Warping machine having knot aligning device

Abstract

 The present invention provides a warping machine having a knot aligning device that can set yarns from a large number of yarn supplying packages at mutually consistent respective winding start positions, each of the yarn supplying packages being obtained by tying predetermined lengths of yarns of various colors or types together and then winding the resulting yarn into the yarn supplying package, in association with small lot machining in many kind production or the manufacture of sample fabrics. When yarns Y are drawn out from a large number of yarn supplying packages P and then wound around a beam 4, they are passed through a slit S that can be freely formed by paired rollers including a moving roller 1 and a fixed roller 2. When the yarns Y drawn out from the respective yarn supplying packages P are set at the mutually consistent respective winding start positions, a slit S is formed which is wider than the thickness of each yarn Y but is narrower than the thickness of a knot YN in the yarn Y. When the aligned yarns Y are taken up all together, the moving roller 1 is separated from the fixed roller 2 to open the slit S.

Description

Field of the Invention

[0001] The present invention relates to a warping machine, and more specifically, to a warping machine having a knot aligning device suitable for setting a large number of packages at mutually consistent respective winding start positions.

Background of the Invention

[0002] As a warping method, a normal warping system or a sectional warping system is conventionally employed depending on process conditions. With the normal warping method, about several hundred or thousand warp yarns are wound directly around a warping beam. Then, warp yarns from a plurality of the warping beams obtained are wound all together around a weaving beam comprising several thousand warp yarns. Subsequently, the weaving beam thus obtained is supplied to a weaving machine for weaving.

[0003] The normal warping system is suitable for mass production in which a large number of warp yarns are warped but is not suited for small lot machining in many kind production. For small lot machining in many kind production or the manufacture of sample fabrics, a sectional warping machine has recently been used which can warp yarns from yarn supplying packages the number of which is equal to the total number of warp yarns divided by several dozens. Such a sectional warping machine is disclosed in, for example, the Unexamined Japanese Patent Application Publication (Tokkai-Hei) No. 7-118981 (p.2 to 5, Figure 1).

[0004] With the sectional warping system, first, yarns are drawn out from a large number of (about several dozen to several hundred) yarn supplying packages disposed on a warping creel, to form a first band at a tapered end of a warping beam having a tapered winding surface. That is, the yarns are wound into one yarn layer having a width smaller than the axial width of the warping beam so that the yarns run obliquely to a shaft of the warping beam.

[0005] Then, a second band is similarly formed adjacent to the first band. Moreover, this operation is repeated until a total number of yarns required are wound around the warping beam. Thus, a sectional warping beam having a plurality of bands is formed. Then, one weaving beam is formed by simultaneously drawing out yarns from the sectional warping beam around which a number of yarns required for weaving have been wound. Alternatively, one weaving beam can be formed using yarns from a plurality of sectional warping beams.

[0006] When a weaving beam is formed, each yarn may be wound up in a specified order in accordance with the sequence of the constituent yarns corresponding to the pattern of a woven fabric. In this case, yarns drawn out from yarn supplying packages installed on the weaving creel are sequentially passed through a reed and then wound around the beam.

[0007] However, the conventional sectional warping machine forms a sectional warping beam simply by drawing out yarns from yarn supplying packages of the same type in which the yarns are dyed in one color and winding them as warp yarns.

[0008] Specifically, the conventional sectional warping machine can use a small amount of yarn supplying packages to form a weaving beam having a large number of warp yarns so as to deal with small lot machining in many kind production. However, after predetermined lengths of yarns of various colors and types have been tied together and the resulting yarns have been wound around a weaving beam in the longitudinal direction, when knots in the respective yarn of supplying packages are checked to set all the yarn of supplying packages at mutually consistent respective winding start positions (starting ends), an operator must drawn out the respective yarns and set all the yarn of supplying packages at respective starting ends, on the basis of the colors of the yarns or the like.

[0009] It is an object of the present invention to provide a warping machine having a knot aligning device that can draw out yarns from a large number of yarn supplying packages by setting the yarns at mutually consistent respective winding start positions, each of the yarn supplying packages being obtained by tying predetermined lengths of yarns of various colors or types together and then winding the resulting yarn into the yarn supplying package, in association with small lot machining in many kind production or the manufacture of sample fabrics.

Summary of the Invention

[0010] To accomplish this object, an aspect of the present invention according to Claim 1 provides a warping machine that draws out yarns from a large number of yarn supplying packages and winds them around a beam, characterized in that a knot aligning device having a slit which is wider than a thickness of each yarn but which is narrower than a thickness of a knot in the yarn is provided in a yarn path between the beam and a creel that supports the yarn supplying packages.

[0011] With the aspect of the present invention according to Claim 1 configured as described above, the knots in the respective yarns can be aligned with one another utilizing the slits.

[0012] An aspect of the present invention according to Claim 2 provides a warping machine that draws out yarns from a large number of yarn supplying packages and winds them around a beam, characterized in that the yarns are passed through a slit formed by a fixed member and a moving member that can contact with and separate from the fixed member, and when knots in the yarns drawn out from the respective yarn supplying packages are aligned with one another, an interval of the slit is set to be wider than the thickness of each yarn but is narrower than the thickness of the knot in the yarn, and when the aligned yarns are wound around the beam all together, the moving member is separated from the fixed member to open the slit.

[0013] With the aspect of the present invention according to Claim 2 configured as described above, when the yarns are aligned with one another before being wound around the beam, all the yarn supplying packages can be set at mutually consistent respective winding start positions, by moving the moving member closer to the fixed member to form a slit and engaging the knots in the respective yarns with the slit. After the alignment, the yarns can be smoothly taken up by opening the slit.

[0014] An aspect of the present invention according to Claim 3 is characterized in that the slit comprises paired rollers including a fixed roller and a moving roller, collars are installed at respective ends of one of the rollers, each of the collars having a larger diameter than the roller, and the paired rollers are tightly contacted with each other to form a slit, whereas the paired rollers are separated from each other to open the slit.

[0015] With the aspect of the present invention according to Claim 3 configured as described above, the slit can be reliably constituted by the paired rollers. Furthermore, the width of the slit can be set at an arbitrary value by changing the thickness of the collars.

[0016] An aspect of the present invention according to Claim 4 is characterized in that step portions are provided at the respective ends of the moving roller, the collars are installed on the respective step portions, and small-diameter shaft end portions are provided so as to follow the respective step portions, and in that the warping machine comprises vertical guides slidably supporting the respective small-diameter shaft end portions and guides which can elevate and lower through the respective vertical guides and which support the respective small-diameter shaft end portions at the corresponding ends of the moving roller so that the small-diameter shaft end portions can fall freely.

[0017] With the aspect of the present invention according to Claim 4 configured as described above, the slit is formed by placing the moving roller on the fixed roller so that the moving roller can fall freely, the moving roller having the collars installed at the respective ends and having a larger diameter than the roller. The collar portions at the respective ends can be reliably contacted tightly with the fixed roller to make the gap of the slit uniform all over its axial length.

[0018] An aspect of the present invention according to Claim 5 is characterized in that neither the fixed roller nor the moving roller rotates.

[0019] With the aspect of the present invention according to Claim 5 configured as described above, the yarn can be stopped with the knot in the yarn sandwiched between the rollers.

[0020] An aspect of the present invention according to Claim 6 is characterized in that each of the yarn supplying packages are obtained by continuously winding predetermined lengths of yarns of various colors and types into the yarn supplying package in a longitudinal direction of the yarns while measuring the predetermined lengths.

[0021] With the aspect of the present invention according to Claim 6 configured as described above, after yarn supplying packages have been obtained by winding yarns of various colors and types into each yarn supplying package, the yarns from such yarn supplying packages can be wound around the beam by using mutually consistent mutually consistent respective winding start positions and maintaining mutually consistent mutually consistent respective sequences.

[0022] According to the present invention, in the warping machine that draws out yarns from the large number of yarn supplying packages and then winds them around the beam, the yarns can be wound around the beam while maintaining mutually consistent respective sequences in the direction of the winding width as well as mutually consistent respective positions and sequences in the direction of the yarn length.

Brief Description of the Drawings

[0023] 

Figure 1 is a schematic view showing an embodiment in which yarns are wound around a beam via a knot aligning device according to the present invention. Figure 1A is a perspective view and Figure 1B is a side view.

Figure 2 is a perspective view of the whole warping machine having the knot aligning device according to the present invention.

Figure 3 is an enlarged perspective view of the knot aligning device.

Figure 4 is a schematic view illustrating the configuration of rollers in the knot aligning device. Figure 4A shows the configuration of an end of a moving roller. Figure 4B shows the configuration of an end of a fixed roller. Figure 4C shows that both rollers abut against each other.

Figure 5 is a view showing an example of a yarn supplying package. Figure 5A is a general perspective view and Figure 5B shows an example of a yarn obtained by splicing predetermined lengths of yarns to one another to form a single continuous yarn.

Figure 6 is a plan view showing an embodiment of a sectional warping machine.

Detailed Description of the Preferred Embodiments

[0024] A configuration according to the present invention accomplishes the object to provide a warping machine that can set yarns at mutually consistent respective winding start positions, the yarns being drawn out from respective yarn supplying packages into each of which yarns of various colors and types have been wound in a length direction of the yarns. In this configuration, a slit formed by paired rollers and which is wider than the thickness of each yarn but which is narrower than the thickness of a knot in the yarn is utilized to align the knots in the respective yarns with one another in order to set all the yarns at mutually consistent respective winding start positions.

[0025] With reference to Figures 1 to 6, a description will be given of an embodiment of a warping machine having a knot aligning device according to the present invention.

[0026] As shown in Figure 1A, when yarns Y drawn out from a large number of yarn supplying packages are wound around a beam 4 in an aligned manner, knots in the respective yarns are aligned with one another using a slit S (see Figure 1B) formed by a moving roller 1 and a fixed roller 2.

[0027] The moving roller 1 has collars 3 installed at respective roller ends and each of which has a larger diameter than the moving roller 1. The moving roller 1 on which the collars 3 have been installed is abutted against the fixed roller 2 to form the slit S, constituting a gap T corresponding to the difference between the diameter of the collar 3 and the diameter of the moving roller 1.

[0028] As shown in Figures 1A and 1B, the plural yarns Y of the plural yarn supplying packages P are passed through the slit S and drawn in the direction of an arrow 5. Then, a knot YN in the yarn Y is caught in the slit S to stop only that yarn Y because the slit S is wider than the thickness of the yarn Y but is narrower than the thickness of the knot YN. When the bundled yarns Y are held and lightly drawn, those yarns Y having their knots YN engaged with the slit S are stopped and are no further drawn. However, those yarns Y not having their knots YN engaged with the slit S yet continue to be lightly drawn out. In this manner, all the yarns Y have their knots YN engaged with the slit S and are the stopped at mutually consistent respective winding start positions.

[0029] The knots YN in all the yarns Y are aligned with one another (all the yarns Y are set at mutually consistent respective winding start positions) by drawing the yarns Y in the direction of the arrow 5. Then, the bundled yarns Y start to be simultaneously wound around the beam 4 in the direction of an arrow 6.

[0030] Figure 2 shows a sectional warping machine W in which the knot aligning device 10 according to the present invention is employed. Yarns Y are drawn out from the respective yarn supplying packages installed on a warping creel K. The yarns Y are then wound around a sectional warping beam 4A via a reed member 20, a knot aligning device 10, and a space reed 30.

[0031] The reed member 20 has a member comprising a passage through which the yarns Y are separately passed. The reed member 20 allows the yarns Y to be wound in respective set orders so as to have mutually consistent respective sequences.

[0032] The aligning device 10 sets the yarns Y at the mutually consistent respective winding start positions. The aligning device 10 can thus set the yarns Y to have respective colors in accordance with the pattern of a woven fabric. In the sectional warping machine W that winds the yarns Y while dividing then into a plurality of bands, the bands must be set for mutually consistent respective winding start positions.

[0033] The sectional warping beam 4A winds the yarns Y drawn out from the several hundred yarn supplying packages P installed on the warping creel K, into a predetermined band width L defined by the space reed 30. Once the yarns Y have been wound until a yarn length equal to one band is reached, winding for the next band is started. At this time, the several hundred yarns Y must be newly set at mutually consistent respective winding start positions (starting ends). To set the yarns Y at the mutually consistent respective starting ends, the moving roller 1 is lowered and abutted against and contacted tightly with the fixed roller 2.

[0034] Now, the knot aligning device 10 will be described with reference to Figures 3 and 4.

[0035] Vertical guides 12, 13 are extended vertically from both sides of a supporting base 11. A fixed shaft 2 is secured to the vertical guides 12, 13 so as to span them. Each of the vertical guides 12, 13 has a U-shaped cross section and comprises a groove portion that is open in one direction. The U-shaped groove positions stand opposite each other so that ends of a shaft of the moving roller 1 can slide using the groove portions as a guide.

[0036] A cylinder member 14 is disposed on the supporting base 11 between the vertical guide 12 and the vertical guide 13 to elevate and lower a guide member 15 comprising guides 15a on the respective sides of the guide member 15. The guides 15A can thus slide through the respective U-shaped groove portions.

[0037] 16 is a switch box that is manually operated by an operator to drive the cylinder member 14. The moving roller 1 can thus be elevated and lowered via the guide member 15 and the guides 15A.

[0038] As shown in Figure 4A, step portions 1A are provided at the respective ends of the moving roller 1. The collars 3 are installed on the respective step portions 1A. Each of the collars 3 has an outer diameter (D) set to be larger than the roller diameter (d) of the moving roller 1. For each collars 3, the difference between the outer diameter (D) of the collar 3 and the roller diameter (d) of the moving roller 1 is defined as T. Moreover, a smaller-diameter shaft end portion 1B is provided so as to follow the step portion 1A and can slide through the U-shaped groove portion of the vertical guide 12.

[0039] Figure 4B shows the configuration of the end of the fixed roller 2. The fixed roller 2 is attached to the vertical guide 12 via fixtures 7.

[0040] The smaller-diameter shaft end portion 1B is fitted into the U-shaped groove portion of each of the vertical guides 12, 13. The smaller-diameter shaft end portions 1B are placed on the respective guides 15A and move up and down as the guides 15A elevate and lower.

[0041] Thus, when the guides 15A, which support the respective smaller-diameter shaft end portions 1B so that the shaft end portions 1B are placed on the respective guides 15A, are lowered to move the moving roller 1 down in the direction of an arrow A to abut against the fixed roller 2, the slit S of the gap T is formed as shown in Figure 4C.

[0042] The gap T is larger than the thickness of the yarn Y and smaller than the thickness of the knot YN. In the present embodiment, the yarn Y is a plied yarn of yarn number 80 (Ne80/2) and the gap T is 0.15 mm. The knot YN is a fisherman knot commonly employed in the textile industry. The knot YN is at least twice as large as the thickness of the original yarn Y.

[0043] It is assumed that the operator grips the yarns Y drawn out from the yarn supplying packages P installed on the warping creel K and draws them out via the reed member 20 and the knot aligning position 10. Then, when the operator draws the yarns Y after abutting the moving roller 1 against the fixed roller 2 to form the slit S, those yarns Y not having their knots YN engaged with the slit S can be easily drawn out. However, once the knot YN reaches the slit S, the yarns Y can no further be drawn out. Thus, the operator can draw out all the yarns Y while sequentially engaging the knots YN in the respective yarns Y with the slit S to stop the yarns Y. In this manner, all the yarns Y can be set at mutually consistent respective starting ends (winding start positions).

[0044] Once all the yarns Y are set at the respective starting ends, the operator operates the switch box 16 to raise and separate the moving roller 1 from the fixed roller 2. The bundled yarns Y are thus wound around the beam 4 or the warping beam 4A. Then, simultaneous winding is started.

[0045] The simultaneous winding is carried for a preset yarn length after the yarns Y have been set at the respective starting ends. Thus, on the resulting beam, the yarns Y have has mutually consistent respective sequences and mutually consistent respective colored yarn lengths.

[0046] The moving roller 1 abuts against the fixed roller 2 owing to its own weight. When the moving roller 1 abuts against the fixed roller 2, the collars 3, installed at the respective ends of the moving roller 1, are tightly contacted with the fixed roller 2 to form the slit S of the gap T. The slit S is parallel to the rollers 1, 2 all over its length in its axial direction. Accordingly, its gap T can be uniform all over its length in its axial direction. Therefore, the slit S is suitable for allowing a large number of yarns Y to pass through the slit S in parallel.

[0047] Of course, the gap T of the slit S must be varied depending on the thickness of the yarn Y. In this case, the slit S can be changed so as to form the optimum gap T, by raising and removing the moving roller 1 from the U-shaped grooves in the vertical guides 12, 13, replacing the collars 3, installed at the respective ends of the moving roller 1, with ones of the appropriate size, and then installing the moving roller 1 in the vertical guides 12, 13 again.

[0048] The collars 3 may be installed on the fixed roller 2. However, the collars 3 are more preferably installed on the removable moving roller 1 because it allows the collars 3 to be more easily replaced with ones of various sizes.

[0049] Furthermore, neither of the rollers 1, 2 rotates, so that no force acts which nips and drives out the knot YN. Consequently, the yarn Y can be reliably stopped at the knot YN.

[0050] In the illustrated configuration, the slit S is formed by the fixed roller 2 and the moving roller 1. The slit S can be formed using, in place of the rollers 1, 2, a fixed member composed of a flat plate or die steel and a moving member that can be contacted with and separated from the fixed member. However, it is easy to polish the surfaces of the rollers 1, 2. Further, by passing the yarns Y through the slit S formed by the polished paired metal rollers, it is possible to draw out all the yarns Y without damaging them until the knots YN in the respective engage with the slit S.

[0051] In the above description of the embodiment, the knot aligning device 10 is installed in the sectional warping machine W. However, the knot aligning device 10 can be employed not only in the sectional warping machine W but also in other warping machines or winders. The knot aligning device 10 is suitably applicable to the setting of a large number of yarns Y at mutually consistent respective winding start positions.

[0052] Moreover, the knot aligning device 10 cannot only be installed in one warping machine but can also be configured to move among a plurality of warping machines so as to be available in a large number of warping machines.

[0053] As an example of the yarn supplying package P, a yarn supplying package PW, shown in Figure 5A, is obtained by winding predetermined lengths of various colored yarns, yarns Y1, Y2, Y3, ..., in a predetermined order to form a single yarn Y. Thus, as shown in Figure 5B, the yarn Y can be obtained which has a color distribution including a red yarn of a length L1 (several dozen to several hundred meters), a yellow yarn of a length L2 (several dozen to several hundred meters), and a blue yarn of a length L3 (several dozen to several hundred meters).

[0054] If the yarn supplying package PW is used in the sectional warping machine W, shown in Figure 6, yarn supplying packages PW1, PW2, PW3, ... with yarns of various colors and types determined taking a woven pattern into account are installed at predetermined positions on the warping creel K. The yarns are then wound from the respective yarn supplying packages via the knot aligning device 10 and the space reed 30 while maintaining the respective predetermined sequences. A band L1 of a predetermined width is thus formed. Once the band L1 of the predetermined length is formed, the warping beam 4B is moved in the direction of an arrow D. The yarns are then set at mutually consistent respective winding start positions. Subsequently, the next band is formed. Then, a weaving beam WB is formed using a sectional warping beam Ba having bands each comprising a predetermined number of warp yarns. Alternatively, the single weaving beam WB may be formed by taking up warp yarns wound around a plurality of sectional warping beams Ba, Bb, Bc, ... so that the yarns maintain mutually consistent respective positions and sequences.

[0055] The yarn supplying packages PW1, PW2, PW3, ... are arranged at predetermined positions on the warping creel K in accordance with a woven pattern, and moreover, the sectional warping beam Ba is formed by taking up the drawn-out yarns Y while maintaining the respective predetermined sequences. Accordingly, the sectional warping beam Ba can be obtained which correctly reproduces the woven pattern.

[0056] According to the present invention, when the yarns from the yarn supplying packages from which the desired pattern can be woven are wound into the warping machine, the knots in the respective yarns can be engaged with the slit by lightly drawing the bundled yarns. Accordingly, the yarns for each band can be easily set at the mutually consistent respective winding start positions. Therefore, an operation of drawing out yarns can be efficiently performed.

Claims

1. A warping machine that draws out yarns from a large number of yarn supplying packages and winds them around a beam, characterized in that:
   a knot aligning device having a slit which is wider than the thickness of each yarn but which is narrower than the thickness of a knot in the yarn is provided in a yarn path between said beam and a creel that supports said yarn supplying packages.

2. A warping machine that draws out yarns from a large number of yarn supplying packages and winds them around a beam, characterized in that:
the yarns are passed through a slit formed by a fixed member and a moving member that can contact with and separate from the fixed member, and
   when knots in the yarns drawn out from the respective yarn supplying packages are aligned with one another, the interval of the slit is set to be wider than the thickness of each yarn but is narrower than the thickness of the the knot in the yarn, and
   when the aligned yarns are wound around the beam all together, said moving member is separated from the fixed member to open the slits.

3. A warping machine having a knot aligning device according to Claim 1 or Claim 2, characterized in that said slit comprises paired rollers including a fixed roller and a moving roller, collars are installed at respective ends of one of the rollers, each of the collars having a larger diameter than the roller, and the paired rollers are tightly contacted with each other to form a slit, whereas said paired rollers are separated from each other to open the slit.

4. A warping machine having a knot aligning device according to Claim 3 characterized in that step portions are provided at the respective ends of said moving roller, said collars are installed on the respective step portions, and smaller-diameter shaft end portions are provided so as to follow said respective step portions, and in that the warping machine comprises vertical guides slidably supporting the respective smaller-diameter shaft end portions and guides which can elevate and lower through the respective vertical guides and which support the respective smaller-diameter shaft end portions at the corresponding ends of the moving roller so that the small-diameter shaft end portions can fall freely.

5. A warping machine having a knot aligning device according to Claim 3 or Claim 4 characterized in that neither said fixed roller nor said moving roller rotates.

6. A warping machine having a knot aligning device according to any one of Claims 1 to 5 characterized in that each of said yarn supplying packages are obtained by continuously winding predetermined lengths of yarns of various colors and types into the yarn supplying package in a longitudinal direction of the yarns while measuring the predetermined lengths.

Drawing