BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The present invention relates to an automatic winder, and specifically, to an unwinding
assisting device that regulates a balloon generated when a yarn is unwound from a
yarn supplying bobbin.
Description of Related Art
[0002] An automatic winder is conventionally known which is configured to regulate a balloon
generated when a yarn is unwound from a yarn supplying bobbin. The unwinding assisting
device lowers a regulating member as an unwinding point of the yarn from the yarn
supplying bobbin lowers. The unwinding assisting device thus maintains the distance
from the unwinding point constant to control formation of the balloon.
[0003] An unwinding assisting device of this kind often comprises a sensor that senses the
position of an upper end of the yarn to be unwound, and an elevating and lowering
means for elevating and lowering the regulating means. The unwinding assisting device
is further configured to control the elevating and lowering means such as an air cylinder
or a stepping motor as the upper end position of the yarn lowers to lower the regulating
member in conjunction with the lowering of the upper end position.
[0004] The Unexamined Japanese Patent Application Publication (
Tokkai-Hei) No. 8-198520 discloses an unwinding assisting device configured to use a stepping motor as the
elevating and lowering means. An unwinding assisting device in the automatic winder
in the Unexamined Japanese Patent Application Publication (
Tokkai-Hei) No. 8-198520 is composed of an elevating and lowering guide for the unwinding assisting device
which controls ballooning when the yarn is unwound from the yarn supplying bobbin,
a driving device provided within the range of the length of the elevating and lowering
guide, and a converting mechanism that converts motion in a direction different from
that of elevating and lowering motion of the driving device into elevating and lowering
motion. Furthermore, the Unexamined Japanese Patent Application Publication (
Tokkai-Hei) No. 8-198520 also discloses that the driving device can be composed of a rack pinion mechanism
and a stepping motor operating integrally with the unwinding assisting device.
BRIEF SUMMARY OF THE INVENTION
[0005] However, where the above-described air cylinder is used as an elevating and lowering
means for the regulating member, the use of air pressure makes it difficult to smoothly
and precisely control the elevating and lowering of the regulating member in conjunction
with movement of the unwinding point.
[0006] Furthermore, in the automatic winder, where yarn breakage or the like occurs and
the regulating member is retracted for a yarn splicing operation, then after the yarn
splicing operation is completed, the regulating member is desirably returned quickly
to the original position to allow a winding operation to be resumed. However, the
air cylinder is configured to drive forward and backward a cylinder rod or the like,
which is relatively heavy. Thus, when the air cylinder returns to the original position
at an excessively high speed, a strong inertia force is generated to impact related
components of the device. This may cause a failure or the like. Moreover, owing to
the configuration of the air cylinder device, an installation space for the air cylinder
requires a length almost double the moving distance of the regulating member. Consequently,
reducing the size of the device is difficult.
[0007] Furthermore, the Unexamined Japanese Patent Application Publication (
Tokkai-Hei) No. 8-198520 is configured such that the stepping motor itself elevates and lowers together with
the elevating and lowering guide (regulating member). Thus, a holding member supporting
the stepping motor also needs to have a certain level of strength and is configured
to allow heavy objects to be elevated and lowered. Thus, the Unexamined Japanese Patent
Application Publication (
Tokkai-Hei) No. 8-198520 still has room for improvement in terms of smooth elevating and lowering control,
energy saving, impact prevention, and the like. Moreover, since the stepping motor
moves up and down, electric wiring for the stepping motor needs to be laid out in
a complicated form.
[0008] Furthermore, where the rack pinion mechanism is used to move the elevating and lowering
guide up and down, then since a gear is configured with possible backlash taken into
account, the rack pinion mechanism is likely to be shaky. Thus, precise positioning
of the elevating and lowering guide is difficult. Moreover, where the stepping motor
side is fixed so that the elevating and lowering guide is elevated and lowered together
with a rack, then since a space for rack movement requires a length almost double
the moving distance of the elevating and lowering guide, a sufficient size reduction
is impossible. Furthermore, where an area in which the rack and the pinion engage
with each other is lubricated, possible fiber dust resulting from yarn unwinding or
the like is likely to adhere to the area. Accumulation of the fiber dust may cause
a failure. Moreover, much time and effort is required for a maintenance operation
of removing the fiber dust firmly attached to the lubricated area.
[0009] The present invention has been made in view of these circumstances. An object of
the present invention is to provide an unwinding assisting device for an automatic
winder which enables fine-tuning of elevating and lowering of the regulating member
and which can prevent a possible impact during elevating or lowering.
[0010] The problems to be solved by the present invention have been described. Means for
solving the problems and the effects thereof will be described.
[0011] A first aspect of the present invention provides an unwinding assisting device for
an automatic winder configured as described below. That is, the unwinding assisting
device comprises a regulating member that regulates a balloon generated when a yarn
is unwound from a yarn supplying bobbin and an elevating and lowering means for elevating
and lowering the regulating means. The elevating and lowering means comprises a stepping
motor and a belt member that transmits driving of the stepping motor.
[0012] Thus, the position of the regulating member can be precisely controlled in very small
incremental steps in pulse unit (in an almost nonstep manner) by performing pulse
control on the stepping motor. Furthermore, the configuration is such that the driving
force of the stepping motor is transmitted to the regulating member by a relatively
light belt member. This enables a reduction in a possible inertia force during elevating
or lowering of the regulating member. Acceleration and deceleration performance is
thus improved. Therefore, very precise balloon control can be performed, and a possible
excessive impact can be prevented where the regulating member is elevated and lowered
at a high speed. Moreover, where a certain impact occurs on the regulating member,
the impact is absorbed by the belt member. A possible excessive impact can thus be
prevented from being transmitted to the stepping motor side to damage the stepping
motor. Moreover, a step-out function of the stepping motor itself can also absorb
the impact, thus preventing the stepping motor from being damaged. Furthermore, the
elevating and lowering means is composed of the stepping motor and the belt member,
and thus has a simple configuration. This enables a reduction in the size of the device
and in costs. Additionally, where the elevating and lowering stroke of the regulating
member is to be changed, the changing operation can be easily performed by making
a minor change to the configuration.
[0013] In the unwinding assisting device for the automatic winder, the belt member is preferably
a toothed belt.
[0014] The toothed belt can transmit the driving force of the stepping motor without slippage.
Thus, required energy can be appropriately saved, and the elevating and lowering of
the regulating member can be further precisely and smoothly controlled.
[0015] A second aspect of the present invention provides an automatic winder configured
as follows. That is, the automatic winder comprises the above-described unwinding
assisting device, a yarn splicing device that performs a yarn splicing operation,
a count means for counting number of pulses transmitted to the stepping motor, and
a control section. The control section controls the regulating means so that when
a yarn unwound from a yarn supplying bobbin is broken or cut, the regulating member
is retracted. Furthermore, the control section controls the regulating member so that
when the yarn splicing operation by the yarn splicing device is completed, the regulating
member is returned to an original position on the basis of a count result from the
count means.
[0016] Thus, where yarn breakage or cutting occurs and the regulating member is retracted,
after the yarn splicing operation is performed, the regulating member can be quickly
and accurately moved to the position where the yarn breakage or cutting has occurred,
on the basis of a stored count value for the pulse number. This allows the yarn winding
operation to be quickly resumed, enabling a reduction in the cycle time of all the
operation steps including the yarn splicing operation.
[0017] Other features, elements, processes, steps, characteristics and advantages of the
present invention will become more apparent from the following detailed description
of preferred embodiments of the present invention with reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018]
Figure 1 is a side view of a winder unit provided in an automatic winder according
to an embodiment of the present invention.
Figure 2 is a front view showing a general configuration of the winder unit.
Figure 3 is a perspective view of an essential part of an unwinding assisting device.
Figure 4 is a flowchart showing the former half of control of a regulating member.
Figure 5 is a flowchart showing the latter half of the control of the regulating member.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0019] A preferred embodiment of the present invention will be described below with reference
to the drawings. Figure 1 is a side view of a winder unit 10 provided in an automatic
winder according to an embodiment of the present invention.
Figure 2 is a front view showing a general configuration of the winder unit 10.
[0020] The winder unit 10, shown in Figures 1 and 2, winds a yarn 20 unwound from a yarn
supplying bobbin 21, around a winding bobbin 22 while traversing the yarn 20, to form
a package 30 of a predetermined length and a predetermined shape. The automatic winder
according to the present embodiment comprises a plurality of winder units 10 arranged
in a row and a frame control device (not shown in the drawings) located at one end
of the arrangement of the winder units in the direction of the arrangement.
[0021] Each of the winder unit 10 comprises a unit frame 11 (Figure 1) provided on one lateral
side thereof in a front view and a winding unit main body 16 provided on a side of
the unit frame 11.
[0022] The winding unit main body 16 comprises a cradle 23 configured to be able to hold
the winding bobbin 22, and a takeup drum (traverse drum) 24 that traverses the yarn
20 while rotating the winding bobbin 22. The cradle 23 is configured to be swingable
in a direction in which the cradle approaches or leaves the takeup drum 24. Thus,
the package 30 contacts with the takeup drum 24 or leaves from the takeup drum 24.
As shown in Figure 2, the takeup drum 24 is configured such that a spiral traverse
groove 27 is formed in an outer peripheral surface of the takeup drum 24. Thus, the
yarn 20 is traversed by the traverse groove 27.
[0023] The cradle 23 comprises a liftup mechanism and a package brake mechanism (neither
of the mechanisms are shown in the drawings). When yarn breakage occurs, the liftup
mechanism can elevate the cradle 23 to leave the package 30 from the takeup drum 24.
The package brake mechanism is configured to stop rotation of the package 30 gripped
by the cradle 23 simultaneously with the elevation of the cradle 23 by the liftup
mechanism.
[0024] The winding unit main body 16 is configured such that an unwinding assisting device
12, a tensioning device 13, a splicer device 14 as a yarn splicing device, and a clearer
(yarn thickness detector) 15 are arranged in this order from the yarn supplying bobbin
21 side, in a yarn traveling path between the yarn supplying bobbin 21 and the takeup
drum 24.
[0025] As shown in Figure 1, the winder unit 10 comprises a magazine-type supply device
60 that supplies the yarn supplying bobbin 21. The illustration of the magazine-type
supply device 60 is omitted in Figure 2 in order to illustrate the unwinding assisting
device 12 in detail. As shown in Figure 1, the magazine-type supply device 60 comprises
a magazine holding section 61 extending obliquely forward and upward from the bottom
of the winder unit and a bobbin housing device 62 attached to the tip of the magazine
holding device 61.
[0026] The bobbin housing device 62 comprises a magazine pocket 63 having a plurality of
housing holes formed therein so as to lie in a circular form. A supply bobbin 70 can
be set in each of the housing holes in an inclined posture. The magazine pocket 63
can be intermittently driven by a motor (not shown in the drawings) so as to be rotationally
fed. The intermittent driving and a control valve (not shown in the drawings) provided
in the magazine pocket 63 enable the supply bobbins 70 to be dropped, one by one,
onto a bobbin supply path (not shown in the drawings) provided in the magazine holding
section 61. The supply bobbin 70 supplied to the bobbin supply path is guided to a
yarn supplying bobbin holding section 71 while maintaining the inclined posture.
[0027] The yarn supplying bobbin holding section 71 comprises a pivoting means (not shown
in the drawings). Upon receiving the supply bobbin 70 from the bobbin supply path,
the yarn supplying bobbin holding section 71 pivots so as to raise the supply bobbin
70 from an inclined posture to an upright posture. Thus, the supply bobbin 70 is appropriately
supplied to the bottom of the winding unit main body 16 as the yarn supplying bobbin
21 to allow the winder unit 10 to perform a winding operation.
[0028] The unwinding assisting device 12 assists in unwinding the yarn from the yarn supplying
bobbin 21 by lowering a regulating member 40 covering a core tube of the yarn supplying
bobbin 21, in conjunction with unwinding of the yarn from the yarn supplying bobbin
21. The regulating member 40 comes into contact with a balloon formed at the top of
the yarn supplying bobbin 21 by the rotation and centrifugal force of the yarn unwound
from the yarn supplying bobbin 21. Thus, the regulating member 40 applies an appropriate
tension to the balloon to assist in unwinding the yarn. The unwinding assisting device
12 will be described below in detail.
[0029] Furthermore, a kink preventer 17 is located in the vicinity of the unwinding assisting
device 12 to prevent possible kink during the yarn splicing operation. The kink preventer
17 comprises a pivoting section and a brush section 31.
The pivoting section is pivotably moved by a rotary solenoid 55 shown in Figure 2.
During the yarn splicing operation, with the above-described unwinding assisting device
12 retracted to the position of the uppermost end thereof, the pivoting section turns
to cause the brush section 31 to abut against an upper end portion of the yarn supplying
bobbin 21. Thus, during the yarn splicing operation, an appropriate tension can be
applied to the yarn to prevent kink.
[0030] The tensioning device 13 applies a predetermined tension to the traveling yarn 20.
The tensioning device 13 may be, for example, of a gate type in which movable comb
teeth are arranged with respect to fixed comb teeth. The movable comb teeth can be
pivotably moved by a rotary solenoid so as to engage with or disengage from the fixed
teeth. The tensioning device 13 can apply the given tension to the yarn being wound,
to improve the quantity of the package 30.
[0031] The splicer device 14 splices a lower yarn on the yarn supplying bobbin 21 side and
an upper yarn on the package 30 side when yarn cutting, yarn breakage, or the like
occurs; the yarn cutting is performed by the clearer 15 detecting a yarn defect, and
yarn breakage may occur during the unwinding of the yarn from the yarn supplying bobbin
21. For example, the splicer device 14 may be of a mechanical type or may use a fluid
such as compressed air.
[0032] The clearer 15 is configured to use an appropriate sensor to detect the thickness
of the yarn 20 in order to detect a defect. Furthermore, the clearer 15 is configured
such that a signal from the sensor of the clearer 15 is processed by an analyzer 52
(Figure 2) so that the clearer 15 can detect a yarn defect such as slab. The clearer
15 can also function as a sensor simply sensing whether or not the yarn 20 is present.
A cutter is provided in the vicinity of the clearer 15 to immediately cut the yarn
20 when the clearer 15 detects a yarn defect.
[0033] A first relay pipe 25 and a second relay pipe 26 are provided below and above the
splicer device 14, respectively; the first relay pipe 25 catches and guides the lower
yarn on the yarn supplying bobbin 21 side, and the second relay pipe 26 catches and
guides the upper yarn on the package 30 side. A suction port 32 is formed at the tip
of the first relay pipe 25 and a suction mouth 34 is provided at the tip of the second
relay pipe 26. An appropriate negative pressure source is connected to each of the
relay pipes 25, 26 to allow the suction port 32 and the suction mouth 34 to provide
a suction stream.
[0034] In this configuration, when yarn cutting or yarn breakage occurs, the suction port
32 of the first relay pipe 25 catches the lower yarn at a position shown in Figures
1 and 2. Subsequently, the suction port 32 pivotably moves upward around a shaft 33
to guide the lower yarn to the splicer device 14. Furthermore, at almost the same
time, the second relay pipe 26 pivotably moves upward from the illustrated position
around a shaft 35. Thus, the upper yarn present on a surface of the package 30 reversed
by a drum driving motor 53 is caught by the suction mouth 34. Subsequently, the second
relay pipe 26 pivotably moves downward around the shaft 35 to guide the upper yarn
to the splicer device 14.
[0035] The yarn unwound from the yarn supplying bobbin 21 is wound around the winding bobbin
22 located downstream side of the splicer device 14. The winding bobbin 22 is driven
by rotational driving of a winding drum 24 located opposite the winding bobbin 22.
As shown in Figure 2, the winding drum 24 is coupled to an output shaft of the drum
driving motor 53, and the operation of the drum driving motor 53 is controlled by
a motor control section 54. The motor control section 54 is configured to receive
an operation signal from a unit control section 50 to perform control such that the
drum driving motor 53 is operated and stopped.
[0036] In the above-described configuration, when the bobbin from the magazine-type supply
device 60 is supplied to the yarn supplying side, the winding bobbin 22 is driven
to wind the yarn 20 unwound from the yarn supplying bobbin 21, around the winding
bobbin 22. Thus, the package 30 of a predetermined length can be formed.
[0037] Now, the unwinding assisting device 12 according to the present embodiment will be
described with reference to Figure 3. Figure 3 is a perspective view showing an essential
part of the unwinding assisting device 12 according to the present embodiment.
[0038] As shown in Figure 3, the unwinding assisting device 12 comprises a regulating member
40 shaped like a cylinder, a stepping motor 41 driving the regulating member 40, a
belt member 42 that transmits the driving of the stepping motor 41 to the regulating
member 40, and a second regulating member 56 located above the regulating member 40.
The regulating member 40 is held at one end of a regulating member support plate 47
that can move slidably in a vertical direction along a guide shaft 45 located to extend
in the vertical direction. Moreover, a chase portion detecting sensor 46 is attached
to the regulating member support plate 47. The chase portion detecting sensor 46 is
configured as a non-contact distance sensor so as to be able to detect what is called
a chase portion of the yarn supplying bobbin 21.
[0039] The second regulating member 56 is shaped like a cylinder, and has an upper end fixed
to the winder unit 10 by a mouthpiece 58 (not shown in Figure 3) or the like. The
outer diameter of the second regulating member 56 is smaller than the inner diameter
of the regulating member 40. Thus, the fixed side second regulating member 56 can
be located so as to be inserted into the moved side regulating member 40. Furthermore,
a throttling section 57 is provided below the second regulating member 56. The throttling
section 57 has a hole smaller than the inner diameter of the second regulating member
56. The throttling section 57 is configured such that the yarn 20 unwound from the
yarn supplying bobbin 21 passes through the hole. The distance from the throttling
section 57 to the top of the yarn supplying bobbin 21 is set to be within the range
of, for example, 10 to 20 millimeters. The throttling section 57 can regulate a balloon
generated above the regulating member 40. This allows the winding operation to be
appropriately performed under a given tension.
[0040] The second regulating member 56 is not limited to the cylindrical shape. The shape
of the second regulating member 56 can be appropriately changed provided that the
second regulating member 56 has the throttling section 57. For example, the second
regulating member 56 can be configured as a metal plate folded member.
[0041] The stepping motor 41 is located in the vicinity of an upper end of the guide shaft
45. A driving gear 43 is fixed to an output shaft of the stepping motor 41. On the
other hand, a driven gear 44 is rotatably supported in the vicinity of a lower end
of the guide shaft 45. An endless belt member 42 is wound around the driving gear
43 and the driven gear 44. The belt member 42 is configured as a toothed belt having
teeth (not shown in the drawings) on an inner peripheral surface.
[0042] The belt member 42 is located to extend elongately in the vertical direction so as
to cover the range within which the regulating member 40 is elevated and lowered.
The regulating member support plate 47 is fixed to an appropriate position on the
belt member 42. In this configuration, the driving gear 43 rotates to drive the belt
member 42 to enable elevating and lowering of the regulating member support plate
47 connected to the belt member 42.
[0043] As shown in Figure 2, the stepping motor 41 is connected to a stepping motor control
section 51, which outputs a driving pulse signal to the stepping motor 41 to drive
the stepping motor 41. Furthermore, the stepping motor control section 51 is configured
to be able to count the number of pulses transmitted to the stepping motor 41 and
to store the count value. The stepping motor control section 51 is connected to the
unit control section 50 to allow control of such sections as the splicer device 14
and the clearer 15 to be interlocked with control of the unwinding assisting device
12. The stepping motor 41 is configured to step out when at least a given load is
imposed on the output shaft.
[0044] The unit control section 50 controls the stepping motor 41 via the stepping motor
control section 51 to control the position of the regulating member 40 while using
the chase portion detecting sensor 46 to determine the position of the chase portion
of the yarn supplying bobbin 21. That is, the position of the chase portion lowers
as the yarn is unwound from the yarn supplying bobbin 21. The chase portion detecting
sensor 46 detects the position of the chase portion to drive the stepping motor 41
to lower the regulating member 40 in conjunction with the lowering of the chase portion.
[0045] Furthermore, the above-described yarn splicing operation is performed when, for example,
the yarn is broke during the unwinding of the yarn from the yarn supplying bobbin
21, the clearer 15 finds a yarn defect to cut the yarn with the cutter, or a new yarn
supplying bobbin 21 is supplied. For the yarn splicing, the unit control section 50
sends a signal to the stepping motor control section 51 to elevate the regulating
member 40 to the position of the uppermost end thereof. Thus, the kink preventer 17
contacts with the brush section 31 with the vicinity of the core tube of the yarn
supplying bobbin 21 to apply tension to the yarn, so that kink can be prevented. Then,
to complete the yarn splicing operation and then to resume winding, the regulating
member 40 is lowered to the original position to recover the condition in which a
balloon generated during yarn unwinding can be controlled again.
[0046] Now, the control of the unwinding assisting device 12 will be described in detail
with reference to Figures 4 and 5. Figures 4 and 5 are flowcharts showing the control
of the unwinding assisting device 12.
[0047] As shown in Figure 4, when the control flow is started, the stepping motor control
unit 51 receives an instruction from the unit control section 50 to drive the stepping
motor 41. The regulating member 40 of the unwinding assisting device 12 is thus elevated
to the uppermost end of an elevating and lowering stroke (S101). The position of the
uppermost end is an origin position. The arrival of the regulating member 40 at the
uppermost end position can be detected by an origin sensor (not shown in the drawings)
composed of, for example, a limit switch. When the elevation of the regulating member
40 is completed, the stepping motor control section 51 resets a variable for storing
the count value to zero (S102).
[0048] After the above-described initialization process, a new yarn supplying bobbin 21
is supplied (S103). Then, the unit control section 50 immediately checks whether or
not the chase portion detecting sensor 46 has detected the chase portion of the yarn
supplying bobbin 21 (S104). Where the chase portion has not been detected, a predetermined
number of driving pulses are transmitted to the stepping motor 41 to lower the regulating
member 40 (S105). Then, the number of transmitted driving pulses is added to the count
value (S106). Subsequently, the process returns to S104 to check again whether or
not the chase portion detecting sensor 46 has detected the chase portion.
[0049] The loop from S104 to S106 allows the regulating member 40 to lower until the chase
portion detecting sensor 46 detects the chase portion and also enables the storage
of the count value for driving pulses transmitted to the stepping motor 41 for the
lowering.
[0050] When the unit control section 50 determines in S104 that the chase portion has been
detected, the process shifts to S107 in Figure 5 to start the winding operation. Even
after the winding operation to the package 30 is actually started, the unit control
section 50 checks whether or not the chase portion detecting sensor 46 has detected
the chase portion of the yarn supplying bobbin 21 (S108). When the yarn is unwound
from the yarn supplying bobbin 21 to lower the chase portion to prevent the chase
portion detecting sensor 46 from detecting the chase portion, the stepping motor control
section 51 transmits a predetermined number of driving pulses to the stepping motor
41 on the basis of a signal from the unit control section 50. The regulating member
40 is thus lowered (S109). Furthermore, the stepping motor control section 51 adds
the number of transmitted driving pulses to the count value (S110).
[0051] Here, as shown in the processing in S105, S106, S109, and S110, according to the
present embodiment, every time the regulating member 40 is lowered, a process is executed
which adds the number of driving pulses transmitted to the stepping motor 41 for the
lowering. Therefore, by lowering the regulating member 40 from the above-described
uppermost end position by a distance corresponding to the number of pulses indicated
by the count value, the current position of the regulating member 40 can be reproduced.
[0052] Furthermore, in parallel with the above-described process of monitoring the chase
portion (the process of moving the regulating member 40), the unit control section
50 checks whether or not yarn cutting or breakage has occurred in the winder unit
10 (S111). That is, the unit control section 50 checks, on the basis of a signal from
the clearer 15, whether or not the yarn has been broken during the unwinding of the
yarn from the yarn supplying bobbin 21 or the clearer 15 has found a yarn defect to
cut the yarn with the cutter.
[0053] Where yarn breakage or cutting has occurred, the unit control section 50 immediately
elevates the regulating member 40 to the uppermost end (the above-described origin
position) (S112) and starts the yarn splicing operation by driving the relay pipes
25, 26, the splicer device 14, and the like (S113). Since the regulating member 40
has been elevated to the uppermost end, the brush section 31 of the kink preventer
17 can be smoothly contacted with the upper end of the core tube of the yarn supplying
bobbin 21 during the yarn splicing operation to prevent possible kink in the yarn.
[0054] Subsequently, the unit control section 50 and the stepping motor control section
51 stand by until the yarn splicing operation is completed (S114). Once the yarn splicing
operation is completed, the stepping motor control section 51 transmits driving pulses
the number of which is equal to the stored count value, to the stepping motor 41.
The regulating member 40 is thus lowered to the position where the yarn breakage or
cutting has occurred (S115). Where the unit control section determines in S111 that
neither yarn breakage nor cutting has occurred, the processing in S112 to S116 is
not executed.
[0055] Then, the unit control section 50 checks whether or not the yarn winding has been
completed (S117). Where the winding has not been completed, the process returns to
S108. Where the winding has been completed, the process is terminated. The above-described
flow enables the regulating member 40 to be gradually lowered smoothly following the
lowering of the chase portion of the yarn supplying bobbin 21, while repeating the
operation of retracting the regulating member 40 when yarn breakage or cutting occurs
and returning the regulating member 40 to the original position after yarn splicing.
The regulating member 40 may be configured so as to stop further lowering upon reaching
a predetermined position, regardless of whether or not the chase portion has been
detected.
[0056] As described above, the unwinding assisting device 12 for the winder according to
the present embodiment comprises the regulating member 40, which regulates the balloon
generated when the yarn 20 is unwound from the yarn supplying bobbin 21, and the elevating
and lowering means for elevating and lowering the regulating means 40. The elevating
and lowering means comprises the stepping motor 41 and the belt member 42, which transmits
the driving of the stepping motor 41.
[0057] This configuration allows the position of the regulating member 40 to be precisely
controlled in very small incremental steps in pulse unit (in an almost nonstep manner)
by performing pulse control on the stepping motor 41. Furthermore, the configuration
is such that the driving force of the stepping motor 41 is transmitted to the regulating
member 40 by the relatively light belt member 42. This enables a reduction in a possible
inertia force during elevating or lowering of the regulating member 40. Acceleration
and deceleration performance is thus improved. Therefore, very precise balloon control
can be performed, and a possible excessive impact can be prevented where the regulating
member 40 is elevated and lowered at a high speed. Furthermore, where the stepping
motor 41 is installed (on the fixed side) so as not to move up and down, the weight
of the elevating and lowering components can be reduced to allow the regulating member
40 to elevate and lower smoothly. Additionally, electric wiring to the stepping motor
41 and the like can be simplified. Moreover, where an impact occurs on the regulating
member 40 for any reason such as collision against another member, the impact is absorbed
by the belt member 42. A possible excessive impact can thus be prevented from being
transmitted to the stepping motor 41 side to damage the stepping motor 41. Moreover,
a step-out function of the stepping motor 41 itself can also absorb the impact, thus
preventing the stepping motor 41 from being damaged. Furthermore, the elevating and
lowering means is composed of the stepping motor 41 and the belt member 42, and thus
has a simple configuration. This enables a reduction in the size of the device and
in costs. Additionally, where the elevating and lowering stroke of the regulating
member 40 is to be changed, the changing operation can be easily performed by making
a minor change to the configuration, for example, replacing the belt member 42 with
a longer one. Furthermore, the belt member 42 basically does not require lubrication,
enabling a reduction in the number of maintenance operations required. Moreover, possible
fiber dust resulting from yarn unwinding or the like can be prevented from adhering
to lubricating oil to cause the unwinding assisting device 12 to fail.
[0058] Furthermore, in the unwinding assisting device 12 according to the present embodiment,
the belt member 42 is a toothed belt.
[0059] The toothed belt can transmit the driving force of the stepping motor 41 without
slippage. Thus, required energy can be appropriately saved, and the elevating and
lowering of the regulating member 40 can be further precisely and smoothly controlled.
[0060] Furthermore, the winder unit 10, used in the automatic winder according to the present
embodiment, comprises the above-described unwinding assisting device 12, the splicer
device 14, which performs the yarn splicing operation, and the stepping motor control
section 51, which counts the number of pulses transmitted to the stepping motor 41.
The winder unit 10 also comprises the unit control section 50, which controls the
regulating means 40 so that when the yarn unwound from the yarn supplying bobbin 21
is broken or cut, the regulating member 40 is retracted. Furthermore, the unit control
section 50 controls the regulating member 40 so that when the yarn splicing operation
by the splicer device 14 is completed, the regulating member 40 is returned to the
original position on the basis of the result of counting of the pulse number by the
stepping motor control section 51.
[0061] Thus, where yarn breakage or cutting occurs and the regulating member 40 is retracted,
after the yarn splicing operation is performed, the regulating member 40 can be quickly
and accurately moved to the position where the yarn breakage or cutting has occurred,
on the basis of the stored count value for the pulse number. This allows the yarn
winding operation to be quickly resumed, enabling a reduction in the cycle time of
all the operation steps including the yarn splicing operation.
[0062] The preferred embodiment of the present invention has been described above. However,
the above-described configuration can further be configured as described below.
[0063] In the above-described embodiment, the toothed belt is used as the belt member 42.
However, the shape of the belt can be appropriately changed; for example, a flat belt
or a V belt can be used instead of the above-described arrangement.
[0064] In the above-described embodiment, the number of pulses is counted which is required
to move the regulating member 40 from the uppermost position to the position corresponding
to the point in time of yarn breakage or cutting. However, instead of this arrangement,
the number of pulses may be counted which is required to retract the regulating member
40 to the uppermost position from the position corresponding to the point in time
of the yarn breakage or cutting so that after the yarn splicing operation, the regulating
member 40 can be lowered by a distance corresponding to the pulse number indicated
by the count value.
[0065] In the above-described embodiment, the stepping motor control section 51 functions
as count means. However, the configuration of the count means may be appropriately
changed; for example, the above-described arrangement may be changed such that the
unit control section 50 functions as count means.
[0066] The winder unit 10 according to the above-described embodiment is supplied with the
yarn supplying bobbin 21 by the magazine-type supply device 60. However, the present
invention is not limited to this arrangement. The arrangement may be changed such
that the yarn supplying bobbin 21 is supplied to the winder unit 10 by conveying a
tray with the yarn supplying bobbin 21 set thereon along an appropriate path.
[0067] While the present invention has been described with respect to preferred embodiments
thereof, it will be apparent to those skilled in the art that the disclosed invention
may be modified in numerous ways and may assume many embodiments other than those
specifically set out and described above. Accordingly, it is intended by the appended
claims to cover all modifications of the present invention that fall within the true
spirit and scope of the invention.