between the quality index and the index threshold is small. The amount of change in winding speed is therefore adjusted in accordance with the degree of margin, whereby yarn can be wound at an appropriate winding speed in accordance with the quality index.

[0014] In an embodiment, the acquisition unit may be a yarn monitoring device having a slit to allow the yarn to pass through to monitor a state of the yarn passing through the slit. In this configuration, information related to quality of yarn can be acquired accurately.

[0015] In an embodiment, the automatic winder may further include another acquisition unit different from the yarn monitoring device. The controller may control the winding speed based on information acquired by the yarn monitoring device and information acquired by the different acquisition unit. The information acquired by the different acquisition unit may be at least one of information about winding tension with which the yarn is wound into the package, information about vibration, and information about a traverse defect related to traverse of the yarn. In this configuration, the winding speed even more suitable for the yarn quality can be set. Alternatively, the winding speed suitable for the quality as a package can also be set.

[0016] A yarn winding system according to an aspect of the present invention includes a spinning frame configured to form a yarn supply bobbin and an automatic winder configured to wind yarn from the yarn supply bobbin to form a package. The spinning frame includes a generator configured to generate spinning information including information about a processing status of forming the yarn supply bobbin and a transmitter configured to transmit the spinning information generated by the generator to the automatic winder. The automatic winder includes a receiver configured to receive the spinning information, an acquisition unit configured to acquire information related to quality of the yarn travelling from the yarn supply bobbin toward the package, and a controller configured to control a winding speed at which the yarn is wound from the yarn supply bobbin. The controller sets a target value of the winding speed based on the spinning information received by the receiver and changes the winding speed toward the target value, based on a quality index of the yarn based on the information related to quality acquired by the acquisition unit and a preset index threshold range related to quality of the yarn, such that the quality index falls within the index threshold range.

[0017] In the yarn winding system according to an aspect of the present invention, the automatic winder includes an acquisition unit configured to acquire information related to quality of the yarn. In the automatic winder, the controller controls the winding speed, based on a quality index of the yarn based on the information related to quality acquired by the acquisition unit and a preset index threshold range related to quality of the yarn, such that the quality index falls within the index threshold range. In the yarn winding system, when the winding speed of the automatic winder is controlled based on a processing status of forming a yarn supply bobbin in the spinning frame, the yarn quality may change with a change in winding speed. In the yarn winding system, therefore, when the winding speed of the automatic winder is controlled based on a processing status of forming a yarn supply bobbin in the spinning frame, the winding speed is controlled such that the quality index falls within the index threshold range, whereby changes in yarn quality in the middle of forming a package can be reduced.

[0018] A yarn winding method according to an aspect of the present invention is performed by a spinning frame configured to form a yarn supply bobbin and an automatic winder configured to wind yarn from the yarn supply bobbin to form a package. The yarn winding method includes a generation step of generating spinning information including information about a processing status of forming the yarn supply bobbin, in the spinning frame, a transmission step of transmitting the spinning information generated at the generation step to the automatic winder, in the spinning frame, a reception step of receiving the spinning information, in the automatic winder, an acquisition step of acquiring information related to quality of the yarn travelling from the yarn supply bobbin to the package, in the automatic winder, and a control step of controlling a winding speed at which the yarn is wound from the yarn supply bobbin, in the automatic winder. In the control step, a target value of the winding speed is set based on the spinning information received at the reception step, and the winding speed is changed toward the target value, based on a quality index of the yarn based on the information related to quality acquired at the acquisition step and a preset index threshold range related to quality of the yarn, such that the quality index falls within the index threshold range.

[0019] In the yarn winding method according to an aspect of the present invention, information related to quality of the yarn is acquired in the automatic winder. In the control step in the automatic winder, the winding speed is controlled, based on a quality index of the yarn based on the information related to quality acquired at the acquisition step and a preset index threshold range related to quality of the yarn, such that the quality index falls within the index threshold range. In the yarn winding method, when the winding speed of the automatic winder is controlled based on a processing status of forming a yarn supply bobbin in the spinning frame, the yarn quality may change with a change in winding speed. In the yarn winding method, therefore, when the winding speed of the automatic winder is controlled based on a processing status of forming a yarn supply bobbin in the spinning frame, the winding speed is controlled such that the quality index falls within the index threshold range, whereby changes in yarn quality in the middle of forming a package can be reduced.

Advantageous Effects of Invention

[0020] According to an aspect of the present invention, changes in yarn quality in the middle of forming a package can be reduced.

Brief Description of Drawings

[0021] 

FIG. 1 is a front view of a yarn winding system according to an embodiment.

FIG. 2 is a side view of a spinning unit of the yarn winding system in FIG. 1.

FIG. 3 is a side view of a winder unit of the yarn winding system in FIG. 1.

FIG. 4 is a block diagram illustrating a functional configuration of the yarn winding system in FIG. 1.

FIG. 5 is a flowchart illustrating the operation of an automatic winder.

FIG. 6 is a flowchart illustrating the operation of the automatic winder.

FIG. 7 is a flowchart illustrating the operation of the automatic winder.

Description of Embodiments

[0022] Preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings. In a description of the drawings, the same or corresponding elements are denoted by the same reference signs and an overlapping description is omitted.

[0023] As illustrated in FIG. 1, a yarn winding system 1 includes a roving frame 2, a spinning frame 3, and an automatic winder 4. The roving frame 2 generates roved yarn from a sliver and winds the roved yarn to form a roved yarn bobbin. The spinning frame 3 generates yarn from the roved yarn and winds the generated yarn to form a yarn supply bobbin 11. The automatic winder 4 winds yarn from the yarn supply bobbin 11 to form a package.

[0024] The automatic winder 4 has a bobbin transfer device 5. The bobbin transfer device 5 transfers a yarn supply bobbin 11 from the spinning frame 3 to the automatic winder 4 and transfers an empty bobbin 12 (a bobbin having no yarn wound thereon) from the automatic winder 4 to the spinning frame 3. The bobbin transfer device 5 is provided with a bobbin preparation device 7, a residual yarn processing device (not shown), and the like. The bobbin preparation device 7 performs preparation for the automatic winder 4 to process yarn on a yarn supply bobbin 11. When yarn is left on a bobbin 12 ejected from the yarn supply bobbin 11, the residual yarn processing device removes the left yarn to produce an empty bobbin 12. Thus, the bobbin transfer device 5 has a complicated guide path with many curves.

[0025] As illustrated in FIG. 1, the roving frame 2 includes a control device 21 configured to control the operation of the roving frame 2 and a plurality of roving units 22 configured to form roved yarn bobbins. The control device 21 has a display unit 21a such as a display and an operation unit 21b such as an input key. The display unit 21a displays, for example, the operating status of each roving unit 22. The operation unit 21b is used by the operator to make settings of the operating condition of each roving unit 22.

[0026] The spinning frame 3 includes a control device 31 configured to control the operation of the spinning frame 3 and a plurality of spinning units 32 configured to form yarn supply bobbins 11. The control device 31 has a display unit 31a such as a display and an operation unit 31b such as an input key. The display unit 31a displays, for example, the operating status of each spinning unit 32. The operation unit 31b is used by the operator to make settings of the operating condition of each spinning unit 32.

[0027] As illustrated in FIG. 2, the spinning unit 32 has a drafting device 33 and a twisting device 34.

[0028] The drafting device 33 has a back roller pair 33a, a middle roller pair 33b, and a front roller pair 33c. The back roller pair 33a, the middle roller pair 33b, and the front roller pair 33c are each configured with a bottom roller and a top roller. An apron belt is looped around each roller of the middle roller pair 33b. In the drafting device 33, the back roller pair 33a, the middle roller pair 33b, and the front roller pair 33c are rotated at a predetermined speed ratio, whereby the roved yarn 13 unwound from a roved yarn bobbin is drafted.

[0029] The twisting device 34 has a hollow guide shaft 35, a ring rail 36, a ring 37, and a traveller 38. The hollow guide shaft 35 holds a bottom portion 12a of the bobbin 12 with a top portion 12b of the bobbin 12 facing upward and rotates the bobbin 12. The ring rail 36 is movable in the axial direction of the bobbin 12. The ring 37 is fixed to the ring rail 36. The traveller 38 is supported by the ring 37 and movable along the ring 37.

[0030] In the twisting device 34, the roved yarn 13 drafted in the drafting device 33 is inserted into a gap between the ring 37 and the traveller 38, and an end of the roved yarn 13 is fixed to the bobbin 12. In this state, the hollow guide shaft 35 rotates the bobbin 12, so that the traveller 38 moves along the ring 37 so as to be pulled by the roved yarn 13. At this moment, the ring rail 36 gradually moves from the bottom portion 12a side to the top portion 12b side while reciprocating in a predetermined range along the axial direction of the bobbin 12. In the twisting device 34, the rotation of the traveller 38 lags behind the rotation of the bobbin 12, whereby the roved yarn 13 is twisted to produce yarn 14. The yarn 14 is then wound onto the bobbin 12 to form a yarn supply bobbin 11.

[0031] The spinning frame 3 having a plurality of spinning units 32 configured as described above is configured as a simultaneous doffing type. More specifically, the spinning frame 3 is stocked with a plurality of empty bobbins 12 transferred by the bobbin transfer device 5 from the automatic winder 4 and simultaneously sets the empty bobbins 12 in the spinning units 32 to simultaneously start winding of yarn. When winding of yarn is finished and a yarn supply bobbin 11 is formed in each spinning unit 32, the spinning frame 3 simultaneously doffs all the yarn supply bobbins 11. The spinning frame 3 then takes out empty bobbins 12 in stock in the meantime from the tray 6, simultaneously sets the empty bobbins 12 in the spinning units 32, and simultaneously sets the doffed yarn supply bobbins 11 in the tray 6 instead.

[0032] As illustrated in FIG. 1, the automatic winder 4 includes a control device (controller) 41 configured to control the operation of the automatic winder 4, a plurality of winder units 42 configured to form packages, and the bobbin transfer device 5. The control device 41 has a display unit 41a such as a display and an operation unit (input unit) 41b such as an input key. The display unit 41a displays, for example, the operating status of each winder unit 42. The operation unit 41b is used by the operator to make settings of the operating condition of each winder unit 42. The control device 41 also controls the operation of the bobbin transfer device 5.

[0033] As illustrated in FIG. 3, the winder unit 42 has a winding device 43, a tension applying device 44, a yarn monitoring device (acquisition unit) 45, an upper yarn catching device 46, a lower yarn catching device 47, and a yarn joining device 48.

[0034] The winding device 43 includes a cradle 43a and a winding drum 43b. The cradle 43a supports a package 15. The winding drum 43b has a traverse groove and rotates the package 15 while allowing the yarn 14 to traverse. With this configuration, yarn 14 is wound from a yarn supply bobbin 11 set at a predetermined position to form a package 15. The tension applying device 44 applies a predetermined tension to yarn 14 travelling from the yarn supply bobbin 11 toward the package 15. The winding device 43 may be configured such that the winding drum 43b does not allow yarn 14 to traverse. In this configuration, the winding drum 43b does not have a traverse groove, and a traverse mechanism (for example, a traverse arm and a motor) maybe provided separately from the winding drum 43b so that the traverse mechanism may allow yarn 14 to traverse.

[0035] The yarn monitoring device 45 monitors a state of yarn 14 travelling through a yarn path (travelling from the yarn supply bobbin 11 toward the package 15). The yarn monitoring device 45 monitors a state of yarn 14 to acquire information related to the quality of yarn 14, such as a hairiness index of yarn 14 (information about hairiness), information about the thickness irregularity of yarn 14, the IPI value of yarn 14 (the counted numbers of extremely thick portions, extremely thin portions, and neps (snags) per unit length of yarn 14), the number of defects of yarn 14, the number of remaining defects, and the number of cuts (the number of yarn breakages) . The information about the thickness irregularity of yarn 14, the IPI value of yarn 14, the number of defects of yarn 14, and the number of remaining defects are information about a defect of yarn 14.

[0036] The yarn monitoring device 45 has a slit to allow yarn 14 to pass through in the yarn path of yarn 14 and monitors the yarn 14 passing through the slit with a not-shown optical sensor. The yarn monitoring device 45 outputs information related to quality (hereinafter may be referred to as "quality information") to the control device 41. In the vicinity of the yarn monitoring device 45, a cutter (not shown) is provided for cutting yarn 14. The yarn monitoring device 45 actuates the cutter when detecting a defect of yarn 14.

[0037] When yarn 14 is cut, the upper yarn catching device 46 catches a yarn end of yarn 14 on the package 15 side and guides the yarn end to the yarn joining device 48. When yarn 14 is cut, the lower yarn catching device 47 catches a yarn end of yarn 14 on the yarn supply bobbin 11 side and guides the yarn end to the yarn joining device 48. The yarn joining device 48 joins the yarn ends guided by the upper yarn catching device 46 and the lower yarn catching device 47.

[0038] Referring now to FIG. 4 andFIG. 5, a method will be described by which the spinning frame 3 transmits spinning information (which will be detailed later) to the automatic winder 4 and the automatic winder 4 controls the operation of the automatic winder 4 based on spinning information and quality information.

[0039] As illustrated in FIG. 4, the spinning frame 3 includes the control device (generator) 31 and a transmitter 31c, as functional elements for embodying the mechanism above. The automatic winder 4 includes the control device (controller) 41, the winder units 42, and a receiver 41c.

[0040] The control device 31 is an electronic control unit including a central processing unit (CPU), a read only memory (ROM), and a random access memory (RAM) . The control device 31 loads a program stored in the ROM to the RAM and executes the program in the CPU to perform a variety of control. The control device 31 may be configured with a plurality of electronic control units. The control device 31 functions as a generator configured to generate spinning information including information about the processing status of forming a yarn supply bobbin 11.

[0041] The information about the processing status of forming a yarn supply bobbin 11 (hereinafter referred to as "processing status information") is, for example, information indicating the remaining time before the yarn supply bobbins 11 are simultaneously doffed in a plurality of spinning units 32 by simultaneous doffing, and information indicating the number of spinning units 32 that are spinning. The control device 31 can obtain the processing status information as described above, for example, by monitoring the operating status of each spinning unit 32 and referring to the settings about the operation of each spinning unit 32.

[0042] In the present embodiment, as an example, the control device 31 generates data including the above-noted processing status information as spinning information and transmits the generated data to the automatic winder 4 through the transmitter 31c. The control device 31 generates and transmits spinning information to the automatic winder 4 at any timing. In the present embodiment, as an example, the control device 31 periodically generates and transmits spinning information to the automatic winder 4 at predetermined intervals. This configuration enables the automatic winder 4 to timely grasp the processing status of the spinning frame 3 and enables appropriate setting of the winding speed of the winder unit 42 each time (detailed later).

[0043] The transmitter 31c transmits the spinning information generated by the control device 31 to the automatic winder 4. The transmission by the transmitter 31c may be wired through a cable or the like or may be wireless. When the transmission by the transmitter 31c is wireless, radio waves, infrared radiation, or light may be employed as a transmission medium. Although FIG. 4 illustrates the transmitter 31c as an element separate from the control device 31, the transmitter 31c may be included in the control device 31. More specifically, the transmitter 31c may be a communication function embedded in the control device 31.

[0044] The receiver 41c receives the spinning information transmitted from the spinning frame 3. The reception by the receiver 41c may be wired through a cable or the like or may be wireless. When the reception by the receiver 41c is wireless, radio waves, infrared radiation, or light may be employed as a transmission medium. Although FIG. 4 illustrates the receiver 41c as an element separate from the control device 41, the receiver 41c may be included in the control device 41. More specifically, the receiver 41c may be a communication function embedded in the control device 41.

[0045] The control device 41 is an electronic control unit including a CPU, a ROM, and a RAM. The control device 41 loads a program stored in the ROM to the RAM and executes the program in the CPU to perform a variety of control. The control device 41 may be configured with a plurality of electronic control units. The control device 41 controls the operation of the automatic winder 4 based on the spinning information received by the receiver 41c. Specifically, the control device 41 determines the operation of each winder unit 42 based on the spinning information and timely transmits a control signal indicating the determined operation to each winder unit 42 to control the operation of the winder unit 42.

[0046] The control device 41 determines the winding speed at which each winder unit 42 winds yarn from a yarn supply bobbin 11, based on the processing status information included in the spinning information, and controls the operation of each winder unit 42 such that yarn is wound from the yarn supply bobbin 11 at the determined winding speed.

[0047] As described above, while a yarn supply bobbin 11 is transferred from the spinning frame 3 to the automatic winder 4, an empty bobbin 12 is transferred from the automatic winder 4 to the spinning frame 3. The pace (supply pace) at which a yarn supply bobbin 11 is transferred from the spinning frame 3 to the automatic winder 4 is matched with the pace (ejection pace) at which an empty bobbin 12 is transferred from the automatic winder 4 to the spinning frame 3. That is, when N bobbins 12 are transferred from the automatic winder 4 to the spinning frame 3, N yarn supply bobbins 11 are supplied from the spinning frame 3 to the automatic winder 4. In the present embodiment, bobbins (yarn supply bobbins 11 and bobbins 12) twice as many as the spinning units 32 are held in the spinning frame 3.

[0048] The control device 41 calculates the present consumption rate of yarn supply bobbins 11 in the automatic winder 4 (the number of yarn supply bobbins 11 consumed in the automatic winder 4 per unit time), based on the supply pace of yarn supply bobbins 11 from the spinning frame 3 to the automatic winder 4 (the ejection pace of bobbins 12 from the automatic winder 4 to the spinning frame 3). The control device 41 calculates the number of yarn supply bobbins 11 (hereinafter referred to as the number of remaining bobbins) held in the spinning frame 3 (waiting for being supplied to the automatic winder 4 and wound by the automatic winder 4). Specifically, the control device 41 calculates the number of remaining bobbins by subtracting the number of supplied or ejected bobbins from the number of spinning units 32 ([the number of spinning units 32] - [the number of supplied or ejected bobbins]).

[0049] The control device 41 calculates the consumption rate necessary for consuming the yarn supply bobbins 11 held in the spinning frame 3, based on the remaining time obtained from the processing status information transmitted from the spinning frame 3 (the remaining time before the yarn supply bobbins 11 are simultaneously doffed in a plurality of spinning units 32 by simultaneous doffing) and the number of remaining bobbins . The control device 41 calculates a target winding speed (a target value of the winding speed), based on the present consumption rate and the necessary consumption rate. The control device 41 determines whether to change the winding speed in the automatic winder 4, based on the target winding speed and the winding speed of the automatic winder 4 at present. When the target winding speed is different from the winding speed, the control device 41 adjusts the winding speed such that the winding speed attains the target winding speed. The initial value of the target winding speed may be set through input by the operator or may be automatically set based on, for example, the lot of yarn 14.

[0050] The control device 41 changes the winding speed of each winder unit 42 based on the quality information output from the yarn monitoring device 45 and controls the operation of each winder unit 42 such that yarn is wound from the yarn supply bobbin 11 at the changed winding speed. That is, the control device 41 sets the target winding speed based on the processing status information and changes the winding speed based on the quality information.

[0051] The control device 41 acquires a quality index of yarn 14, based on the quality information. The quality index is an index indicating the quality of yarn 14 and is set based on a variety of information included in the quality information. Specifically, the control device 41 calculates the quality index of moving average per unit winding length of yarn 14, based on the quality information. The quality index is, for example, a numerical value. In the present embodiment, the control device 41 calculates a margin, based on the quality index and a preset index threshold range related to the quality of yarn 14. The index threshold range may be set through input by the operator or may be automatically set, for example, based on the lot of yarn 14. The control device 41 calculates a margin, based on the difference between the quality index and the index threshold. The degree of margin is large when the difference between the quality index and the index threshold is large, and the degree of margin is small when the difference between the quality index and the index threshold is small.

[0052] The control device 41 determines whether it is possible to change the winding speed based on the margin. When the margin is equal to or greater than a predetermined degree, that is, when it is expected that the quality index falls within the index threshold range after the winding speed is changed, the control device 41 determines that it is possible to change the winding speed. When the margin is equal to or smaller than a predetermined degree, that is, it is expected that the quality index falls outside the index threshold range after the winding speed is changed, the control device 41 determines that it is impossible to change the winding speed.

[0053] Referring now to FIG. 5 to FIG. 7, the operation of the automatic winder 4 will be described. First of all, the spinning frame 3 generates and transmits spinning information (generation step, transmission step). As illustrated in FIG. 5, the receiver 41c of the automatic winder 4 receives the spinning information transmitted from the spinning frame 3 (step S01, reception step). The spinning information received by the receiver 41c is forwarded to the control device 41. The control device 41 then performs a target winding speed calculating process of calculating a target winding speed of the automatic winder 4, based on the processing status information included in the spinning information (step S02).

[0054] The target winding speed calculating process (step S02) is described in detail with reference to FIG. 6. As illustrated in FIG. 6, the control device 41 calculates the present consumption rate of yarn supply bobbins 11, based on the number of empty bobbins 12 ejected per unit time (step S11). The control device 41 then calculates the number of remaining yarn supply bobbins 11, based on the number of spinning units 32 and the number of yarn supply bobbins 11 supplied (or empty bobbins 12 ejected) (step S12). Subsequently, the control device 41 calculates the consumption rate necessary for consuming yarn supply bobbins 11 held in the spinning frame 3, based on the remaining time obtained from the processing status information transmitted from the spinning frame 3 and the number of remaining bobbins (step S13). The control device 41 calculates the target winding speed, based on the present consumption rate and the necessary consumption rate (step S14).

[0055] As illustrated in FIG. 5, upon calculating the target winding speed, the control device 41determines whether it is necessary to change the winding speed (step S03). If it is determined that it is necessary to change the winding speed, the control device 41 performs a winding speed changing process (step S04). If it is not determined that it is necessary to change the winding speed, the control device 41 terminates the process.

[0056] The speed changing process (step S04) is described with reference to FIG. 7. As illustrated in FIG. 7, the yarn monitoring device 45 acquires information related to quality of yarn 14 (step S21, acquisition step) . The control device 41 then calculates a margin, based on the quality index of yarn 14 based on the information related to quality of yarn 14 that is output from the yarn monitoring device 45 and the preset index threshold range related to quality of yarn 14 (step S22). Subsequently, the control device 41 determines whether it is possible to change the winding speed based on the margin (step S23) .

[0057] If it is determined that it is possible to change the winding speed based on the margin, the control device 41 proceeds to step S24. If it is not determined that it is possible to change the winding speed based on the margin, the control device 41 terminates the process . At step S24, the control device 41 calculates the amount of change in winding speed based on the margin. Specifically, if the margin is high, the control device 41 sets the amount of change in winding speed to be large. If the margin is low, the control device 41 sets the amount of change in winding speed to be small. Upon calculating the amount of change in winding speed, the control device 41 changes the winding speed in accordance with the amount of change (step S25, control step). That is, the control device 41 controls the winding speed such that the quality index falls within the index threshold range.

[0058] The control device 41 determines whether the changed winding speed has reached the target winding speed (step S26). If it is determined that the changed winding speed has reached the target winding speed, the control device 41 terminates the process. If it is not determined that the changed winding speed has reached the target speed, the control device 41 returns to the process at step S21.

[0059] As described above, in the yarn winding system 1 according to the present embodiment, the automatic winder 4 includes the yarn monitoring device 45 that acquires information related to quality of yarn 14 travelling from the yarn supply bobbin 11 toward the package 15. In the automatic winder 4, the control device 41 controls the winding speed, based on the quality index of yarn 14 based on the information related to quality acquired by the yarn monitoring device 45 and a preset index threshold range related to the quality of yarn 14, such that the quality index falls within the index threshold range. With this configuration, in the automatic winder 4, yarn 14 is wound such that the quality of yarn 14 is within a certain range. In the automatic winder 4, therefore, changes in yarn quality in the middle of forming a package 15 can be reduced.

[0060] In the yarn winding system 1 according to the present embodiment, the yarn monitoring device 45 of the automatic winder 4 acquires at least information about hairiness of yarn 14. The winding speed affects, in particular, the amount of hairiness of yarn 14. The amount of hairiness therefore has a large effect on yarn quality. A change in the amount of hairiness leads to a change in yarn quality. Thus, in the automatic winder 4, at least information about hairiness is acquired by the yarn monitoring device 45 as the information related to quality, and the winding speed is controlled such that the quality index falls within the index threshold range, whereby changes in yarn quality in the middle of forming a package 15 can be reduced appropriately.

[0061] In the yarn winding system 1 according to the present embodiment, the spinning frame 3 generates spinning information including information about the processing status of forming a yarn supply bobbin 11 and transmits the spinning information to the automatic winder 4. The automatic winder 4 includes the receiver 41c configured to receive the spinning information. The control device 41 of the automatic winder 4 sets a target winding speed based on the spinning information received by the receiver 41c and changes the winding speed such that the quality index falls within the index threshold range. When the winding speed of the automatic winder 4 is controlled based on the processing status of forming a yarn supply bobbin 11 in the spinning frame 3, the yarn quality may change with a change in winding speed. Thus, when the winding speed of the automatic winder 4 is controlled based on the processing status of forming a yarn supply bobbin 11 in the spinning frame 3, controlling the winding speed such that the quality index falls within the index threshold range is particularly effective in reducing changes in yarn quality in the middle of forming a package 15. In the yarn winding system 1, since the target winding speed is set (the winding speed is increased or decreased) based on the spinning information, changes in yarn quality can be reduced while energy saving, longevity of parts and devices, improvement in production efficiency, and the like are well balanced.

[0062] In the yarn winding system 1 according to the present embodiment, the control device 41 of the automatic winder 4 calculates a margin based on the quality index and the index threshold range and calculates the amount of change in winding speed based on the margin to control the winding speed in accordance with the amount of change in winding speed. In this configuration, since the amount of change in winding speed is calculated in accordance with the margin and the winding speed is controlled in accordance with the amount of change, the winding speed can be controlled such that the quality index falls within the index threshold range.

[0063] In the yarn winding system 1 according to the present embodiment, the control device 41 of the automatic winder 4 may increase the amount of change in winding speed as the margin is higher and may reduce the amount of change in winding speed as the margin is lower. The degree of margin is high when the difference between the quality index and the index threshold is large, and the degree of margin is small when the difference between the quality index and the index threshold is small. The amount of change in winding speed is therefore adjusted in accordance with the margin, whereby yarn can be wound at an appropriate winding speed in accordance with the quality index.

[0064] Although an embodiment of the present invention has been described above, the present invention is not necessarily limited to the foregoing embodiment and is susceptible to various modifications without departing from the spirit of the invention.

[0065] In the foregoing embodiment, the yarn monitoring device 45 acquires a hairiness index of yarn 14, information about the thickness irregularity of yarn 14, the IPI value, the number of defects of yarn 14, the number of remaining defects, the number of cuts (the number of yarn breakages), and the like, as the information related to quality of yarn 14 (quality information), as an example. However, information about winding tension with which yarn 14 is wound into a package 15 may be additionally used as the information related to quality of yarn 14. The winding tension can be detected, for example, by a tension sensor (acquisition unit, different acquisition unit) provided on the yarn path between the tension applying device 44 and the winding device 43. In this way, more information related to yarn quality can be used to set the winding speed more suitable for the yarn quality. In an embodiment, at least one of the hairiness index, information about thickness irregularity, the IPI value, the number of yarn defects, the number of remaining defects, the number of cuts (the number of yarn breakages), and the winding tension may be used as the information related to yarn quality.

[0066] As information other than yarn quality, information about vibration of the winder unit 42 and/or the number of defects of traverse may be acquired to change the winding speed. More specifically, the control device 41 may control the winding speed, based on information about yarn quality and information other than yarn quality (for example, information about quality as a package). With this configuration, the winding speed suitable for not only yarn itself but also the quality as a package can be set. More specifically, when a take-up tube (tube serving as the core of a package) has a poor shape (not a perfect circle), the take-up tube may be broken if vibration is large. In addition, the traverse defect related to traverse of yarn 14 affects the shape of a package and/or the yarn unwindability. The winding speed suitable for the quality of package therefore can be set by controlling the winding speed considering information of vibration and/or the number of traverse defects. When the control is performed considering vibration, wear on parts (for example, bearing) of the cradle holding a package can be reduced. Specifically, when vibration is large, parts (for example, bearing) of the cradle holding a package may be worn earlier, and this wear can be reduced. The vibration of the winder unit 42 can be detected, for example, by an acceleration sensor (different acquisition unit) provided at an appropriate place in the winder unit 42 (for example, installed in a unit controller described later). The traverse defect can be detected by a traverse sensor (different acquisition unit) provided in the winding device 43 (for example, provided in the vicinity of the winding drum 43b or the traverse arm). More specifically, the control device 41 may control the winding speed, based on information about yarn quality acquired by the yarn monitoring device 45 and information acquired by the acquisition unit different from the yarn monitoring device 45. The information acquired by the different acquisition unit may be information about yarn quality or may be information other than yarn quality.

[0067] In the foregoing embodiment, the control device 41 of the automatic winder 4 controls the operation of each winder unit 42, as an example. However, a controller (unit controller) configured to control the operation of the winder unit 42 may be provided for each winder unit 42.

[0068] In the foregoing embodiment, the control device 41 has the display unit 41a and the operation unit 41b, as an example. However, the control device may have a touch panel display functioning as a display unit and an operation unit. The display unit 21a and the operation unit 21b in the control device 21 of the roving frame 2 and the display unit 31a and the operation unit 31b in the control device 31 of the spinning frame 3 may also be touch panel displays.

[0069] In the foregoing embodiment, the yarn monitoring device 45 monitors yarn 14 passing through the slit with an optical sensor, as an example. However, the yarn monitoring device may monitor yarn 14 passing through the slit with a capacitive sensor. In the foregoing embodiment, a cutter is provided in the vicinity of the yarn monitoring device 45, as an example. However, the yarn monitoring device may include a cutter.

[0070] In the foregoing embodiment, the control device 41 sets a target winding speed and adjusts the winding speed such that the winding speed attains the target winding speed, as an example. However, when the quality index falls outside the index threshold range, the control device 41 of the automatic winder 4 may return the winding speed to the one before the quality index falls outside the index threshold range. Alternatively, when the quality index falls outside the index threshold range, the control device 41 may set the winding speed to a preset speed. In this configuration, the speed is set such that the quality index falls within the index threshold range, whereby the winding speed is kept such that the quality index does not fall outside the index threshold range. Thus, in the automatic winder 4, changes in yarn quality in the middle of forming a package 15 can be reduced.

[0071] In addition to the foregoing embodiment, in the yarn winding system 1, input of an upper limit value and a lower limit value of winding speed may be accepted in the operation unit 41b of the automatic winder 4. Alternatively, when input of a reference winding speed (one value) serving as a reference is accepted in the operation unit 41b, the control device 41 of the automatic winder 4 may automatically set the lower limit value and the upper limit value, based on the winding speed. In this case, for example, when the operator inputs a reference winding speed to the operation unit 41b, the control device 41 adds and subtracts a predetermined value to/from the reference winding speed to set the upper limit value and the lower limit value. Specifically, when the reference winding speed is "1500 m/min", the control device 41 sets the upper limit value to "1700 m/min" and the lower limit value to "1300 m/min", using "200 m/min" as a predetermined value. The control device 41 of the automatic winder 4 controls the winding speed within a range of the upper limit value and the lower limit value. In this configuration, the winding speed is set within a range of the upper limit value and the lower limit value. More specifically, for example, when the target winding speed calculated at step S14 in the target winding speed calculating process (step S02) exceeds the upper limit value (or falls below the lower limit value), the target winding speed may be corrected to the upper limit value (or the lower limit value) (the upper limit value or the lower limit value may be reset as a target winding speed). This configuration can prevent control unintended by the operator.

[0072] In the yarn winding system, the winding speed of the automatic winder is appropriately controlled based on the processing status of forming a yarn supply bobbin in the spinning frame (for example, the supply timing of a yarn supply bobbin transferred from the spinning frame to the automatic winder) . However, when the winding speed is automatically set, the winding speed may be a speed unintended by the operator. The operator then may feel something wrong.

[0073] In order to solve the problem above, the following configuration can be used. More specifically, the automatic winder according to another embodiment of the present invention winds yarn from a yarn supply bobbin to form a package. The automatic winder includes a controller configured to control a winding speed at which the yarn is wound from the yarn supply bobbin and an input unit configured to accept input of an upper limit value and a lower limit value of the winding speed. The controller controls the winding speed within a range of the upper limit value and the lower limit value.

[0074] An automatic winder according to another embodiment of the present invention winds yarn from a yarn supply bobbin to form a package. The automatic winder includes a controller configured to control a winding speed at which the yarn is wound from the yarn supply bobbin and an input unit configured to accept input of a reference winding speed serving as a reference of the winding speed. The controller sets an upper limit value and a lower limit value of the winding speed based on the reference winding speed input in the input unit and controls the winding speed within a range of the upper limit value and the lower limit value.

[0075] In the automatic winder above, the controller controls the winding speed within a range of the upper limit value and the lower limit value. The upper limit value and the lower limit value are input by the operator or set based on a value input by the operator. In the automatic winder, therefore, control unintended by the operator can be prevented.

Reference Signs List

[0076] 1 ... yarn winding system, 3 ... spinning frame, 4 ... automatic winder, 11 ... yarn supply bobbin, 14 ... yarn, 15 ... package, 31 ... control device (generator), 31c ... transmitter, 41 ... control device (controller), 41b ... operation unit (input unit), 41c ... receiver, 45 ... yarn monitoring device (acquisition unit).

Claims

1. An automatic winder configured to wind yarn from a yarn supply bobbin to form a package, the automatic winder comprising:

an acquisition unit configured to acquire information related to quality of the yarn travelling from the yarn supply bobbin toward the package; and

a controller configured to control a winding speed at which the yarn is wound from the yarn supply bobbin, wherein

the controller controls the winding speed, based on a quality index of the yarn based on the information related to quality acquired by the acquisition unit and a preset index threshold range related to quality of the yarn, such that the quality index falls within the index threshold range.

2. The automatic winder according to claim 1, wherein the acquisition unit acquires at least information about hairiness of the yarn.

3. The automatic winder according to claim 1 or 2, wherein the acquisition unit acquires information about a defect of the yarn.

4. The automatic winder according to any one of claims 1 to 3, further comprising a receiver configured to receive spinning information transmitted from a spinning frame configured to form the yarn supply bobbin, the spinning information including information about a processing status of forming the yarn supply bobbin, wherein
the controller sets a target value of the winding speed based on the spinning information received by the receiver and changes the winding speed toward the target value such that the quality index falls within the index threshold range.

5. The automatic winder according to any one of claims 1 to 4, further comprising an input unit configured to accept input of an upper limit value and a lower limit value of the winding speed, wherein
the controller controls the winding speed within a range of the upper limit value and the lower limit value.

6. The automatic winder according to any one of claims 1 to 5, wherein the controller calculates a margin based on the quality index and the index threshold range and calculates the amount of change in the winding speed based on the margin to control the winding speed in accordance with the amount of change in the winding speed.

7. The automatic winder according to claim 6, wherein the controller increases the amount of change in the winding speed as the margin is higher and reduces the amount of change in the winding speed as the margin is lower.

8. The automatic winder according to any one of claims 1 to 7, wherein the acquisition unit is a yarn monitoring device having a slit to allow the yarn to pass through, the yarn monitoring device being configured to monitor a state of the yarn passing through the slit.

9. The automatic winder according to claim 8, further comprising another acquisition unit different from the yarn monitoring device, wherein
the controller controls the winding speed based on information acquired by the yarn monitoring device and information acquired by the different acquisition unit, and
the information acquired by the different acquisition unit is at least one of information about winding tension with which the yarn is wound into the package, information about vibration, and information about a traverse defect related to traverse of the yarn.

10. A yarn winding system comprising a spinning frame configured to form a yarn supply bobbin and an automatic winder configured to wind yarn from the yarn supply bobbin to form a package,
the spinning frame including

a generator configured to generate spinning information including information about a processing status of forming the yarn supply bobbin, and

a transmitter configured to transmit the spinning information generated by the generator to the automatic winder,

the automatic winder including

a receiver configured to receive the spinning information, an acquisition unit configured to acquire information related to quality of the yarn travelling from the yarn supply bobbin toward the package, and

a controller configured to control a winding speed at which the yarn is wound from the yarn supply bobbin, wherein

the controller sets a target value of the winding speed based on the spinning information received by the receiver and changes the winding speed toward the target value, based on a quality index of the yarn based on the information related to quality acquired by the acquisition unit and a preset index threshold range related to quality of the yarn, such that the quality index falls within the index threshold range.

11. A yarn winding method performed by a spinning frame configured to form a yarn supply bobbin and an automatic winder configured to wind yarn from the yarn supply bobbin to form a package, the yarn winding method comprising:

a generation step of generating spinning information including information about a processing status of forming the yarn supply bobbin, in the spinning frame;

a transmission step of transmitting the spinning information generated at the generation step to the automatic winder, in the spinning frame;

a reception step of receiving the spinning information, in the automatic winder;

an acquisition step of acquiring information related to quality of the yarn travelling from the yarn supply bobbin toward the package, in the automatic winder; and

a control step of controlling a winding speed at which the yarn is wound from the yarn supply bobbin, in the automatic winder, wherein

in the control step, a target value of the winding speed is set based on the spinning information received at the reception step, and the winding speed is changed toward the target value, based on a quality index of the yarn based on the information related to quality acquired at the acquisition step and a preset index threshold range related to quality of the yarn, such that the quality index falls within the index threshold range.

Drawing