BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The present invention is applied to a loom for an air bag, a towel, and the like,
and relates to a control device for doffing-weaving in which a woven cloth is removed
from a loom every predetermined weaving amount.
2. Description of the Related Art
[0002] Airbags, towels, and the like, are typically produced by so-called doffing-weaving
in which a woven product of a predetermined weaving amount is removed from a loom.
When weaving by a set weaving amount is completed, a predetermined operation, for
example, weaving of a doffing edge for cutting is performed. When weaving of the doffing
edge is completed, weaving of towel or the like for next doffing is performed. When
a doffing edge reaches a doffing position in a woven-cloth path, that is, when an
end portion of a woven cloth corresponding to the set weaving amount reaches the doffing
position in the woven-cloth path, an operator cuts the woven cloth at a doffing-edge
portion, and removes the woven cloth from the loom. Then, the operator installs a
new cloth roller to the loom (see, Japanese Unexamined Patent Application Publication
No.
9-3749, [0024] to [0027]).
[0003] However, in some cases, doffing is performed before the set weaving amount is achieved,
due to restriction of an operation time and request of a next process. Also, depending
on a production lot, the operator may decide that a winding diameter of the woven
cloth still has a margin for an additional weaving amount in addition to the set weaving
amount, through visual observation or measurement. In such a case, weaving is continued
even after the set weaving amount is achieved, the woven cloth is produced by an amount
more than the normal weaving amount, and then the doffing is performed.
[0004] When the doffing is performed by the amount other than the set weaving amount, the
operator has to wait until the end portion of the woven cloth corresponding to a desired
weaving amount reaches the doffing position for doffing. This may deteriorate productivity
and workability.
[0005] A countermeasure to the disadvantage may be conceivable, in which, when the end portion
of the woven cloth corresponding to the set weaving amount reaches the doffing position,
the loom is automatically stopped, and the set weaving amount is changed to the desired
weaving amount during weaving. In such a case, the set amount has to be restored to
the original set amount for next doffing-weaving. The set amount may not be sometimes
restored to the original set amount for a plurality of times until an excess or a
deficiency of the weaving amount is found, because of, for example, an operator's
error, such as a lack of communication between operators. This may deteriorate production
efficiency and cause production control to be troublesome.
SUMMARY OF THE INVENTION
[0006] In light of the above situations, an object of the present invention is, in doffing-weaving,
to allow a weaving amount to be changed without deteriorating workability when the
weaving amount is temporarily changed due to a certain reason during weaving, and,
in next doffing-weaving or later, to reliably hold the weaving amount without an excess
or a deficiency.
[0007] According to any aspect of the present invention, it is presupposed that a loom has
a doffing-weaving control device which measures a weaving amount during weaving, determines
whether or not the measurement value reaches a set amount, and performs a predetermined
operation for doffing when the measurement value reaches the set amount.
[0008] According to a first aspect of the present invention, the loom includes a weaving
amount setting unit which sets the set amount including a first set amount and a second
set amount; and a manually operable command output unit which outputs a change command
of changing the determination from determination based on the first set amount to
determination based on the second set amount. The doffing-weaving control device performs
the determination based on the first set amount after weaving is started, performs
the determination based on the second set amount when the change command is input
before the measurement value reaches the first set amount, and automatically changes
the determination to be based on the first set amount after the measurement value
reaches the second set amount.
[0009] With the first aspect, when the command output unit is operated and the determination
whether or not the measurement value reaches the set amount is changed to the determination
based on the second set amount, the doffing-weaving control device performs the predetermined
operation for doffing when the measurement value reaches the second set amount. Accordingly,
workability of doffing can be provided similarly to the case with the determination
based on the first set amount. Also, the doffing-weaving control device automatically
changes the determination to be based on the first set amount after the measurement
value reaches the second set amount. Accordingly, an operation of restoring the determination
to be based on the first set amount is not necessary in next doffing-weaving or later.
An operator's error can be prevented, and the weaving amount can be provided without
an excess or a deficiency.
[0010] According to a second aspect of the present invention, the doffing-weaving control
device may automatically change the determination to be based on the first set amount
when a weaving amount after the measurement value reaches the second set amount reaches
a predetermined value, or when a time clocked from a predetermined timing after the
measurement value reaches the second set amount reaches a predetermined value. The
weaving amount after the measurement value reaches the second set amount may be obtained
by measuring a weaving length with a sensor. Alternatively, assuming that, a single
rotation of a loom main shaft defines a single step, the weaving amount after the
measurement value reaches the second set amount may be measured based on an integrated
number of steps. When the weaving amount reaches the predetermined value, the determination
is changed to be based on the first set amount. The predetermined value of the weaving
amount after the measurement value reaches the second set amount may be 0. In such
a case, the determination is changed to be based on the first set amount simultaneously
when the measurement value reaches the second set amount. Alternatively, the determination
may be changed when the time clocked from the predetermined timing after the measurement
value reaches the second set amount reaches the predetermined value through measurement
with a timer. The predetermined timing may be a timing at which the measurement value
reaches the second set amount, a timing at which weaving is performed by a predetermined
number of steps after the measurement value reaches the second set amount, or other
timing.
[0011] With the second aspect, the determination is automatically changed to be based on
the first set amount when the weaving amount after the measurement value reaches the
second set amount reaches the predetermined value, or when the time clocked from the
predetermined timing after the measurement value reaches the second set amount reaches
the predetermined value. Accordingly, the determination is reliably restored to be
based on the first set amount.
[0012] According to a third aspect of the present invention, the predetermined operation
for doffing may include outputting a loom stop signal. The doffing-weaving control
device may automatically change the determination to be based on the first set amount
at a predetermined timing until when the loom is restarted through a manual operation,
or at a predetermined timing after the restart.
[0013] With the third aspect, the determination is automatically changed to be based on
the first set amount at the predetermined timing until when the loom is restarted,
or at the predetermined timing after the restart. Accordingly, in doffing-weaving
after the loom is restarted, the operator need not perform a special changing operation,
thereby reliably performing the determination based on the first set amount.
[0014] According to a fourth aspect of the present invention, the predetermined operation
for doffing may cause weaving to be continued even after the measurement value reaches
the second set amount, and cause notification to be provided or cause the loom to
be stopped when an end portion of a woven cloth corresponding to weaving by the second
set amount reaches a predetermined position in a woven-cloth path. Notification may
include lighting-on or blinking a dedicated notification light, lighting-on or blinking
a loom stop light with a pattern similar to that of normal stop, or with a pattern
different from that of the normal stop.
[0015] With the fourth aspect, the notification is provided or the loom is stopped when
the end portion of the woven cloth corresponding to weaving by the second set amount
reaches the predetermined position in the woven-cloth path. Accordingly, the operator
can be away from the loom and perform other operation after the operator operates
the command output unit to change the determination to be based on the second set
amount. This can increase productivity.
[0016] The second set amount may be set by inputting the value of the second set amount.
Alternatively, according to a fifth aspect of the present invention, the weaving amount
setting unit may store an additional weaving amount in advance, and when the change
command is input, the weaving amount setting unit may set a value, in which the additional
weaving amount is added to a measurement value at a timing when the change command
is input, as the second set amount.
[0017] With the fifth aspect, the weaving amount setting unit stores the additional weaving
amount in advance. When the change command is input, the weaving amount setting unit
sets the value, in which the additional weaving amount is added to the measurement
value at the timing when the change command is input, as the second set amount. Accordingly,
the operator need not set the second set amount by adding the measurement value and
the additional weaving amount. The productivity can be increased, and an erroneous
weaving amount due to a calculation failure, an input failure of numbers, and the
like, can be prevented.
[0018] According to a sixth aspect of the present invention, the loom may further include
a cancel switch which cancels the change command. When the cancel switch is operated
during the determination based on the second set amount, if a timing of the operation
of the cancel switch is before the measurement amount reaches the first set amount
and the second set amount, the doffing-weaving control device may change the determination
to be based on the first set amount.
[0019] With the sixth aspect, if the determination is unexpectedly changed to be based on
the second set amount, the determination can be restored to be based on the first
set amount. Also, the determination can be temporarily restored to be based on the
first set amount by operating the cancel switch, and then, a new second set amount
can be set. Accordingly, the setting of the second set amount can be changed. Thus,
it is not necessary to add a function of outputting a chance command of changing the
determination based on the current second set amount to that based on another second
set amount, in addition to the function of outputting the change command of changing
the determination based on the first set amount to that based on the second set amount.
The change of the determination to be based on a desired weaving amount can be performed.
In particular, the weaving amount setting unit stores the additional weaving amount
in advance, and when the change command is input, the weaving amount setting unit
sets the value, in which the additional weaving amount is added to the measurement
value at the timing when the change command is input, as the second set amount. Also,
when the value of the second set amount is input, the determination can be temporarily
restored to the first set amount by operating the cancel switch. Accordingly, the
change to the desired weaving amount can be performed without a function being additionally
provided in the command output unit.
[0020] According to a seventh aspect of the present invention, the loom may further include
a repeat switch which repeats the determination based on the second set amount. The
doffing-weaving control device may perform the determination based on the second set
amount, in weaving after the measurement value reaches the second set amount, the
determination is automatically changed to be based on the first set amount, and when
the repeat switch is operated before the measurement value reaches the first set amount
and the second set amount, the determination is changed to be based on the second
set amount.
[0021] With the seventh aspect, the weaving amount of the second set amount of the previous
doffing-weaving can be easily obtained.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022]
Fig. 1 is an explanatory illustration, in time series, showing change of determination
based on a set amount during doffing-weaving, and operations for doffing, in correspondence
with a weaving amount;
Fig. 2 is an explanatory illustration, in time series, showing the change of the determination
based on the set amount during doffing-weaving, and the operations for doffing, in
correspondence with the weaving amount;
Fig. 3 is an explanatory illustration showing healds, a reed, a part of a woven-cloth-moving
type terry motion device, and a take-up device, of a towel loom to which the present
invention is applied;
Fig. 4 is a block diagram showing control of the towel loom;
Fig. 5 is a flowchart showing a determination procedure of a doffing-weaving control
device based on a weaving amount, and an operation procedure for doffing, Fig. 5 illustrating
a first part of the procedures;
Fig. 6 is a flowchart showing the determination procedure of the doffing-weaving control
device based on the weaving amount, and the operation procedure for doffing, Fig.
6 illustrating a middle part of the procedures; and
Fig. 7 is a flowchart showing the determination procedure of the doffing-weaving control
device based on the weaving amount, and the operation procedure for doffing, Fig.
7 illustrating a last part of the procedures.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] Figs. 1 and 2 illustrate, in time series, change of determination whether or not
a measurement value reaches a set amount, and predetermined operations for doffing,
in correspondence with a weaving amount according to an embodiment of doffing-weaving
to which the present invention is applied. In Figs. 1 and 2, time advances from the
right side to the left side of each drawing. Fig. 1 shows a state from when previous
doffing-weaving is completed, then doffing-weaving is restarted, the determination
is changed to determination based on a second set amount during weaving, and a loom
is automatically stopped, until when next doffing-weaving is restarted. Fig. 2 shows
doffing-weaving from when the determination is changed to be based on the second set
amount during weaving until when the determination is restored to be based on a first
set amount. Fig. 3 illustrates healds 2, a reed 3, a part of a woven-cloth-moving
type terry motion device 5, and a take-up device, of a towel loom having the woven-cloth-moving
type terry motion device 5 as an embodiment of the present invention. Fig. 4 is a
block diagram showing control of the towel loom. Fig. 4 illustrates operations performed
by a doffing-weaving control device 19 for doffing. Figs. 5 to 7 are flowcharts showing
a determination procedure of the doffing-weaving control device 19 based on a weaving
amount and a predetermined operation procedure for doffing. Figs. 5 to 7 partly show
a start operation of the loom and a doffing operation by an operator.
[0024] Referring to Fig. 3, the towel loom lets warps 1 off from a warp beam of pile warps
and from a warp beam of ground warps (both warp beams not shown) arranged at an upstream
side of a warp path. The warps 1 are guided to a cloth fell of a woven cloth 4 via
the healds 2 and the reed 3. When wefts (not shown) are beaten, the warps 1 and the
wefts become the woven cloth 4. The woven cloth 4 is taken up by a cloth roller 8
via the terry motion device 5, a take-up roller 6, and a plurality of pressed rollers
7, which are arranged downstream of the cloth fell along a woven-cloth path in that
order.
[0025] The woven-cloth-moving type terry motion device 5 shifts the position of the cloth
fell by moving the woven cloth 4 in a warp direction during weaving of a pile construction.
At a first pick in which the position of the cloth fell is advanced toward the reed
3, beating causes the pile warps to be loosened in a loop manner, and hence, pile
is formed. A single towel 9, that is, a towel 9 with a unit design pattern, in particular,
a towel 9 which is formed by weaving with a unit design pattern generally includes
a pile construction which is woven while the terry motion device 5 is operated, and
a border construction which is woven while the terry motion device 5 is not operated.
Border constructions are typically arranged at both ends of a pile construction. In
some cases, a border construction may be arranged between pile constructions in addition
to the border constructions at both ends. Depending on a unit design pattern, a single
towel 9 may be formed of only a pile construction without a border construction. A
towel 9 obtained by weaving with a unit design pattern defines a unit weaving amount,
or a single towel. Towels 9 are produced by a predetermined weaving amount (a number
of weaving pieces) by repeating weaving with the unit design pattern. The towel 9
is generally woven by so-called doffing-weaving in which the woven cloth 4 is cut
every predetermined weaving amount, or every predetermined number of pieces, and is
removed from the loom. In the doffing-weaving of the embodiment, a doffing edge 11
is woven so as to continuously extend from an end portion 41 of the woven cloth 4
corresponding to weaving for a predetermined weaving amount, thereby facilitating
a doffing operation. The doffing edge 11 is woven based on a doffing-edge pattern.
The doffing edge 11 is formed of the border construction, or a construction serving
as a doffing edge which is different from the border construction. The doffing edge
11 is woven while the terry motion device 5 is not operated, and does not include
the pile construction. In the doffing-weaving in the embodiment, when the predetermined
weaving amount is achieved, the end portion 41 of the woven cloth 4 is woven. Subsequently,
doffing-edge weaving with the doffing-edge pattern is started. Assuming that a single
rotation of a loom main shaft 17 defines a single step, the doffing edge 11 is woven
in a step in which a doffing-edge pattern is formed, in particular, in a step in which
a doffing-edge pattern is formed. Referring to Figs. 1 and 3, the doffing edge 11
is woven by a length B at a position adjacent to the end portion 41. Subsequently
to weaving of the doffing edge 11, weaving with the unit design pattern, that is,
weaving of the woven cloth 4 for next doffing is performed. Referring to Figs. 1 and
3, weaving is performed up to a number of steps S after weaving with the unit design
pattern is started, and then, the loom is automatically stopped in this embodiment.
Accordingly, the woven cloth 4 based on the unit design pattern is woven by a length
C. Then, the loom is automatically stopped in the middle of weaving in which a first
towel 9, or an N-th (N is a certain number) towel 9 is woven. Fig. 3 illustrates a
state in which the weaving amount reaches the set amount, the doffing edge 11 is woven,
the woven cloth 4 with the unit design pattern, for next doffing, is woven by the
predetermined number of steps S so as to continuously extend from the doffing edge
11, and then the loom is automatically stopped. Since the woven cloth 4 with the unit
design pattern is woven by the predetermined number of steps S, the doffing edge 11
is located downstream of the take-up roller 6. A portion of the woven cloth 4 arranged
upstream of the doffing edge 11 is held by the take-up roller 6 and the pressed rollers
7. Hence, the woven cloth 4 can be cut at the doffing edge 11, and the woven cloth
4 is prevented from being loosened as a result of cutting. In this embodiment, the
number of steps S is set such that the loom is automatically stopped after the doffing
edge 11 reaches a position between the downstream-side pressed roller 7 and the cloth
roller 8. Accordingly, the doffing operation becomes efficient.
[0026] The woven-cloth-moving type terry motion device 5 shown in Fig. 3 includes a drive
device (not shown), a pair of left and right rocking levers 12, engaged levers 13,
and a terry roller 14. Lower end portions of the rocking levers 12 serve as supporting
points for rocking motion. Intermediate portions of the engaged levers 13 are coupled
to the drive device, and first ends of the engaged levers 13 are coupled to intermediate
portions of the rocking levers 12. Both ends of the terry roller 14 are fixed to upper
end portions of the pair of left and right rocking levers 12 such that the terry roller
14 bridges over the rocking levers 12 in a weaving-width direction. Second ends of
the engaged levers 13 are coupled to rocking levers (not shown) which supports a tension
roller (not shown) of the ground warps. The terry roller 14 and the tension roller
are synchronously driven in a front-rear direction, that is, in the warp direction
via the engaged levers 13. Hence, the woven cloth 4 wound around the terry roller
14 is moved in the warp direction with the terry roller 14. At this time, since the
tension roller is moved in the same direction as that of the terry roller 14 synchronously
with the terry roller 14, change in length of the warp path as a result of movement
of the woven cloth 4 is absorbed. Hence, the woven cloth 4 is not loosened as a result
of decrease in tensile force of the ground warps even when the woven cloth 4 is moved
to the rear side (let-off side), and an excessive tensile force as a result of increase
in tensile force of the ground warps is not added to the woven cloth 4 even when the
woven cloth 4 is moved to the front side (take-up side). The cloth fell of the woven
cloth 4 is reliably shifted in the warp direction.
[0027] Next, control for performing a weaving amount monitoring operation by the doffing-weaving
control device 19 is described with reference to the block diagram in Fig. 4 showing
the control of the towel loom. The loom drives a motor 16 in response to a command
from a loom control device 15. The motor 16 rotates the loom main shaft 17. The loom
main shaft 17 is connected to an encoder 18. The encoder 18 detects a main shaft rotation
angle, and outputs main shaft rotation angle information to the loom control device
15 and the doffing-weaving control device 19.
[0028] The loom control device 15 receives input signals from, for example, the encoder
18, a design pattern setting unit 21, the doffing-weaving control device 19, a shed
pattern setting unit (not shown), a weft-insertion pattern setting unit (not shown),
and a terry motion pattern setting unit (not shown). The loom control device 15 uses
the input signals to drive the respective devices such as the terry motion device
5.
[0029] The design pattern setting unit 21 sets the unit design pattern and the doffing-edge
pattern in the loom control device 15. The loom control device 15 recognizes a current
step as a last step of a pattern set by the design pattern setting unit 21, with reference
to current step advancement information based on the main shaft rotation angle information,
and with reference to information on the number of steps defining the pattern. The
loom control device 15 outputs an end signal to the doffing-weaving control device
19 every last step of the single design pattern, and every last step of the doffing-edge
pattern.
[0030] The doffing-weaving control device 19 measures a weaving amount, and determines whether
or not the measurement value reaches a set amount. The doffing-weaving control device
19 performs a predetermined operation for doffing when the measurement value reaches
the set amount. In this embodiment, the predetermined operation for doffing includes
a series of operations, in which the doffing-weaving control device 19 outputs a doffing-edge
weaving start command to the loom control device 15, and outputs a loom stop command
to the loom control device 15 when the doffing edge 11 reaches a doffing position
in the woven-cloth path based on the weaving amount since the start of the doffing-edge
weaving.
[0031] The set amount, which serves as a criterion of the measurement value, is set by the
weaving amount setting unit 22 connected to the doffing-weaving control device 19.
The weaving amount setting unit 22 sets a weaving amount of a unit design pattern
(the number of weaving pieces, namely, the number of towels) as a set amount of the
doffing-weaving. The weaving amount setting unit 22 includes a first weaving amount
setting portion 23 and a second weaving amount setting portion 24.
[0032] The first weaving amount setting portion 23 sets a normal set amount for the weaving
amount of the doffing-weaving, that is, it sets a first set amount.
[0033] The second weaving amount setting portion 24 sets a set amount when the first set
amount is changed based on decision of the operator or the like, that is, it sets
a second setting amount. In this embodiment, the second weaving amount setting portion
24 includes an input unit 25, a storage unit 26, and a calculation unit 27. When the
operator inputs a number of pieces (at least 1) to the input unit 25 and performs
a registration operation, the input number of pieces is saved, or registered, in the
storage unit 26 as an additional weaving amount. When the calculation unit 27 receives
a command of changing the first set amount to the second set amount from a command
output unit 32 through the operation by the operator, the calculation unit 27 reads
out the additional weaving amount registered in the storage unit 26, calculates the
second set amount, and outputs the second set amount to the doffing-weaving control
device 19. That is, the calculation unit 27 adds the read additional weaving amount
to the current measurement value input from a piece-number counter 28 via the doffing-weaving
control device 19, that is, to the measurement value (the number of weaving pieces)
at the timing when the command is input from the command output unit 32. The calculation
unit 27 outputs the calculated value as the second set amount to the doffing-weaving
control device 19.
[0034] The piece-number counter 28 adds 1 to an integrated value which is held in the piece-number
counter 28 every input of the last step of the unit design pattern from the loom control
device 15 via the doffing-weaving control device 19. Also, the piece-number counter
28 outputs the integrated value, that is, a count, as a measurement value, to the
doffing-weaving control device 19. The doffing-weaving control device 19 determines
whether or not the measurement value reaches the set amount. When the measurement
value reaches the first set amount or the second set amount, the doffing-weaving control
device 19 outputs a weaving start command of the doffing edge 11 so as to continuously
extend from the end portion 41 of the woven cloth 4, to the loom control device 15.
Also, when weaving of the doffing edge 11 is completed, the doffing-weaving control
device 19 inputs a reset signal to the piece-number counter 28. Then, the piece-number
counter 28 resets the integrated value, that is, the measurement value to 0.
[0035] Also, the doffing-weaving control device 19 is connected to a stop-step-number setting
unit 29 and a step counter 31. The stop-step-number setting unit 29 sets a number
of steps S, which is the number of steps of weaving with the unit design pattern to
be performed after weaving of the doffing edge 11 is completed. The number of steps
S is determined in such a way that a single rotation of the loom main shaft 17 defines
a single step.
[0036] At the completion of weaving of the doffing edge 11, i.e., at the last step of the
doffing-edge pattern, the loom control device 15 outputs a doffing-edge end signal
to the doffing-weaving control device 19. When the doffing-edge end signal is input,
the doffing-weaving control device 19 outputs a reset signal to the step counter 31,
so as to reset an integrated value, that is, a measurement value of the step counter
31. The doffing-weaving control device 19 recognizes a single rotation of the loom
main shaft 17 based on the main shaft rotation angle information from the encoder
18, that is, recognizes a single step of weaving. The doffing-weaving control device
19 outputs a pulse signal, as a count-up signal, to the step counter 31 every step.
The step counter 31 integrates the number of steps of weaving based on the count-up
signal, and outputs the integrated value to the doffing-weaving control device 19,
as a measurement number of steps. When the measurement number of steps input from
the step counter 31 reaches the number of steps S set by the stop-step-number setting
unit 29, the doffing-weaving control device 19 outputs a loom stop signal to the loom
control device 15. Accordingly, the loom is stopped such that the doffing edge 11
is at the doffing position in the woven-cloth path.
[0037] The doffing-weaving control device 19 is also connected to a repeat switch 33, a
cancel switch 34, a display unit 35, and a notification light 36.
[0038] The repeat switch 33 outputs a command for performing again the determination based
on the second set amount of the previous doffing-weaving, to the doffing-weaving control
device 19, through a manual operation. In this embodiment, the doffing-weaving control
device 19 stores, or saves the weaving amount of the previous doffing-weaving until
the doffing-edge weaving is completed, regardless of the criterion of the determination
(the first set amount or the second set amount) of the previous doffing-weaving. The
doffing-weaving control device 19 reads out the stored weaving amount in response
to the command from the repeat switch 33, so as to perform again the determination
based on the second set amount of the previous doffing-weaving. Alternatively, the
previous weaving amount may be saved only when the determination in the previous doffing-weaving
is based on the second set amount.
[0039] The cancel switch 34 outputs a command of canceling the determination based on the
second set amount, that is, a command of changing the determination to be based on
the first set amount, to the doffing-weaving control device 19 through a manual operation.
In response to the command from the cancel switch 34, the doffing-weaving control
device 19 changes the determination to be based on the first set amount.
[0040] The display unit 35 displays the measurement value (the number of weaving pieces
up to the current time), the first set amount, the second set amount, the additional
weaving amount (the registered number of pieces) input by the second weaving amount
setting portion 24, and the previous weaving amount or the weaving amount of the current
doffing-weaving stored in the doffing-weaving control device 19.
[0041] When doffing-weaving is completed, or when the doffing edge 11 is woven, and the
doffing edge 11 reaches the doffing position in the woven-cloth path, the loom is
automatically stopped, and the doffing-weaving control device 19 outputs a light-on
signal, resulting in the notification light 36 being lit, or blinked. Also, the notification
light 36 is automatically turned OFF in this embodiment. When the operation of the
loom is started for the next doffing-weaving, the doffing-weaving control device 19
outputs a light-off signal or stops the output of the light-on signal.
[0042] A determination procedure of the doffing-weaving control device 19 based on the weaving
amount, and a predetermined operation procedure for doffing are described with reference
to flowcharts in Figs. 5 to 7, the procedures partly including operations by the operator.
[0043] First, a case is described, in which only the determination based on the first set
amount is performed, or a case without the change command or the repeat command.
[0044] In STEP 1 in Fig. 5, the doffing-weaving control device 19 automatically performs
the determination of the measurement value based on the first set amount. When the
operator turns ON an operation start switch, the loom control device 15 drives the
motor 16 to rotate the loom main shaft 17, and outputs a doffing-weaving start signal
to the doffing-weaving control device 19. In response to the doffing-weaving start
signal, the doffing-weaving control device 19 turns OFF the notification light 36.
[0045] Then, the procedure goes to STEP 2, in which the doffing-weaving control device 19
determines whether or not an end signal of the unit design pattern is input. The determination
is NO immediately after the operation is started. If NO, the determination process
is continued until the end signal of the unit design pattern is input. The loom control
device 15 recognizes that the current step is the last step of the unit design pattern
with reference to the current step advancement information of the unit design pattern
based on the main shaft rotation angle information from the encoder 18 and with reference
to the information on the number of steps defining the unit design pattern set by
the design pattern setting unit 21. The loom control device 15 outputs the end signal
of the unit design pattern to the doffing-weaving control device 19. Hence, the determination
becomes YES when weaving with the unit design pattern is completed. If YES, the procedure
goes to STEP 3, in which the doffing-weaving control device 19 outputs the pulse signal
to the piece-number counter 28 as the count-up signal. The piece-number counter 28
adds 1 to the integrated value up to the current time, that is, adds 1 to the count.
[0046] Then, the procedure goes to STEP 4, in which the doffing-weaving control device 19
determines whether or not the repeat command is input. In this case, there is no repeat
command, and hence, the determination is NO. If NO, the procedure goes to STEP 5,
in which the doffing-weaving control device 19 determines whether or not the change
command is input from the command output unit 32. In this case, there is no change
command, and hence, the determination is NO. If NO, the procedure goes to STEP 11,
in which the doffing-weaving control device 19 determines whether or not the count
of the piece-number counter 28, more specifically, the measurement value of the piece-number
counter 28, reaches the first set amount (a first number of weaving pieces set for
doffing-weaving). In this case, since the first set amount is set as a number larger
than 1, the determination is NO. If NO, the procedure returns to STEP 2. When weaving
is continued, and the processes of STEPS 1 to 5, and 11 are repeated, the measurement
value of the piece-number counter 28 reaches the first set amount in STEP 11, and
the determination becomes YES.
[0047] If YES, the procedure goes to STEP 31 in Fig. 7, in which the doffing-weaving control
device 19 outputs the weaving start command of the doffing edge 11 to the loom control
device 15. Then, the procedure goes to STEP 32, in which the doffing-weaving control
device 19 determines whether or not the doffing-edge end signal is input. The determination
is NO immediately after weaving of the doffing edge 11 is started, and the determination
process is continued. The loom control device 15 recognizes that the current step
is the last step of the doffing-edge pattern with reference to the current step advancement
information of the doffing-edge pattern based on the main shaft rotation angle information
from the encoder 18, and with reference to the information on the number of steps
defining the doffing-edge pattern set by the design pattern setting unit 21. The loom
control device 15 outputs the end signal of the doffing-edge pattern to the doffing-weaving
control device 19. In response to the input of the end signal, the determination becomes
YES. If YES, the procedure goes to STEP 33, in which the doffing-weaving control device
19 outputs the reset signal to the step counter 31. The doffing-weaving control device
19 also deletes the storage of the previous doffing-weaving amount (the number of
weaving pieces), stores the measurement value of the piece-number counter 28, that
is, the current doffing-weaving amount (the number of weaving pieces), and then, outputs
the reset signal to the piece-number counter 28. Also, the loom control device 15
continues weaving even after the doffing-weaving is completed, and restarts weaving
with the unit design pattern.
[0048] Then, the procedure goes to STEP 34, in which the doffing-weaving control device
19 determines whether or not the count of the step counter 31, or the measurement
number of steps input from the step counter 31 reaches the predetermined number of
steps S set by the stop-step-number setting unit 29. At the timing when weaving with
the unit design pattern is restarted, the determination is NO, and the determination
process is continued. When the measurement number of steps reaches the number of steps
S, and the determination is YES, the procedure goes to STEP 35, in which the weaving
stop signal is output to the loom control device 15, and the light-on signal is output
to the notification light 36. Hence, the loom is stopped such that the doffing edge
11 is at the doffing position in the woven-cloth path, and the notification light
36 is lit or blinked, thereby reminding the operator of the doffing operation. Also,
the set amount of the doffing-weaving amount, which serves as the criterion of the
measurement value, is set to the first set amount. Since the doffing-weaving amount
is already set to the first set amount, the doffing-weaving control device 19 holds
the first set amount as the doffing-weaving amount. Then, the procedure goes to STEP
36, in which the loom control device 15 automatically stops the loom. The operator
performs the doffing operation. In particular, the operator cuts the woven cloth 4,
the weaving amount of which is the first set amount, at a substantially center position
of the doffing edge 11 continuously extending from the end portion 41 of the woven
cloth 4. The operator removes the woven cloth 4 from the loom, and installs a cloth
roller 8 to the loom for next doffing-weaving. Then, the procedure goes to STEP 37,
in which the doffing-weaving control device 19 determines whether or not the repeat
command is input. In this case, there is no repeat command, and hence, the determination
is NO. If NO, the procedure goes to STEP 38, in which it is determined whether or
not the operation of the loom is started. If NO in STEP 38, the procedure returns
to STEP 37, in which the determination process whether or not the repeat command is
input is continuously performed. When the next doffing-weaving is started, and the
operation of the loom is started, the determination becomes YES in STEP 38, and the
procedure is ended.
[0049] Next, referring back to STEP 5 in Fig. 5, a case is described, in which the operator
operates the command output unit 32 to perform the determination based on the second
set amount while the determination of the measurement value is performed based on
the first set amount.
[0050] In this case, in STEP 5, the determination whether or not the change command is input
from the command output unit 32 is YES. If YES, the procedure goes to STEP 6, in which
the doffing-weaving control device 19 changes the criterion of the measurement value
from the first set amount to the second set amount (a second number of weaving pieces
for doffing-weaving), and deletes the change command.
[0051] Then, the procedure goes to STEP 7, in which the doffing-weaving control device 19
determines whether or not the cancel command is input from the cancel switch 34. Assuming
that the cancel switch 34 is not operated, the determination is NO.
[0052] If NO, the procedure goes to STEP 8, in which the doffing-weaving control device
19 determines whether or not the measurement value of the piece-number counter 28
reaches the second set amount. The determination is NO immediately after the command
output unit 32 is operated. The procedure returns to the process of STEP 2. When weaving
is continued, and the processes of STEPS 2 to 8 are repeated, the measurement value
of the piece-number counter 28 reaches the second set amount. Then, the determination
of the doffing-weaving control device 19 in STEP 8 becomes YES. If YES, the procedure
goes to STEP 31, which is described above, and the subsequent processes of STEPS 32
to 38 are performed. In STEP 35, the doffing-weaving control device 19 sets the set
amount, which serves as the criterion of the measurement value, to the first set amount,
that is, the doffing-weaving control device 19 changes the determination based on
the second set amount to that based on the first set amount. Then, the procedure goes
to STEP 36, in which the loom is automatically stopped, and the operator performs
the doffing operation.
[0053] Incidentally, in the process of STEP 7, the determination may be YES. For example,
when the command output unit 32 is incorrectly operated, the operator may operate
the cancel switch 34, so that the determination is restored to be based on the first
set amount. Also, the operator may operate the cancel switch 34 when the second set
amount is required to be changed after the command output unit 32 is operated to change
the determination to be based on the second set amount. That is, the operator operates
the cancel switch 34 to temporarily restore the determination to be based on the first
set amount, and then, the operator operates the command output unit 32 to change the
determination to be based on a new second set amount.
[0054] As described above, when the cancel switch 34 is operated, the determination in STEP
7 becomes YES, and the procedure goes to STEP 9, in which the doffing-weaving control
device 19 determines whether or not the measurement value based on the count of the
piece-number counter 28 reaches the first set amount. When the measurement value reaches
the first set amount, the determination becomes YES, and the procedure goes to STEP
31, in which the determination is changed to be based on the first set amount. For
example, assuming that the first set amount is 100 pieces, the additional weaving
amount is 15 pieces, and the command output unit 32 is operated when the measurement
value is 95 pieces, the second set amount is expressed as 95 pieces + 15 pieces =
110 pieces. The determination is thus changed to be based on the second set amount.
If weaving is continued and the cancel switch 34 is operated when the measurement
value is 105 pieces, the measurement value reaches the first set amount. Hence, the
doffing-weaving control device 19 invalidates the cancel command of changing the determination
to be based on the fist set amount, and the procedure goes to the next step. As the
next step, the procedure may goes to STEP 8 for performing the determination based
on the second set amount. However, in this embodiment, it is assumed that weaving
has achieved the predetermined weaving amount. Thus, the procedure goes to STEP 31,
in which the weaving start command of the doffing edge 11 is output. When the measurement
value does not reach the first set amount, and hence, if NO in STEP 9, the procedure
goes to STEP 10, in which the doffing-weaving control device 19 changes the determination
to be based on the first set amount, and deletes the cancel command. Then, the procedure
goes to STEP 11, and the above-described processes are performed.
[0055] Next, referring back to STEP 4, a case is described, in which the operator operates
the repeat switch 33 while the doffing-weaving control device 19 performs the determination
based on the first set amount.
[0056] While the determination based on the first set amount is performed, the processes
of STEPS 2 to 5, and 11 are repeated. During the repeating, when the repeat switch
33 is operated before the measurement value reaches the first set amount, a signal
of changing the determination to be based on the second set amount of the previous
doffing-weaving is output. In STEP 4, the determination whether or not the repeat
command is input from the repeat switch 33 becomes YES.
[0057] If YES, the procedure goes to STEP 21 in Fig. 6, in which the doffing-weaving control
device 19 determines whether or not the current measurement value reaches the previous
doffing-weaving amount saved as the second set amount of the previous doffing-weaving.
If the current measurement value reaches the previous doffing-weaving amount, or YES,
the repeat command is invalidated, and the procedure goes to STEP 5. If NO, the procedure
goes to STEP 22, in which the doffing-weaving control device 19 changes the determination
to be based on the previous doffing-weaving amount (the number of weaving pieces)
of the previous doffing-weaving saved in STEP 33, so as to change the determination
to be based on the previous second set amount, and to delete the repeat command.
[0058] After STEP 22, the procedure successively goes to STEP 23, in which the doffing-weaving
control device 19 determines whether or not the cancel command is input. If YES, the
procedure returns to STEP 10 in Fig. 5, in which the doffing-weaving control device
19 changes the determination to be based on the first set amount, and then, the procedure
is shifted to the process in STEP 11. If NO in STEP 23, the procedure goes to STEP
24, in which the doffing-weaving control device 19 determines whether or not the measurement
value input from the piece-number counter 28 reaches the saved previous doffing-weaving
amount. If NO, the procedure goes to STEP 25, in which the doffing-weaving control
device 19 determines whether or not the end signal of the unit design pattern is input.
If NO, the determination process is continued. If YES because weaving with the unit
design pattern is completed and the end signal of the unit design pattern is input,
the procedure goes to STEP 26, in which the pulse signal as the count-up signal is
output to the piece-number counter 28, and the procedure returns to the process in
STEP 23.
[0059] As weaving is continued, and the processes in STEPS 23 to 26 are repeated, the measurement
value input from the piece-number counter 28 reaches the saved previous doffing-weaving
amount, or the previous second set amount, and the determination becomes YES in STEP
24. Hence, the procedure is shifted to STEP 31 in Fig. 7, in which the doffing-edge
weaving is started.
[0060] Finally, referring to Fig. 7, a case is described, in which the doffing-weaving control
device 19 performs the determination based on the second set amount, and the operator
operates the repeat switch 33, in a time from the completion of doffing-weaving to
the start of the next doffing-weaving, more specifically, from when the determination
is automatically changed to be based on the first set amount in response to the output
of the loom stop signal until when the next doffing-weaving is started. In STEP 8
in Fig. 5, when the measurement value reaches the second set amount and the determination
becomes YES, the procedure goes to STEP 31 in Fig. 7, in which doffing-edge weaving
is started. Then, the record of the previous doffing-weaving amount is deleted in
STEP 33, and the current doffing-weaving amount is stored. Hence, the second set amount
is stored as the current doffing-weaving amount. Then, the determination is changed
to be based on the first set amount in STEP 35. The loom is automatically stopped
in STEP 36, and then, the procedure goes to STEP 37. When the repeat switch 33 is
operated after doffing-weaving is completed, more particularly, after the determination
is automatically changed to be based on the first set amount in response to the output
of the loom stop signal, the determination becomes YES, and the procedure goes to
STEP 39. In STEP 39, the determination is changed to be based on the saved current
doffing-weaving amount. Hence, the determination is changed to be based on the current
second set amount, and the procedure is ended. The next doffing-weaving is started
with the determination based on the current second set amount. If NO in STEP 37, the
procedure goes to STEP 38, in which it is determined whether or not the operation
of the loom is started. If NO in STEP 38, the procedure returns to STEP 37, in which
the determination process whether or not the repeat command is input is continuously
performed. When the next doffing-weaving is started and the operation of the loom
is started, the determination becomes YES in STEP 38, and the procedure is ended.
The next doffing-weaving is started with the determination based on the first set
amount.
[0061] A case is described, in which the determination of doffing-weaving is changed from
the first set amount to the second set amount, with reference to Fig. 1 in time series.
Fig. 1 illustrates time series from the right side to the left side. The loom has
the first set amount of N pieces, while a woven cloth obtained by weaving with a unit
design pattern defines a single piece having a length A. The count of the piece-number
counter 28, that is, the measurement value of the piece-number counter 28 is N. When
weaving of the woven cloth for N pieces is completed, weaving of the doffing edge
11 is started such that the doffing edge 11 continuously extends from the end portion
41 of the woven cloth. Weaving is performed with a doffing-edge pattern by a length
B, and then, the piece-number counter 28 and the step counter 31 are reset, so as
to continuously perform weaving with the unit design pattern for next doffing. When
weaving is completed by a predetermined number of steps S which is set by the stop-step-number
setting unit 29, the loom is automatically stopped, and the notification light 36
is lit or blinked. The operator performs so-called doffing operation, in which the
woven cloth is cut at the doffing-edge portion, and the woven cloth is removed from
the loom. Then, the operator installs a new cloth roller 8 to the loom. Then, when
the operator operates the operation start switch, the determination based on the first
set amount is automatically performed. Weaving with the unit design pattern is repeated
to continuously produce a woven cloth having the length A. The count is incremented
every weaving with the unit design pattern. When the operator inputs 2 as an additional
weaving amount, to the input unit 25 and operates the command output unit 32 during
weaving of a (M+1)-th piece, since the measurement value of the piece-number counter
28 is M at the operation, the determination is changed to be based on the second set
amount, which is M+2. When weaving is performed by M+2, and when the measurement value
of the piece-number counter 28 reaches M+2, weaving of the doffing edge 11 is started.
[0062] Next, with reference to Fig. 2, a case is described, in which the determination in
doffing-weaving is changed from the determination based on the first set amount to
that based on the second set amount. The same procedure is held until the determination
is changed to be based on the second set amount (M+2). When the cancel switch 34 is
operated during weaving of a (M+2)-th piece, the determination is changed to be based
on the first set amount. Thereafter, the count of the piece-number counter 28 is incremented
every weaving with the unit design pattern.
[0063] In this embodiment, since the doffing edge 11 is woven so as to continuously extend
from the end portion 41 of the woven cloth 4 corresponding to weaving of the first
set amount and the second set amount, the cutting operation in the doffing operation
is easily performed. However, the doffing edge 11 does not have to be woven. In this
case, the cutting operation is performed at a border between the woven clothes 4 produced
by two cycles of doffing-weaving, that is, at the end portion 41 of the woven cloth
4, or at a position near the end portion 41.
[0064] In this embodiment, the loom is automatically stopped when the doffing edge 11 reaches
the doffing position in the woven-cloth path, that is, when the end portion 41 of
the woven cloth 4 reaches the predetermined position in the woven-cloth path. However,
the loom does not have to be automatically stopped. In particular, as long as the
end portion 41 is at a predetermined position located downstream of a winding position
of the take-up roller 6, the woven cloth 4 is not loosened at the upstream side even
when the woven cloth 4 is cut at the end portion 41 of the woven cloth 4. The doffing
operation can be performed while the operation of the loom is continued. Since the
notification light 36 is lit or blinked when the end portion 41 reaches the predetermined
position in the woven-cloth path, the notification light 36 visually notifies the
operator of the doffing timing. The operator performs the doffing operation including
a light-off operation of the notification light 36.
[0065] In this embodiment, the set amount uses the number of pieces, a piece corresponding
to a unit design pattern. However, the unit of length, such as yard, meter, or the
like, may be used. The stop-step-number setting unit 29 does not have to set the number
of steps S, and may set an actual weaving length. In this case, preferably, the input
weaving length may be converted into the number of steps S in accordance with a weft
density or the like.
[0066] In this embodiment, the determination is changed to be based on the first set amount
when it is detected that the count of the step counter 31 reaches the set number of
steps S, and the change of the determination is performed in response to the output
of the loom stop signal and the light-on signal of the notification light 36. Accordingly,
the change of the determination is performed at a predetermined timing until the restart
of the loom, or at a predetermined timing after the restart. The predetermined timing
corresponds to output of the loom stop signal. However, the change of the determination
may be performed when a timer is operated in response to the output of the loom stop
signal and a predetermined time elapses from the output of the loom stop signal. Alternatively,
the change of the determination may be automatically performed in association with
a manual operation of restart. Still alternatively, the determination may be automatically
changed to be based on the first set amount when measurement with a counter or a timer
is automatically started in association with the manual operation of restart and when
weaving by a predetermined number of steps as a weaving amount after the restart is
completed, or when a predetermined time elapses. In this embodiment, the determination
is automatically changed to be based on the first set amount when a weaving amount
or a time after the weaving amount reaches the second set amount reaches a predetermined
value. Hence, the predetermined timing for changing corresponds to the output of the
loom stop signal and the light-on signal. However, the changing may be performed before
the output of the loom stop signal and the light-on signal. For example, the determination
may be changed to be based on the first set amount when it is detected that the measurement
value of the piece-number counter 28 reaches the second set amount. Yet alternatively,
for example, the change of the determination may be performed in response to the end
signal in a last weft-insertion step in doffing-weaving. Still alternatively, for
example, measurement with a timer may be started at the detection of that the measurement
value of the piece-number counter 28 reaches the second set amount, or at the detection
of the end signal in the last weft-insertion step in doffing-weaving, and the changing
may be performed after a predetermined time elapses. Still further alternatively,
a sensor or a limit switch may be provided, and the doffing operation may be detected
by detecting attachment or detachment of the cloth roller 8, so that the changing
is automatically performed. In any case, the operator need not perform a special operation
merely for changing the determination to be based on the first set amount.
[0067] In this embodiment, the display unit 35, the input unit 25 of the second weaving
amount setting portion 24, an input unit (not shown) of the first weaving amount setting
portion 23, the repeat switch 33, the cancel switch 34, an input unit (not shown)
of the stop-step-number setting unit 29, and the command output unit 32 are provided
in a common liquid crystal display screen of an operation panel. However, some of
these elements may be provided on different liquid crystal display screens of the
operation panel. Alternatively, when commercially available devices are used, these
elements do not have to be provided on a liquid crystal display screen.
[0068] In this embodiment, the second weaving amount setting portion 24 can change the number
of pieces to be input to the input unit 25, as the additional weaving amount, during
the determination being performed based on the second set amount until the measurement
value reaches the second set amount. However, an invariable predetermined number of
pieces may be registered in the storage unit 26. In this case, the input unit 25 may
be omitted. Alternatively, the number of pieces input to the input unit 25 does not
have to be set as the additional weaving amount, but may be set as the second set
amount. In this case, the calculation unit 27 may be omitted.
[0069] Further, in the second weaving amount setting portion 24, the operation signal for
registering the input number of pieces input to the input unit 25 may be also used
as a change command for changing the determination to be based on the second set amount.
In this case, the command output unit 32 may be omitted.
[0070] In this embodiment, the command output unit 32 only has a function of outputting
the change command for changing the determination based on the first set amount to
that based on the second set amount. However, the command output unit 32 may additionally
have a new function of outputting a change command for changing the determination
from the determination based on the current second set amount to that based on another
second set amount. To change the determination from the determination based on the
current second set amount to that based on another desired second set amount, the
cancel switch 34 may be operated so as to restore the determination to be based on
the first set amount. Alternatively, the command output unit 32 may be operated so
as to change the determination to be based on the another desired second set amount
without the determination being restored to be based the first set amount.
[0071] The piece-number counter 28 and the step counter 31 are provided separately from
the doffing-weaving control device 19. However, the piece-number counter 28 and the
step counter 31 may be installed into the doffing-weaving control device 19. That
is, by performing an operation program for determination of the measurement value
and a doffing operation regarding the determination, a portion of the doffing-weaving
control device 19 may serve as counters, so that the operations of the counters are
cooperatively performed.