BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The present invention relates to a yarn winding unit that winds a spun yarn to form
a package, a yarn winding apparatus and a spinning machine.
2. Description of the Related Art
[0002] This type of yarn winding apparatus is disclosed in, for example, Japanese Patent
Application Laid-open No.
2010-77576 (Patent Document 1). The spinning machine disclosed in Patent Document 1 includes
a plurality of spinning units. Each of the spinning units includes a spinning device
that supplies a spun yarn and a winding device that winds the spun yarn and forms
a package. A yarn slack eliminating device is arranged between the spinning device
and the winding device. The yarn slack eliminating device temporarily pools the spun
yarn around a rotating roller called a slack eliminating roller.
[0003] A yarn clearer and a cutter are arranged between the spinning device and the yarn
slack eliminating device. The yarn clearer monitors a thickness of the running spun
yarn to detect any yarn defect. Upon detection of a yarn defect, the yarn clearer
causes the cutter to cut the yarn to remove the yarn defect.
[0004] The spinning machine disclosed in Patent Document 1 includes a yarn joining carrier.
The yarn joining carrier includes a yarn joining device that joins the yarn on the
spinning device side and the yarn on the package side. When a yarn breakage or a cutting
of the yarn by the cutter upon detection of a yarn defect by the yarn clearer takes
place in a particular spinning unit, the yarn joining carrier moves to and stops at
the position corresponding to the concerned spinning unit so that the yarn joining
device can perform a yarn joining operation. Once the yarn joining operation is completed,
the spinning operation of the spinning unit is resumed.
SUMMARY OF THE INVENTION
[0005] It is an object of the present invention to provide a yarn winding unit that includes
a yarn joining device, and that removes a faulty yarn joint and efficiently performs
yarn joining with the yarn joining device.
[0006] This object is achieved by a yarn winding unit of claim 1, by a yarn winding apparatus
of claim 7, and by a spinning machine according to claim 8.
[0007] It has been found by the inventors of the present invention that in a yarn winding
apparatus that includes the yarn joining device, there is the need for assessing the
quality of a portion where yarn-joining has been performed by the yarn joining device.
If faulty yarn-joining can be detected, the yarn joining operation can be automatically
redone after removal of the faulty portion and a package that is of good quality can
be produced efficiently.
[0008] In the spinning machine disclosed in Patent Document 1, the yarn slack eliminating
device is arranged upstream of the yarn joining device in a yarn running direction,
and the cutter is arranged further upstream of the yarn slack eliminating device.
Therefore, even if a faulty yarn-joining is detected, the following operation needs
to be undertaken to remove the faulty yarn joint. That is, the faulty yarn joint is
cut by the cutter, and further, the entire spun yarn pooled in the yarn slack eliminating
device is temporarily wound into the package. Thereafter, the package is rotated in
the reverse direction to draw out the faulty yarn joint, and yarns are again joined
by the yarn joining device after removing the faulty yarn joint.
[0009] The spun yarn that is pooled in the yarn slack eliminating device can be of considerable
length. Therefore, winding the entire spun yarn and again drawing the yarn up to the
faulty yarn joint can take a long time.
[0010] The present invention overcomes the prior art problems.
[0011] According to an aspect of the present invention, a yarn winding apparatus includes
a yarn supplying device, a winding device, a yarn joining device, a yarn pooling device,
and a first cutting device. The yarn supplying device is adapted to supply a spun
yarn. The winding device is adapted to wind the spun yarn onto a package. The yarn
joining device is adapted to join an end of the spun yarn on the yarn supplying device
side and an end of the spun yarn on the winding device side at a position between
the yarn supplying device and the winding device in a yarn running direction. The
yarn pooling device is adapted to temporarily pool the spun yarn at a position between
the yarn supplying device and the yarn joining device in the yarn running direction.
The first cutting device is adapted to cut the spun yarn at a position between the
yarn pooling device and the yarn joining device in the yarn running direction.
[0012] According to the above aspect, when the spun yarn is cut with the first cutting device,
the length of the spun yarn that is wound by the winding device is shortened. Consequently,
the length of the spun yarn that needs to be drawn from the package for a yarn joining
operation by the yarn joining device is also shortened, and the yarn joining operation
can be performed efficiently.
[0013] According to another aspect of the present invention, the yarn winding apparatus
includes a monitoring device adapted to monitor the spun yarn joined by the yarn joining
device at a position immediately downstream of the yarn joining device in the yarn
running direction. The first cutting device is adapted to cut the spun yarn based
on a monitoring result obtained in the monitoring device.
[0014] According to the above aspect, since any yarn-joining defect generated by the yarn
joining device can be detected early by the monitoring device, the spun yarn can be
immediately cut by the first cutting device, and the yarn joining operation can be
redone by the yarn joining device. Consequently, the package can be wound more efficiently.
[0015] According to still another aspect of the present invention, the yarn winding apparatus
further includes a second cutting device and a removal device. The second cutting
device is adapted to cut the spun yarn supplied from the yarn supplying device to
the yarn pooling device. The removal device is adapted to remove the spun yarn pooled
in the yarn pooling device.
[0016] According to the above aspect, the spun yarn at the downstream of the yarn pooling
device is cut by the first cutting device and the spun yarn at the upstream of the
yarn pooling device is cut by the second cutting device. Consequently, the spun yarn
pooled in the yarn pooling device can be removed easily by the removal device.
[0017] According to still another aspect of the present invention, in the yarn winding apparatus,
the yarn pooling device includes a pooling roller adapted to pool the spun yarn by
winding the spun yarn on an outer peripheral surface thereof. The yarn removal device
includes a suction section and a driving section. The suction section is arranged
near the yarn pooling device and adapted to suck in the spun yarn pooled in the yarn
pooling device. The driving section is adapted to drive the yarn pooling device in
the direction that assists the suction of the spun yarn by the suction section.
[0018] According to the above aspect, by proactively causing the spun yarn pooled in the
yarn pooling device to be sucked in by the suction section, the spun yarn can be removed
definitively and in a short time.
[0019] According to still another aspect of the present invention, the yarn winding apparatus
includes a detecting section adapted to detect whether the spun yarn is removed from
the yarn pooling device. The yarn joining device is adapted to perform joining of
the spun yarn when the detecting section detects that the spun yarn has been removed.
[0020] According to the above aspect, the unnecessary spun yarn pooled in the yarn pooling
device is prevented from getting in the way when the yarn joining device is performing
the yarn joining operation. Consequently, failure of the yarn joining operation and
a drop in the quality of the package can be prevented.
[0021] According to still another aspect of the present invention, in the yarn winding apparatus,
it is preferable that the yarn supplying device be a spinning device that is adapted
to use airflow to form the spun yarn from a fiber bundle.
[0022] According to the above aspect, in the yarn winding apparatus in which an air-jet
spinning device is used as the yarn supplying device, and in which the spun yarn is
formed continuously at a high speed and pooled in the yarn pooling device located
downstream of the yarn supplying device, the spun yarn pooled in the yarn pooling
device tends to be fairly long. Therefore, in the yarn winding apparatus of this kind,
it is preferable that the spun yarn be cut between the yarn pooling device and the
yarn joining device.
[0023] According to still another aspect of the present invention, the yarn winding apparatus
includes a plurality of yarn winding units arranged side-by-side and a carrier. Each
of the yarn winding units includes at least the yarn supplying device, the winding
device, and the yarn pooling device. The carrier is adapted to move to the yarn winding
units, and includes at least one of the first cutting device and the yarn joining
device.
[0024] According to the above aspect, in the yarn winding apparatus that includes the carrier,
the yarn joining operation by the yarn joining device can be performed efficiently
so that the package can be wound more efficiently.
[0025] According to still another aspect of the present invention, a yarn winding unit includes
a yarn supplying device, a winding device, a yarn joining device, a yarn pooling device,
and a first cutting device. The yarn supplying device is adapted to supply the spun
yarn. The winding device is adapted to wind the spun yarn onto the package. The yarn
joining device is arranged at a position between the yarn supplying device and the
winding device in the yarn running direction and adapted to join the end of the spun
yarn on the yarn supplying device side and the end of the spun yarn on the winding
device side. The yarn pooling device is arranged at a position between the yarn supplying
device and the yarn joining device in the yarn running direction and adapted to temporarily
pool the spun yarn. The first cutting device is arranged at a position between the
yarn pooling device and the yarn joining device in the yarn running direction and
adapted to cut the spun yarn.
[0026] According to the above aspect, when the spun yarn is cut with the first cutting device,
the length of the spun yarn that is wound by the winding device is shortened. Consequently,
the length of the spun yarn that needs to be drawn from the package for the yarn joining
operation by the yarn joining device is also shortened, and the yarn joining operation
can be performed efficiently.
[0027] According to still another aspect of the present invention, the yarn winding unit
includes a monitoring device adapted to monitor the spun yarn joined by the yarn joining
device at a position immediately downstream of the yarn joining device in the yarn
running direction. The first cutting device is adapted to cut the spun yarn based
on the monitoring result obtained in the monitoring device.
[0028] According to the above aspect, since any yarn-joining defect generated by the yarn
joining device can be detected early by the monitoring device, the spun yarn can be
immediately cut by the first cutting device, and the yarn joining operation can be
redone by the yarn joining device. Consequently, the package can be wound more efficiently.
[0029] According to still another aspect of the present invention, the yarn winding unit
further includes a second cutting device and a removal device. The second cutting
device is adapted to cut the spun yarn supplied from the yarn supplying device to
the yarn pooling device. The removal device is adapted to remove the spun yarn pooled
in the yarn pooling device.
[0030] According to the above aspect, the spun yarn at the downstream of the yarn pooling
device is cut by the first cutting device and the spun yarn at the upstream of the
yarn pooling device is cut by the second cutting device. Consequently, the spun yarn
pooled in the yarn pooling device can be removed easily by the removal device.
[0031] According to still another aspect of the present invention, in the yarn winding unit,
the yarn pooling device includes a pooling roller adapted to pool the spun yarn by
winding the spun yarn on an outer peripheral surface thereof. The yarn removal device
includes a suction section and a driving section. The suction section is arranged
near the yarn pooling device and adapted to suck in the spun yarn pooled in the yarn
pooling device. The driving section is adapted to drive the yarn pooling device in
the direction that assists the suction of the spun yarn by the suction section.
[0032] According to the above aspect, by proactively causing the spun yarn pooled in the
yarn pooling device to be sucked in by the suction section, the spun yarn can be removed
definitively and in a short time.
[0033] According to still another aspect of the present invention, the yarn winding unit
includes a detecting section adapted to detect whether the spun yarn is removed from
the yarn pooling device. The yarn joining device is adapted to perform joining of
the spun yarn when the detecting section detects that the spun yarn has been removed.
[0034] According to the above aspect, the unnecessary spun yarn pooled in the yarn pooling
device is prevented from getting in the way when the yarn joining device is performing
the yarn joining operation. Consequently, failure of the yarn joining operation and
a drop in the quality of the package can be prevented.
[0035] According to still another aspect of the present invention, in the yarn winding unit,
it is preferable that the yarn supplying device be a spinning device that is adapted
to use airflow to form the spun yarn from the fiber bundle.
[0036] According to the above aspect, in the yarn winding unit in which an air-jet spinning
device is used as the yarn supplying device, and in which the spun yarn is formed
continuously at high speed and pooled in the yarn pooling device located downstream
of the yarn supplying device, the spun yarn pooled in the yarn pooling device tends
to be fairly long. Therefore, in the yarn winding unit of this kind, it is preferable
that the spun yarn be cut between the yarn pooling device and the yarn joining device.
[0037] According to still another aspect of the present invention, the yarn winding apparatus
includes a plurality of the yarn winding units.
[0038] According to the above aspect, the yarn joining operation by the yarn joining device
in each of the yarn winding units can be performed efficiently so that the package
can be wound more efficiently.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039]
FIG. 1 is a front view of an overall structure of a spinning machine according to
an embodiment of the present invention;
FIG. 2 is a side view of a spinning unit shown in FIG. 1;
FIG. 3 is a cross-sectional view of a spinning device shown in FIG. 1;
FIG. 4 is a side view of the spinning unit in a state in which a spun yarn is cut
upon detection of a defect in the spun yarn by a yarn-quality measuring equipment
during winding of the spun yarn by the spinning unit;
FIG. 5 is a side view showing a state in which, from the state shown in FIG. 4, a
yarn joining carrier has stopped at the relevant spinning unit, and ends of the spun
yarn on a spinning device side and a package side have been held by suction by a suction
pipe and a suction mouth, respectively;
FIG. 6 is a side view showing a state in which, from the state shown in FIG. 5, the
yarn joining carrier guides the ends of the spun yarn into a yarn joining device;
FIG. 7 is a side view showing a state in which, immediately after yarn-joining by
the yarn joining device, the spun yarn is monitored by a yarn-joint quality monitor;
FIG. 8 is a side view showing a state in which the spun yarn is cut by a cutter and
the spinning device upon detection of a yarn-joining defect by the yarn-joint quality
monitor in the state shown in FIG. 7; and
FIG. 9 is a side view showing a state in which the spun yarn is unspooled by rotating
a yarn spooling roller in a reverse direction from a state shown in FIG. 8 and removed
by a yarn sucking device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0040] Exemplary embodiments of a spinning machine according to the present invention are
explained in detail below with reference to the accompanying drawings. A spinning
machine 1 as an example of a yarn winding apparatus shown in FIG. 1 includes a plurality
of spinning units (yarn winding units) 2 arranged in a line, a yarn joining carrier
(carrier) 3, a blower box 80, and a motor box 5.
[0041] As shown in FIG. 2, each of the spinning units 2 includes, arranged from upstream
to downstream, a drafting device 7, a spinning device (yarn supplying device) 9, a
yarn pooling device 12, and a winding device 13. The terms "upstream" and "downstream"
used in this specification are upstream and downstream, respectively, with respect
to a running direction of a fiber bundle 8 and a spun yarn 10 during spinning. In
each of the spinning units 2, the spinning device 9 spins the fiber bundle 8 fed from
the drafting device 7 to form the spun yarn 10, and the winding device 13 winds the
spun yarn 10 to form a package 45.
[0042] The drafting device 7 is arranged near an upper end of a frame 6 of the spinning
machine 1. The drafting device 7 includes, sequentially from the upstream side, four
drafting rollers, namely, a back roller 16, a third roller 17, a middle roller 19
with an apron belt 18 made of rubber stretched over it, and a front roller 20. Each
of the drafting rollers is driven to rotate at a predetermined speed. The drafting
device 7 includes one roller each arranged opposing each of the drafting rollers.
[0043] A sliver 15, which serves as a raw material for the fiber bundle 8, is fed into the
drafting device 7 from a not shown sliver case via a not shown sliver guide. The drafting
device 7 extends (drafts) the sliver 15 until a predetermined width is reached by
feeding the sliver 15 sandwiched between the rotating drafting rollers and the opposing
rollers to form the fiber bundle 8.
[0044] The spinning device 9 is arranged immediately downstream of the front roller 20.
The fiber bundle 8 drafted by the drafting device 7 is fed into the spinning device
9. The spinning device 9 twists the fiber bundle 8 fed from the drafting device 7
to form the spun yarn 10.
[0045] The spinning device 9 used in the spinning machine 1 according to the present embodiment
is an air-jet spinning device that twists the fiber bundle 8 by using a swirling airflow.
As shown in FIG. 3, the spinning device 9 includes a nozzle block 35, a hollow guide
shaft 23, and a fiber guiding section 22.
[0046] A spinning chamber 26 is formed between the nozzle block 35 and the hollow guide
shaft 23. An air blowing nozzle 27 that blows air into the spinning chamber 26 is
formed in the nozzle block 35. An introducing port 21 is formed in the fiber guiding
section 22 for introducing the fiber bundle 8 into the spinning chamber 26. The air
blowing nozzle 27 blows air into the spinning chamber 26 and produces the swirling
airflow.
[0047] The fiber bundle 8 that is fed from the drafting device 7 is guided into the spinning
chamber 26 by the fiber guiding section 22 that includes the introducing port 21.
Inside the spinning chamber 26, the fiber bundle 8 is swung around the hollow guide
shaft 23 by the swirling airflow, and is twisted into a spun yarn 10. The twisted
spun yarn 10 passes through a yarn path formed in the center of the hollow guide shaft
23, and is delivered outside of the spinning device 9 through a not shown yarn outlet
at the downstream side.
[0048] A guiding needle 22a with a tip thereof pointing inside the spinning chamber 26 is
arranged in the introducing port 21. The fiber bundle 8 that is guided through the
introducing port 21 is guided into the spinning chamber 26 via the guiding needle
22a. The guiding needle 22a need not be provided if the downstream end of the fiber
guiding section 22 is able to perform the function of the guiding needle 22a.
[0049] As shown in FIG. 2, the winding device 13 is arranged downstream of the spinning
device 9. The winding device 13 includes a cradle arm 71 that is pivotable about a
support shaft 73. The cradle arm 71 rotatably supports a bobbin 48 onto which the
spun yarn 10 is wound.
[0050] The winding device 13 includes a winding drum 72 and a traverse device 75. The winding
drum 72 is driven while being in contact with an outer peripheral surface of the bobbin
48 or an outer peripheral surface of the package 45 that is formed by winding the
spun yarn 10 on the bobbin 48. The traverse device 75 includes a traverse guide 76
on which the spun yarn 10 can be engaged. A not shown electric motor drives the winding
drum 72, thereby rotating the package 45 that is in contact with the winding drum
72. Simultaneously, the traverse guide 76 is caused to reciprocate by a not shown
driving mechanism. Thus, the winding device 13 winds the spun yarn 10 onto the package
45 while causing the spun yarn 10 to traverse.
[0051] As shown in FIGS. 1 and 2, the yarn joining carrier 3 includes a yarn joining device
43, suction devices (a suction pipe 44 and a suction mouth 46), a yarn-joint quality
monitor 47, a cutter 55, and a reverse driving mechanism 49. The reverse driving mechanism
49 includes a supporting arm 91 extendable from the yarn joining carrier 3 towards
the winding device 13 or retractable, and a reverse roller 92 that is supported at
the end of the supporting arm 91.
[0052] When a yarn breakage or cutting takes place in a certain spinning unit 2, the yarn
joining carrier 3 travels on a rail 41 to and stops at the concerned spinning unit
2. The suction pipe 44, while turning upward and downward about an axis, holds by
suction an end of the yarn coming out of the spinning device 9, and guides the end
to the yarn joining device 43. The suction mouth 46, while turning upward and downward
about an axis, holds by suction an end of the yarn from the package 45 that is supported
by the winding device 13, and guides the end of the yarn to the yarn joining device
43. In the spinning unit 2 in which a yarn breakage or cutting has taken place, the
cradle arm 71 is turned by a not shown driving mechanism so that the winding drum
72 and the package 45 are separated. Meanwhile, the reverse driving mechanism 49 causes
the reverse roller 92 to come into contact with the outer peripheral surface of the
package 45 by causing the supporting arm 91 to extend toward the winding device 13.
In this state, the reverse roller 92 is driven by a not shown motor, thereby causing
the package 45 to rotate in a direction of unspooling the spun yarn 10. A time period
for which the reverse roller 92 is driven is set such that, if the spun yarn 10 includes
a portion that needs to be removed, a length of the spun yarn 10 sufficient enough
to include that portion can be drawn into the suction mouth 46. The yarn joining device
43 joins the two ends of the yarn that are guided therein in this manner.
[0053] The yarn-joint quality monitor (monitoring device) 47 that monitors the quality of
the spun yarn 10 that is joined by the yarn joining device 43 is arranged immediately
downstream of the yarn joining device 43. The quality of the yarn joining performed
by the yarn joining device 43 is not always satisfactory. The yarn joining device
43 used in the present embodiment is of the type in which the yarn ends are untwisted
before they are twisted and joined by the swirling airflow. Therefore, for example,
the extent of untwisting of the end of the yarn, etc., can affect the quality of the
yarn joint. In the present embodiment, the quality of the yarn joint is detected by
the yarn-joint quality monitor 47, and if the quality does not satisfy a certain standard,
the yarn joining device 43 performs the yarn joining operation again.
[0054] The yarn-joint quality monitor 47 monitors a thickness of the spun yarn 10 that includes
a portion where yarn-joining has been performed by the yarn joining device 43 by using
a not shown optical sensor or electrostatic capacitance sensor. If any abnormality
is detected in the thickness of the spun yarn 10, the yarn-joint quality monitor 47
sends a fault signal to a not shown unit controller.
[0055] The cutter 55 is arranged immediately upstream of the yarn joining device 43. When
the unit controller receives the fault signal, the unit controller controls the cutter
55 to immediately cut the spun yarn 10 so that the yarn joining operation can be redone.
How the yarn joining operation is redone is explained in detail later.
[0056] The yarn pooling device 12 is arranged between the spinning device 9 and the winding
device 13. As shown in FIG. 2, the yarn pooling device 12 includes a yarn pooling
roller (pooling roller) 14 and an electric motor (driving section) 25 that drives
the yarn pooling roller 14 to rotate.
[0057] The yarn pooling roller 14 temporarily pools the spun yarn 10 by winding a specific
quantity of the spun yarn 10 on an outer peripheral surface thereof. By causing the
yarn pooling roller 14 to rotate at a predetermined rotation speed with the spun yarn
10 wound on the outer peripheral surface thereof, the spun yarn 10 can be drawn from
the spinning device 9 and conveyed downstream at a predetermined speed. By temporarily
pooling the spun yarn 10 on the outer peripheral surface of the yarn pooling roller
14, the yarn pooling device 12 functions as a kind of buffer between the spinning
device 9 and the winding device 13. Accordingly, any problem (such as, a slack in
the spun yarn 10) that arises due to a mismatch in a spinning speed of the spinning
device 9 and a winding speed of the winding device 13 due to whatever reason can be
resolved.
[0058] The electric motor 25 normally rotates the yarn pooling roller 14 in a direction
of spooling the spun yarn 10 on the yarn pooling roller 14, but can also rotate the
yarn pooling roller 14 in the opposite direction, that is, in the direction of unspooling
the spun yarn 10 from the yarn pooling roller 14.
[0059] The yarn pooling device 12 includes a yarn detecting sensor (detecting section) 86
and a yarn sucking device (suction section) 87 that are arranged opposing the yarn
pooling roller 14.
[0060] The yarn detecting sensor 86 is a non-contact type optical sensor and is electrically
connected to the unit controller. The yarn detecting sensor 86 detects whether the
spun yarn 10 has been currently wound on the outer peripheral surface of the yarn
pooling roller 14, and transmits a detection signal representing the detection result
to the unit controller.
[0061] The yarn sucking device 87 includes a suction pipe that is connected to a not shown
blower arranged in the blower box 80. The opening of the suction pipe is located near
the outer peripheral surface of the yarn pooling roller 14. The opening of the suction
pipe is located facing near an upstream end of the yarn pooling roller 14. The yarn
sucking device 87 creates a suction flow at the opening of the suction pipe and thereby
is able to suck in and remove the spun yarn 10. A yarn removal device (removal device)
88 that removes the spun yarn 10 pooled in the yarn pooling device 12 includes the
electric motor 25 that drives the yarn pooling roller 14 in the direction of unspooling
the spun yarn 10 from the yarn pooling roller 14, and the yarn sucking device 87.
[0062] A yarn-quality measuring equipment 59 is arranged between the spinning device 9 and
the yarn pooling device 12. The spun yarn 10 spun by the spinning device 9 passes
through the yarn-quality measuring equipment 59 before being wound in the yarn pooling
device 12.
[0063] The yarn-quality measuring equipment 59 has a structure that is similar to that of
the yarn-joint quality monitor 47, and monitors the thickness of the running spun
yarn 10 by using a not shown optical sensor or electrostatic capacitance sensor. Upon
detection of a yarn defect (portion of the spun yarn 10 having abnormal thickness
or the like) in the spun yarn 10, the yarn-quality measuring equipment 59 transmits
a yarn defect detection signal to the not shown unit controller. The yarn-quality
measuring equipment 59 can also detect the presence or absence of a foreign matter
in the spun yarn 10 as the yarn defect.
[0064] Upon detection of an abnormality in the spun yarn 10 based on a detection result
obtained in the yarn-quality measuring equipment 59, the unit controller controls
the air blowing nozzle 27 to stop the blow of air. Thus, the spinning of the spun
yarn 10 in the spinning device 9 is stopped. Consequently, the strength of the spun
yarn 10 at the position of the spinning device 9 decreases, and the spun yarn 10 is
cut at this position by tearing off. Thus, the air blowing nozzle 27 arranged in the
spinning device 9 on the one hand spins the fiber bundle 8 to form the spun yarn 10
while on the other hand plays the role of cutting the spun yarn 10. The unit controller
also stops the drafting by the drafting device 7.
[0065] Further downstream of the portion where the spun yarn 10 is cut, the spun yarn 10
is once wound onto the package 45 via the yarn pooling device 12. FIG. 4 shows the
cut spun yarn 10 in the state of being wound onto the package 45. The spun yarn 10
wound onto the package 45 includes the abnormal portion detected by the yarn-quality
measuring equipment 59.
[0066] Subsequently, the unit controller stops the winding operation of the winding device
13. Specifically, the cradle arm 71 is made to slant as shown in FIG. 4 by a not shown
cylinder, and the package 45 separates from the winding drum 72 that is always rotating.
A not shown brake mechanism arranged in the winding device 13 acts on the package
45 so that the package 45 is brought to a complete stop after a certain degree of
inertial rotation.
[0067] Subsequently, the unit controller sends a control signal to the yarn joining carrier
3, causing the yarn joining carrier 3 to move to and stop at the location of the spinning
unit 2 where the abnormality in the spun yarn 10 has been detected. Accordingly, the
yarn joining device 43 takes a position between the spinning device 9 and the winding
device 13 in the yarn running direction in the spinning unit 2. In this state, the
yarn pooling device 12 takes a position between the spinning device 9 and the yarn
joining device 43 in the yarn running direction, and the cutter 55 takes a position
between the yarn pooling device 12 and the yarn joining device 43 in the yarn running
direction.
[0068] When the yarn joining carrier 3 stops at the intended spinning unit 2, the unit controller
causes the drafting device 7 to restart and the spinning by the spinning device 9
to be resumed. The unit controller sends the control signal to the yarn joining carrier
3, and the yarn joining carrier 3 causes the suction pipe 44 and the suction mouth
46 to turn, as shown in FIG. 5, to hold by suction the yarn end on the spinning device
9 side and the yarn end on the package 45 side, respectively.
[0069] The yarn joining carrier 3 causes the supporting arm 91 of the reverse driving mechanism
49 to extend to the winding device 13 side, causing the reverse roller 92 to come
into contact with the package 45, and drives the reverse roller 92 to rotate in this
state to rotate the package 45 in the reverse direction. Thus, a length of the spun
yarn 10 on the package 45 side sufficient enough to include the abnormal portion wound
onto the package 45 is drawn into the suction mouth 46 by suction.
[0070] Next, as shown in FIG. 6, the yarn joining carrier 3 causes the suction pipe 44 and
the suction mouth 46 to turn in the opposite direction to guide the held yarn ends
to the yarn joining device 43, where yarn-joining is carried out.
[0071] Any excess spun yarn 10 is cut and removed by the yarn joining device 43. The abnormal
portion detected by the yarn-quality measuring equipment 59 is also removed. Although
the spinning device 9 continues to operate without stopping even during the yarn joining
operation, because the spun yarn 10 formed by the spinning device 9 sequentially is
pooled in the yarn pooling device 12, no slack occurs in the spun yarn 10.
[0072] Thereafter, the cradle arm 71 that is slanting is returned to its original position,
and as shown in FIG. 7, the package 45 comes into contact with the winding drum 72,
and the winding of the spun yarn 10 onto the package 45 resumes.
[0073] The yarn path is guided by a not shown lever-like movable guide member, or suchlike,
so that the spun yarn 10 passes through the yarn-joint quality monitor 47 and the
cutter 55 immediately after the winding is resumed. Accordingly, the yarn joint formed
by the yarn joining operation performed recently passes through the yarn-joint quality
monitor 47 and the quality of the joint is monitored.
[0074] In the state shown in FIG. 7, the yarn-joint quality monitor 47 monitors the thickness
of the running spun yarn 10. If a preset condition is satisfied, for example, that
the thickness, etc., of the spun yarn 10 is greater than a standard value, the yarn-joint
quality monitor 47 transmits the fault signal to the unit controller. In case the
winding of the spun yarn 10 onto the package 45 proceeds to some extent and still
the unit controller does not receive the fault signal, it signifies that the yarn
joining performed by the yarn joining device 43 has been good. In this case, the unit
controller controls the guiding member to cancel guiding of the yarn path so that
the spun yarn 10 is not guided to pass through the yarn-joint quality monitor 47 and
the cutter 55. In this manner, the spinning unit 2 returns to the normal state shown
in FIG. 2, and continues to wind the spun yarn 10 onto the package 45.
[0075] A case in which the yarn-joint quality monitor 47 detects a faulty yarn joint in
the state shown in FIG. 7, and sends the fault signal to the unit controller is explained
below. Upon receiving the fault signal, the unit controller causes the cutter 55 to
immediately cut the spun yarn 10, and similar to the case in which an abnormality
is detected by the yarn-quality measuring equipment 59, cuts the spun yarn 10 by stopping
the air blowing nozzle 27 from blowing air, and stops the drafting device 7. FIG.
8 shows the spun yarn 10 that is cut at two places by the control exerted by the unit
controller.
[0076] Immediately, thereafter, the unit controller stops the winding in the winding device
13 and rotates the yarn pooling roller 14 in the yarn pooling device 12 in a direction
opposite to the normal direction. Consequently, as shown in FIG. 9, the spun yarn
10 wound on the yarn pooling roller 14 is sequentially unspooled, sucked in and removed
by the yarn sucking device 87. The reverse rotation of the yarn pooling roller 14
continues until all the spun yarn 10 that was pooled is removed and the yarn detection
sensor 86 arranged near the yarn pooling roller 14 can no longer detect the spun yarn
10.
[0077] Thereafter, as explained with reference to FIG. 5, the unit controller causes the
operations of the drafting device 7 and the spinning device 9 to be resumed, and the
yarn joining carrier 3 causes the suction pipe 44 and the suction mouth 46 to turn
to hold by suction the yarn end on the spinning device 9 side and the yarn end on
the package 45 side, respectively. The yarn joining carrier 3 rotates the package
45 in the reverse direction by driving the reverse roller 92 of the reverse driving
mechanism 49.
[0078] Thereafter, as explained with reference to FIGS. 6 and 7, the unit controller causes
the yarn joining device 43 to perform the yarn joining operation, and causes the winding
of the spun yarn 10 to be resumed while the yarn joint is being monitored by the yarn-joint
quality monitor 47.
[0079] As a result, the removal of the faulty yarn joint and redoing of the yarn joining
operation are completed. In the present embodiment, the faulty yarn joint detected
by the yarn-joint quality monitor 47 is once wound onto the package 45; however, once
the faulty yarn joint is detected, the spun yarn 10 is not only cut by the spinning
device 9 but also by the cutter 55 that is located immediately upstream of the yarn-joint
quality monitor 47. Therefore, the length of the spun yarn 10 that needs to be drawn
to remove the faulty yarn joint by rotating the package 45 in the reverse direction
can be reduced. Furthermore, the reverse rotation of the yarn pooling roller 14 happens
fast because the yarn pooling roller 14 is usually much lighter than the package 45,
though the weight of the package 45 depends on the wound amount of the spun yarn 10.
Consequently, the spun yarn 10 that is pooled in the yarn pooling device 12 between
the two places where the spun yarn 10 is cut can be quickly removed by the fast reverse
rotation of the yarn pooling roller 14. Thus, the process can swiftly proceed to the
yarn joining operation by the yarn joining device 43, and the time required for redoing
the yarn joining operation can be effectively reduced.
[0080] As explained above, the spinning machine 1 according to the present embodiment includes
the spinning device 9, the winding device 13, the yarn joining device 43, the yarn
pooling device 12, and the cutter 55. The spinning device 9 supplies the spun yarn
10. The winding device 13 winds the spun yarn 10 onto the package 45. The yarn joining
device 43 joins the yarn end of the spun yarn 10 on the spinning device 9 side and
the yarn end of the spun yarn 10 on the winding device 13 side at a position between
the spinning device 9 and the winding device 13 in the yarn running direction. The
yarn pooling device 12 temporarily pools the spun yarn 10 at a position between the
spinning device 9 and the yarn joining device 43 in the yarn running direction. The
cutter 55 cuts the spun yarn 10 at a position between the yarn pooling device 12 and
the yarn joining device 43 in the yarn running direction.
[0081] When the spun yarn 10 is cut with the cutter 55, the length of the spun yarn 10 that
is wound by the winding device 13 can be made short. Consequently, the length of the
spun yarn 10 that needs to be drawn from the package 45 for the yarn joining operation
by the yarn joining device 43 is also made short, and the yarn joining operation can
be performed efficiently.
[0082] In the spinning machine 1 according to the present embodiment, the yarn-joint quality
monitor 47 that detects any abnormality in the spun yarn 10 by monitoring the spun
yarn 10 that is joined by the yarn joining device 43 is arranged immediately downstream
of the yarn joining device 43 in the yarn running direction. The cutter 55 cuts the
spun yarn 10 when an abnormality is detected in the spun yarn 10 by the yarn-joint
quality monitor 47.
[0083] Thus, since any defective yarn-joining made by the yarn joining device 43 can be
detected early by the yarn-joint quality monitor 47, the spun yarn 10 can be immediately
cut by the cutter 55, and the yarn joining operation can be redone by the yarn joining
device 43. Consequently, the package 45 can be wound more efficiently.
[0084] The spinning machine 1 according to the present embodiment further includes the air
blowing nozzle 27 and the yarn removal device 88. The air blowing nozzle 27 cuts the
spun yarn 10 that is supplied from the spinning device 9 to the yarn pooling device
12 by stopping air blowing therefrom. The yarn removal device 88 removes the spun
yarn 10 pooled in the yarn pooling device 12.
[0085] Thus, the spun yarn 10 at the downstream of the yarn pooling device 12 is cut by
the cutter 55 and the spun yarn 10 at the upstream of the yarn pooling device 12 is
cut by the air blowing nozzle 27. Consequently, the spun yarn 10 pooled in the yarn
pooling device 12 can be removed easily by the yarn removal device 88.
[0086] In the spinning machine 1 according to the present embodiment, the yarn pooling device
12 includes the yarn pooling roller 14 for pooling the spun yarn 10 by winding the
spun yarn 10 on the outer peripheral surface thereof. The yarn removal device 88 includes
the yarn sucking device 87 and the electric motor 25. The yarn sucking device 87 is
arranged near the yarn pooling device 12 and sucks in the spun yarn 10 pooled in the
yarn pooling device 12. The electric motor 25 drives the yarn pooling device 12 in
the direction that assists the suction of the spun yarn 10 by the yarn sucking device
87.
[0087] Thus, by proactively causing the spun yarn 10 pooled in the yarn pooling device 12
to be sucked in by the yarn sucking device 87, the spun yarn 10 can be removed definitively
and in a short time.
[0088] The spinning machine 1 according to the present embodiment includes the yarn detecting
sensor 86 that detects whether the spun yarn 10 has been removed from the yarn pooling
device 12. The yarn joining device 43 performs joining of the spun yarn 10 when the
yarn detecting sensor 86 detects that the spun yarn 10 has been removed.
[0089] Thus, the unnecessary spun yarn 10 pooled in the yarn pooling device 12 is prevented
from getting in the way when the yarn joining device 43 is performing the yarn joining
operation. Consequently, failure of the yarn joining operation and a drop in the quality
of the package 45 can be prevented.
[0090] In the spinning machine 1 according to the present embodiment, the spinning device
9 used as the yarn supplying device forms the spun yarn 10 by spinning the fiber bundle
8 by using airflow.
[0091] The spun yarn 10 pooled in the yarn pooling device 12 tends to be fairly long in
the spinning machine 1 in which the air-jet spinning device 9 is used as the yarn
supplying device and the spun yarn 10 is formed continuously at high speed and pooled
in the yarn pooling device 12 located downstream of the spinning device 9. Therefore,
in the spinning machine 1 of this kind, it is preferable that the spun yarn 10 be
cut between the yarn pooling device 12 and the yarn joining device 43.
[0092] The spinning machine 1 according to the present embodiment includes a plurality of
the spinning units 2 arranged side-by-side and the yarn joining carrier 3. Each of
the spinning units 2 includes the spinning device 9, the winding device 13, and the
yarn pooling device 12. The yarn joining carrier 3 is movable to each of the spinning
units 2, and includes the cutter 55 and the yarn joining device 43.
[0093] Thus, in the spinning machine 1 that includes the yarn joining carrier 3, the yarn
joining operation by the yarn joining device 43 can be performed efficiently, and
thereby, the overall winding efficiency of the package 45 can be improved.
[0094] Exemplary embodiments of the present invention have been explained above; however,
the following modifications can be made in the structure.
[0095] At least one of the cutter 55 and the yarn joining device 43 can be arranged in each
of the spinning units 2 instead of in the yarn joining carrier 3. If both the cutter
55 and the yarn joining device 43 are arranged in the spinning unit 2, the yarn joining
carrier 3 can be omitted. If the frequency of cutting, etc., in the spinning units
2 is less, as explained in the above embodiment, the yarn joining carrier 3 can be
provided to perform yarn joining operation in a plurality of the spinning units 2.
Accordingly, it is possible to reduce the number of cutters, yarn joining devices
as well as the cost.
[0096] Instead of cutting the spun yarn 10 with the air blowing nozzle 27 of the spinning
device 9, a second cutter can be arranged, for example, between the spinning device
9 and the yarn pooling device 12 for cutting the spun yarn 10.
[0097] The spinning device according to the present embodiment performs spinning by the
air blowing nozzle 27 that produces airflow that swirls in one direction; however,
the structure of the spinning device is not limited to this. Various spinning methods
can be used. For example, the spinning device can include a pair of nozzles that produce
airflows in mutually opposite directions, and can thus twist the fiber bundle in opposite
directions at the same time.
[0098] Alternatively, a pair of rollers constituting a yarn supplying device can be arranged
at a position between the spinning device 9 and the yarn pooling device 12 in the
yarn running direction.
[0099] The yarn pooling device in the present embodiment pools the spun yarn 10 by winding
the spun yarn 10 on the outer peripheral surface of the yarn pooling roller 14; however,
the structure of the yarn pooling device is not limited to this. Various pooling methods
can be used. For example, in a spinning machine having the yarn supplying device mentioned
above, an elongated tube (slack tube) that sucks and pools the spun yarn inside can
serve as a yarn pooling device. In this case, the pooled spun yarn is further sucked
and removed by the slack tube immediately after being cut by the cutter 55 and the
air blowing nozzle 27. The slack tube serves both as a yarn pooling device and a removal
device.
[0100] The present invention is not limited to the spinning machine explained in the present
embodiment but can be widely applied to yarn winding apparatuses that include a yarn
joining device. The present invention can be applied, for example, to an automatic
winder that unspools a yarn from a yarn supplying bobbin, which is formed by winding
the spun yarn, and winds the yarn to form a package. In this case, the part where
the yarn supplying bobbin is set corresponds to the yarn supplying device.