BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The present invention relates to a yarn winding machine and a textile machine including
the yarn winding machine.
2. Description of the Related Art
[0002] Conventionally, as an art in this field, there has been known a yarn withdrawal method
of a winding package disclosed in Japanese Unexamined Patent Application Publication
No.
2-75674. In the yarn withdrawal method of the winding package, when a suction mouth adapted
to suck a yarn end from the winding package is adjacent to the package, an initial
driving to reversely rotate a winding drum at a low speed is started and, after the
rotation is performed a set number of times, the winding drum is switched to a normal
reverse rotation, which is faster.
SUMMARY OF THE INVENTION
[0003] In a yarn winding machine, when the yarn end from the package is sucked and caught,
a double withdrawal in which a yarn on a surface of the package is also sucked and
caught may occur, which may cause defects to the package.
[0004] An object of the present invention is to provide a yarn winding machine capable of
preventing defects in the package.
[0005] A yarn winding machine according to the present invention includes a winding unit
main body adapted to form a package by winding a yarn, a first catching and guiding
device provided in the winding unit main body and adapted to suck and catch the yarn
from the package and to guide the yarn, a control section adapted to control the first
catching and guiding device to perform a first catching operation at a catching region
to suck and catch the yarn from the package by the first catching and guiding device,
a separating operation to separate the first catching and guiding device farther away
from the package than the catching region to withdraw the yarn, which has been sucked
and caught by the first catching and guiding device from a surface of the package,
a guiding operation to guide the yarn to a target region by the first catching and
guiding device, and a second catching operation at the catching region to suck and
catch the yarn from the package again by the first catching and guiding device between
the separating operation and the guiding operation, and a setting section adapted
to set a control value relating to adjustment of the second catching operation by
the first catching and guiding device.
[0006] In the yarn winding machine, the control section performs the first catching operation,
which is performed for the first time as a catching operation at the catching region
to suck and catch the yarn from the package, and the second catching operation, which
is a catching operation performed for the second time. By the second catching operation,
a yarn waste, which is generated by a yarn cut performed after a double withdrawal
occurs, can be sucked and removed. In addition, in a case where a sucking and catching
error occurs in the first catching operation, the yarn end that could not be caught
can be caught. Furthermore, since the setting section adapted to adjust the second
catching operation is provided, the second catching operation can be performed under
an optimal condition that suits a yarn winding condition. Accordingly, this preferably
allows removing the yarn waste and catching the yarn end that could not be caught.
[0007] In one embodiment, the yarn winding machine further includes a yarn supplying section
adapted to supply the yarn to be wound around the package, a second catching and guiding
device adapted to catch the yarn from the yarn supplying section and to guide the
yarn, a yarn joining device adapted to join the yarn from the package guided by the
first catching and guiding device and the yarn from the yarn supplying section guided
by the second catching and guiding device when continuation of the yarn is disconnected
between the yarn supplying section and the package, and the yarn detecting device
provided in a path where the yarn travels during yarn winding operation and adapted
to determine whether or not the yarn from the package has been guided to the yarn
joining device by the first catching and guiding device. The target region is a receiving
position where the yarn joining device receives the yarn. Since this configuration
allows the determination to be made whether or not the yarn from the package has been
guided to the yarn joining device, a determination can be made whether or not to be
able to perform yarn joining by the yarn joining device, which is a next step. In
addition, with the above-described configuration, since determinations whether or
not the yarn joining has been performed are collectively made after carrying out the
catching operation, the separating operation, the standby operation and the guiding
operation two times, waiting time can be saved in comparison with a configuration
in which the determination is made between the operations. Furthermore, since success
rate of catching the yarn is improved by performing the catching operation two times,
entire operation efficiency is improved by collectively making the determinations.
When a large amount of failures occurs, operation efficiency may be reduced in some
cases by collectively making the determinations, however, in this case, the entire
operation efficiency can be improved by adjusting the second catching operation with
the setting section and by improving the success rate.
[0008] In one embodiment, in a case where a determination is made by the yarn detecting
device that guiding of the yarn from the package to the yarn joining device by the
first catching and guiding device has failed, the control section controls the first
catching and guiding device to perform a repeating operation in which each of the
first catching operation, the separating operation, the second catching operation
and the guiding operation is repeated by the first catching and guiding device. With
this configuration, in a case where the guiding of the yarn from the package to the
yarn guiding device has failed, since the repeating operation in which each of the
first catching operation, the separating operation, the second catching operation
and the guiding operation is repeated by the first catching and guiding device is
performed, the guiding of the yarn from the package can be performed again without
manual operation by an operator.
[0009] In one embodiment, the setting section is configured to be capable of setting the
control value relating to the adjustment of the second catching operation by the first
catching and guiding device in performing the repeating operation. With this configuration,
in the case where the guiding of the yarn from the package to the yarn joining device
has failed, the first catching and guiding device can be controlled under a different
condition when performing the repeating operation in which each of the first catching
operation, the separating operation, the second catching operation and the guiding
operation is performed. Consequently, success rate of guiding of the yarn from the
package is improved.
[0010] The setting section includes at least either one of a time setting section adapted
to set a period of time in which the second catching operation is performed or a number-of-rotation
setting section adapted to set the number of rotations for the second catching operation.
The control section controls the first catching and guiding device to perform the
second catching operation based on, as the control value relating to the adjustment
of the second catching operation, at least either one of the period of time set by
the time setting section or the number of rotations set by the number-of-rotation
setting section. Consequently, the second catching operation can be performed under
an optimal condition that suits production purpose.
[0011] In one embodiment, the control section controls the first catching and guiding device
to perform the second catching operation with a priority on the period of time in
a case where the setting section sets both the period of time with the time setting
section and the number of rotations with the number-of-rotation setting section. With
this configuration, since the period of time is applied on a priority basis, the second
catching operation is prevented from unnecessarily taking time, thereby improving
production efficiency.
[0012] In one embodiment, the control section is adapted to control the first catching and
guiding device to perform the second catching operation with a priority on the number
of rotations in the case where the setting section sets both the period of time with
the time setting section and the number of rotations with the number-of-rotation setting
section. With this configuration, since the number of rotations is applied on a priority
basis, which allows rotation of the package as much as required in the second catching
operation, prevention of the yarn waste from mixing in and prevention of a yarn catching
error can be both realized, thereby improving production quality.
[0013] In one embodiment, the yarn detecting device serves as a yarn defect detecting device
adapted, in a case where a yarn defect is included in the yarn being wound around
the package, to detect the yarn defect. With this configuration, the yarn detecting
device can double as the yarn defect detecting device, thereby allowing a configuration
of the yarn winding machine to be simplified.
[0014] In one embodiment, the yarn supplying section is configured to be capable of setting
a yarn supplying bobbin around which a yarn is wound. With this configuration, in
an automatic winder, yarn joining operation is appropriately performed and thereby
winding the yarn around the package can be smoothly resumed in the yarn winding machine.
[0015] In one embodiment, a textile machine including a plurality of the yarn winding machines
further includes a machine setting device adapted to control each of the yarn winding
machines. The setting section is arranged in the machine setting device. With this
configuration, since setting of the yarn winding machine provided in plural can be
collectively changed by the setting section in the machine setting device, change
in the setting is not required to be performed in every yarn winding machine, thereby
saving trouble of the operator.
[0016] With the present invention, defect in the package can be prevented.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017]
FIG. 1 is a schematic view of an automatic winder including a winder unit according
to one embodiment;
FIG. 2 is a schematic view and a block diagram illustrating a structure of the winder
unit;
FIG. 3 is an enlarged left-side view of a portion in proximity to a traverse device
of the winder unit;
FIG. 4 is an enlarged right-side view illustrating a portion in proximity to a cradle
of the winder unit;
FIG. 5 is a left-side view of the winder unit;
FIG. 6 is a left-side view of the winder unit;
FIG. 7 is a left-side view of the winder unit;
FIG. 8 is a left-side view illustrating a package moving to a non-contact position
or a contact position;
FIG. 9 is a diagram illustrating a relation between rotational speeds of the package
and movements of an upper-yarn catching member;
FIG. 10 is a diagram illustrating a relation between the rotational speeds of the
package and the movements of the upper-yarn catching member according to an alternative
embodiment;
FIG. 11 is a diagram illustrating a relation between the rotational speeds of the
package and the movements of the upper-yarn catching member according to a still further
alternative embodiment;
FIG. 12 is a diagram illustrating a relation between the rotational speeds of the
package and the movements of the upper-yarn catching member according to a still further
alternative embodiment;
FIG. 13 is a diagram illustrating a relation between the rotational speeds of the
package and the movements of the upper-yarn catching member according to a still further
alternative embodiment;
FIG. 14 is a block diagram illustrating a schematic structure of the winder unit and
a machine setting device;
FIGS. 15 are each a schematic operation diagram according to the embodiment of FIG.
13;
FIG. 15A illustrates a first catching operation of the upper-yarn catching member;
FIG. 15B illustrates a separating operation of the upper-yarn catching member;
FIG. 15C illustrates a second catching operation of the upper-yarn catching member;
FIG. 15D illustrates a standby operation of the upper-yarn catching member; and
FIG. 15E illustrates a guiding operation of the upper-yarn catching member.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0018] A preferred embodiment of the present invention will be hereinafter described in
detail with reference to the attached drawings. The same reference numerals are denoted
on the same or corresponding portions throughout the drawings, and redundant description
will be omitted.
[0019] An overall configuration of an automatic winder (textile machine) 1 including a winder
unit (yarn winding machine) 10 of the present embodiment will be described with reference
to FIG. 1. "Upstream" and "downstream" in the present specification respectively indicate
upstream and downstream in a travelling direction of a yarn 20 at the time of yarn
winding.
[0020] As illustrated in FIG. 1, the automatic winder 10 includes as main components, a
plurality of the winder units 10 arranged next to each other, an automatic doffing
device 80 and a machine setting device 90.
[0021] Each of the winder units 10 is capable of forming a package 30 by winding the yarn
20 unwound from a yarn supplying bobbin 21 while traversing the yarn 20.
[0022] When the package 30 is fully wound in each winder unit 10, the automatic doffing
device 80 travels to a position of the relevant winder unit 10 and removes the fully-wound
package 30 from the winder unit 10. The automatic doffing device 80 may supply an
empty bobbin to the winder unit 10 after removing the package 30.
[0023] The machine setting device 90 includes as main components, a setting section (inputting
section) 91 and a display section 92. The setting section 91 is capable of performing
setting to each winder unit 10 when an operator inputs a predetermined set value (control
value) or selects an appropriate control method. The display section 92 is capable
of displaying a winding status of the yarn 20 of each winder unit 10, contents of
an occurred trouble, or the like.
[0024] Next, a configuration of the winder unit 10 will be specifically described with reference
to FIGS. 2 to 8. As illustrated in FIG. 2, each winder unit 10 includes a winding
unit main body 16 and a unit control section (control section) 50.
[0025] The winding unit main body 16 includes a yarn unwinding assisting device 12, a tension
applying device 13, a splicer device (yarn joining device) 14 and a clearer (yarn
defect detecting section) 15 sequentially arranged from a side of the yarn supplying
bobbin 21 in a yarn travelling path between the yarn supplying bobbin 21 and a contact
roller 29.
[0026] A yarn supplying section 11 adapted to supply the yarn 20 to a winding bobbin 22
is provided in a lower part of the winding unit main body 16 in a direction of machine
height. The yarn supplying section 11 is capable of holding at a predetermined position,
the yarn supplying bobbin 21 transported by a bobbin transporting system, which is
not illustrated.
[0027] By lowering a regulating member 40 adapted to cover a core tube of the yarn supplying
bobbin 21 in conjunction with unwinding of the yarn 20 from the yarn supplying bobbin
21, the yarn unwinding assisting device 12 assists the unwinding of the yarn 20 from
the yarn supplying bobbin 21. The regulating member 40 makes contact with a balloon
of the yarn 20, which is formed in an upper portion of the yarn supplying bobbin 21
with swinging and centrifugal force of the yarn 20 unwound from the yarn supplying
bobbin 21, and controls the balloon to an appropriate size to assist the unwinding
of the yarn 20. A sensor (not illustrated) adapted to detect a chase section of the
yarn supplying bobbin 21 is provided in proximity to the regulating member 40. When
the sensor detects lowering of the chase section, the yarn unwinding assisting device
12 can lower the regulating member 40 with an air cylinder (not illustrated), e.g.,
following the chase section.
[0028] The tension applying device 13 applies a predetermined tension on the travelling
yarn 20. The tension applying device 13 may be, e.g., a gate type in which movable
comb teeth are arranged with respect to fixed comb teeth. The movable comb teeth can
be swung by a rotary solenoid such that the movable comb teeth and the fixed comb
teeth can be engaged with each other or released from each other. The tension applying
device 13 may be, e.g., a disc type other than the above-described gate type.
[0029] The splicer device 14 joins a lower yarn from the yarn supplying bobbin 21 and an
upper yarn form the package 30 at the time of a yarn cut performed by the clearer
15 upon detection of a yarn defect, at the time of a yarn breakage during unwinding
of the yarn 20 from the yarn supplying bobbin 21, or the like. As a yarn joining device
adapted to join the upper yarn and the lower yarn in such a manner, a mechanical type,
a type that uses fluid such as compressed air, or the like may be employed.
[0030] The clearer 15 includes a clearer head 49 in which a sensor (not illustrated) adapted
to detect a thickness of the yarn 20 is arranged, and an analyzer 52 adapted to process
a yarn thickness signal from the sensor. The clearer 15 detects the yarn defect such
as a slub by monitoring the yarn thickness signal from the sensor. A cutter 39 is
provided in proximity to the clearer head 49 to immediately cut the yarn 20 upon detection
of the yarn defect by the clearer 15. The clearer 15 may detect a presence or an absence
of a foreign substance included in the yarn 20 as a presence or an absence of the
yarn defect.
[0031] Below and above the splicer device 14, there are respectively provided a lower-yarn
catching member (second catching and guiding device) 25 adapted to catch a yarn end
from the yarn supplying bobbin 21 and to guide the yarn end to the splicer device
14, and an upper-yarn catching member (first catching and guiding device) 26 adapted
to catch a yarn end from the package 30 and to guide the yarn end to the splicer device
14. The lower-yarn catching member 25 includes a lower-yarn pipe arm 33 and a lower-yarn
suction mouth 32 that is formed at a tip end of the lower-yarn pipe arm 33. The upper-yarn
catching member 26 includes an upper-yarn pipe arm 36 and an upper-yarn suction mouth
(suction mouth) 35 that is formed at a tip end of the upper-yarn pipe arm 36.
[0032] The lower-yarn pipe arm 33 and the upper-yarn pipe arm 36 are respectively swingable
with shafts 34 and 37 as a center. An appropriate negative pressure source is connected
to each of the lower-yarn pipe arm 33 and the upper-yarn pipe arm 36. In this manner,
suction flow is generated in the lower-yarn suction mouth 32 and the upper-yarn suction
mouth 35, and thereby the yarn ends of the upper yarn and the lower yarn can be sucked
and caught. The upper-yarn catching member 26 is swung independently from the lower-yarn
catching member 25 by a motor 38. As the motor 38, various types of motors such as
a servomotor, a step motor, and an induction motor may be employed.
[0033] As illustrated in FIGS. 5 to 7, the upper-yarn catching member 26 is arranged in
a movable manner such that the upper-yarn suction mouth 35 is located at a catching
region R1, a standby region R2 and a yarn joining region (target region) R3. The catching
region R1 is located in proximity to the package 30 and is a region where the yarn
end 30a of the package 30 can be caught. The standby region R2 is a region where the
upper-yarn suction mouth 35 is located farther away from the package 30 than the catching
region R1 by the upper-yarn pipe arm 36 of the upper-yarn catching member 26 being
swung in a direction to be farther away from the package than the catching region
R1. The yarn joining region R3 is a region where the yarn end 30a, which has been
caught in the catching region R1, is guided to the splicer device 14 and is received
and joined by the splicer device 14. The standby region R2 and the yarn joining region
R3 are regions where the upper-yarn catching member 26 is located when moving from
the catching region R1 to the splicer device 14.
[0034] As illustrated in FIG. 2, the winding unit main body 16 includes a cradle 23 adapted
to support the winding bobbin 22 in a removable manner, and a contact roller 29 capable
of rotating in contact with a peripheral surface of the winding bobbin 22 or a peripheral
surface of the package 30. The winding unit main body 16 includes in proximity to
the cradle 23, an arm-type traverse device 70 adapted to traverse the yarn 20, and
is capable of winding the yarn 20 around the package 30 while traversing the yarn
20 with the traverse device 70.
[0035] A guide plate 28 is provided slightly upstream of a traverse portion and is adapted
to guide the upstream yarn 20 to the traverse portion. A ceramics traverse fulcrum
27 is arranged farther upstream of the guide plate 28. The traverse device 70 traverses
the yarn 20 in a winding width direction of the package 30 (a direction indicated
by an arrow in FIG. 2) with the traverse fulcrum 27 as a fulcrum.
[0036] The cradle 23 is capable of swinging with a swinging shaft 48 as a center. An increase
in a yarn layer diameter of the package 30 associated with winding of the yarn 20
around the winding bobbin 22 can be absorbed with swinging of the cradle 23.
[0037] A package driving motor 41 formed of a servomotor, e.g., is mounted to the cradle
23. The winder unit 10 winds the yarn 20 by rotationally driving the winding bobbin
22 with the package driving motor 41. The package driving motor 41 is capable of rotationally
driving the winding bobbin 22 (the package 30) in a winding direction as well as in
an unwinding direction A.
[0038] When the winding bobbin 22 is supported by the cradle 23, a motor shaft of the package
driving motor 41 is coupled to the relevant winding bobbin 22 so as not to relatively
rotate with respect to the winding bobbin 22 (a so-called direct drive system). Operation
of the package driving motor 41 is controlled by a package driving control section
(control section) 42. The package driving control section 42 controls the package
driving motor 41 to operate or stop in response to a drive signal from a unit control
section 50. As the package driving motor 41, various types of motors such as a step
motor or an induction motor may be employed without being limited to the servomotor.
[0039] An angle sensor (diameter acquiring section) 44 adapted to detect an angle of the
cradle 23 is mounted to the swinging shaft 48. The angle sensor 44 is formed of a
rotary encoder, e.g., and transmits an angle signal, which corresponds to the angle
of the cradle 23, to the unit control section 50. Since the angle of the cradle 23
changes as a wound diameter of the package 30 increases, the diameter of the package
30 can be detected by detecting a swing angle of the cradle 23 with the angle sensor
44. Any appropriate configuration may be employed to detect the diameter of the package
30 other than the angle sensor 44. For example, a configuration that uses a Hall IC,
an absolute type encoder, or the like may be employed to detect the diameter of the
package 30.
[0040] Next, a layout of a configuration of the traverse device 70 and a configuration in
proximity to the traverse device 70 will be described with reference to FIG. 3. In
the present embodiment, since the contact roller 29 is arranged such that an axial
direction thereof corresponds to a lateral direction of the winding unit main body
16, a side view such as FIG. 3, e.g., can be a view in the axial direction of the
contact roller 29. In FIG. 3, rotation of the package 30 in the winding direction
is clockwise and rotation of the package 30 in the unwinding direction is counterclockwise.
[0041] As illustrated in FIG. 3, the traverse device 70 includes a traverse driving motor
76, an output shaft 77 and a traverse arm (traverse guide) 74.
[0042] The traverse driving motor 76 is adapted to drive the traverse arm 74 and is formed
of a servomotor or the like. As illustrated in FIG. 2, operation of the traverse driving
motor 76 is controlled by a traverse control section 78. The traverse driving motor
76 may be another motor such as a step motor or a voice coil motor.
[0043] The traverse control section 78 is formed of hardware such as a dedicated microprocessor
or the like, and is adapted to control the traverse driving motor 76 to operate or
stop in response to a signal from the unit control section 50.
[0044] Power of the traverse driving motor 76 is transmitted to a base-end portion of the
traverse arm 74 via the output shaft 77 illustrated in FIG. 3. Since a rotor of the
traverse driving motor 76 forwardly and reversely rotates, the traverse arm 74 swings
into and/or out of the page of FIG. 3 (in a left-right direction (traverse direction)
in FIG. 2). The traverse arm 74 illustrated in FIG. 3 indicates a position at a traverse
end portion.
[0045] A hook-shaped yarn guiding section 73 is formed at a tip-end portion of the traverse
arm 74. The yarn guiding section 73 can hold and guide the yarn 20. The yarn guiding
section 73 reciprocates in a state of holding the yarn 20, thereby allowing traverse
of the yarn 20.
[0046] Next, a configuration of the cradle 23 will be described in further detail with reference
to FIG. 4. As illustrated in FIG. 4, the winding unit main body 16 includes a swinging
plate 17 adapted to be capable of swinging with the swinging shaft 48 as a center.
The cradle 23 swings with the swinging shaft 48 as a center in a unified manner with
the swinging plate 17. A spring 18 formed as a tension spring for gradually decreasing
contact pressure and an air cylinder 60 are both connected to the swinging plate 17.
A predetermined swinging torque can be applied to the cradle 23 by the spring 18 and
the air cylinder 60.
[0047] The air cylinder 60 is formed as a double-acting cylinder including a piston 601
in an interior thereof. In FIG. 4, compressed air of air pressure P1 and compressed
air of air pressure P2 are respectively supplied to a cylinder chamber in a right
side and a cylinder chamber in a left side of a drawing of the piston 601.
[0048] An electro-pneumatic regulator 61 is connected to a pipe that supplies the compressed
air of the air pressure P2 to the air cylinder 60. The electro-pneumatic regulator
61 is capable of adjusting the air pressure P2 steplessly. The electro-pneumatic regulator
61 controls the air pressure P2 based on a control signal input from the unit control
section 50.
[0049] In a configuration illustrated in FIG. 4, since force of the air cylinder 60 to pull
the cradle 23 increases when the air pressure P2 is decreased, torque that causes
the cradle 23 to swing to a front side of the winding unit main body 16 with the swinging
shaft 48 as a center increases. Since the contact roller 29 is arranged closer to
the front side of the winding unit main body 16 than the swinging shaft 48, contact
pressure between the package 30 and the contact roller 29 can be increased with the
decrease of the air pressure P2. On the contrary, since the force of the air cylinder
60 to pull the cradle 23 decreases when the air pressure P2 is increased, torque that
causes the cradle 23 to swing to a rear side of the winding unit main body 16 with
the swinging shaft 48 as a center increases. Consequently, the contact pressure between
the package 30 and the contact roller 29 can be weakened. By further increasing the
air pressure P2, the package 30 can even be located away from a surface of the contact
roller 29.
[0050] The air cylinder 60 can swing the cradle 23 and thereby move the package 30. In this
case, the package 30 can be moved to a position where the package 30 is located away
from the contact roller 29 (a position where the package is not in contact with the
contact roller 29) and a position where the package is in contact with the contact
roller 29.
[0051] The unit control section 50 includes, e.g., a CPU, a RAM, a ROM, an I/O port and
a communication port. A program to control each component of the winding unit main
body 16 is recorded in the ROM. Each section, which is provided in the winding unit
main body 16, and the machine setting device 90 are connected to the I/O port and
the communication port, which enables communication of control information or the
like. Consequently, the unit control section 50 can control operations of each section
provided in the winding unit main body 16.
[0052] The unit control section 50 transmits a drive signal to the package driving control
section 42 to control rotational driving (a rotational speed) of the package driving
motor 41. The unit control section 50 controls movements of the lower-yarn catching
member 25 and the upper-yarn catching member 26 (swings of the lower-yarn pipe arm
33 and the upper-yarn pipe arm 36). Specifically, the unit control section 50 controls
the motor 38 of the upper-yarn catching member 26 to perform a catching operation
at the catching region R1 to suck and catch the yarn 20, a standby operation to be
under standby at the standby region R2 and a guiding operation to guide the yarn 20
to the yarn joining region R3.
[0053] The unit control section 50 adjusts the standby operation of the upper-yarn catching
member 26 at the standby region R2 according to the package diameter of the package
30 detected by the angle sensor 44, a length of a yarn defect in the yarn 20 detected
by the clearer 15 and a rotational speed of the package 30. The unit control section
50 adjusts at least one of a stopped position of the upper-yarn suction mouth 35 at
the standby region R2, a period of time the upper-yarn suction mouth 35 is stopped
at the standby region R2, a speed at which the upper-yarn catching member 26 moves
from the catching region R1 to the standby region R2, and acceleration of the upper-yarn
catching member 26 moving from the catching region R1 to the standby region R2.
[0054] Specifically, the unit control section 50 sets, e.g., a period of standby time (stopping
time) of the upper-yarn catching member 26 at the standby region R2 based on the length
of the yarn defect in the yarn 20 detected by the clearer 15. The unit control section
50 sets both of a separation distance between the package 30 and the catching region
R1 and a separation distance between the package 30 and the stopped position of the
upper-yarn suction mouth 35 at the standby region R2 to be large according to an increase
in the diameter of the package 30 detected by the angle sensor 44. That is, the unit
control section 50 controls the upper-yarn catching member 26 such that the upper-yarn
suction mouth 35 is farther away from the package 30 as the diameter of the package
30 becomes large. The unit control section 50 sets the stopped position of the upper-yarn
suction mouth 35 at the standby region R2 according to the rotational speed (a yarn
guiding speed) of the package 30.
[0055] The setting section 91 of the machine setting device 90 illustrated in FIG. 1 sets
a number of rotations, which is a number of times the package 30 is rotated at a yarn-end
catching speed (to be described later in detail) in the unwinding direction A when
continuation of the yarn 20 is disconnected (hereinafter referred to as a "yarn disconnection
and the like") by a yarn cut performed by the clearer 15 upon detection of the yarn
defect, a yarn breakage during unwinding of the yarn 20 from the yarn supplying bobbin
21, or the like. The setting section 91 sets the number of rotations of the package
30 based on, e.g., the diameter of the package 30 detected by the angle sensor 44,
or the like. In a case, e.g., where the diameter of the package 30 is small, the setting
section 91 sets the number of rotations large since the yarn end 30a is unlikely to
come off the surface of the package 30. In a case where the diameter of the package
30 is large, the setting section 91 sets the number of rotations small since the yarn
end 30a is likely to come off the surface of the package 30. The setting section 91
transmits the set number of rotations of the package 30 to the unit control section
50.
[0056] The setting section 91 may set the number of rotations of the package 30 in the unwinding
direction A at the time of yarn disconnection based on information that has been set
and input in advance. In other words, the setting section 91 sets the number of rotations
of the package 30 based on information input from the setting section 91 with a key
operation and the like by an operator. In such a configuration, the operator can set
the number of rotations of the package 30 to a desired number.
[0057] In the above-described winder unit 10, when the yarn disconnection and the like occurs,
the lower yarn and the upper yarn are required to be joined by the splicer device
14. Thus, the lower yarn from the yarn supplying bobbin 21 is required to be caught
by the lower-yarn suction mouth 32 and the upper yarn from the package 30 is required
to be caught and withdrawn by the upper-yarn suction mouth 35. Control of a withdrawal
operation of the upper yarn and a yarn withdrawal method both performed in the winder
unit 10 will be described in detail with reference to FIGS. 2 to 9.
[0058] As illustrated in FIG. 3, the surface of the package 30 is in contact with the contact
roller 29 during winding operation before the yarn disconnection and the like occurs.
As just described, a position of the package 30 where the package 30 is in contact
with the contact roller 29 is hereinafter referred to as a "contact position" and
is indicated by a reference symbol "Q2" in FIGS. 4 and 8.
[0059] Immediately after the yarn disconnection and the like occurs during the winding operation,
the unit control section 50 transmits a drive signal to the electro-pneumatic regulator
61. Since the electro-pneumatic regulator 61 is driven based on the drive signal,
the air pressure P2 of the air cylinder 60 is changed, thereby, as illustrated in
FIGS. 5 and 8, causing the cradle 23 to be driven in a direction to be located away
from the contact roller 29. The unit control section 50 transmits a drive signal to
the traverse control section 78 to drive the traverse driving motor 76 and causes
the traverse arm 74 to be under standby at a position located at one end in the traverse
direction.
[0060] The package 30 is moved away from the contact roller 29 and is held at a predetermined
position where the package 30 is not in contact with the contact roller 29. The position
of the moved package 30 at this time is hereinafter referred to as a "non-contact
position" and is indicated by a reference symbol "Q1" in FIG. 8. Simultaneously, the
unit control section 50 transmits a drive signal to the package driving control section
42 to decelerate and stop the rotation of the package 30 and then to start rotating
the package 30 in the unwinding direction (a direction indicated by an arrow A). At
this time, as illustrated in FIG. 9, the unit control section 50 rotationally drives
the package driving motor 41 at the yarn-end catching speed (a first speed).
[0061] The unit control section 50 sets the yarn-end catching speed, e.g., as follows. In
the case where the diameter of the package 30 is small, since the yarn end 30a is
unlikely to come off the surface of the package 30, the unit control section 50 sets
the yarn-end catching speed so as to slowly rotate the package 30. In the case where
the diameter of the package 30 is large, since the yarn end 30a is likely to come
off the surface of the package 30, the unit control section 50 sets the yarn-end catching
speed faster in comparison with the case where the diameter of the package 30 is small.
[0062] Furthermore, the unit control section 50 swings the upper-yarn pipe arm 36 by transmitting
a drive signal to the upper-yarn catching member 26 and, as illustrated in FIGS. 5
and 9, moves the upper-yarn suction mouth 35 to a position at the catching region
R1 in proximity to the surface of the package 30. Then, under a state where the package
30 at the non-contact position Q1 is being rotated at the yarn-end catching speed
in the unwinding direction A, the upper-yarn suction mouth 35 performs the catching
operation. With the above-described catching operation, the yarn end 30a of the upper
yarn connected to the package 30 can be sucked and caught by the upper-yarn suction
mouth 35.
[0063] When the package 30 is rotated at the yarn-end catching speed the number of times
set by the setting section 91 and the yarn end 30a is sucked and caught by the upper-yarn
suction mouth 35 in the above-described catching operation, the unit control section
50 drives the cradle 23 in a direction to be closer to the contact roller 29. Consequently,
the package 30 returns to the contact position Q2 where the package 30 is in contact
with the contact roller 29. At this time, since the rotation of the package 30 in
the unwinding direction A is continued, the package 30 is rotated in the unwinding
direction A while being in contact with the contact roller 29, and thereby the contact
roller 29 rotates with the package 30.
[0064] When the yarn end 30a of the package 30 is sucked and caught by the upper-yarn suction
mouth 35, the unit control section 50 controls the upper-yarn catching member 26 to
swing the upper-yarn pipe arm 36 and, as illustrated in FIGS. 6 and 9, moves the upper-yarn
suction mouth 35 to a position at the standby region R2 where the upper-yarn suction
mouth 35 is located away from the package 30 and then stops the upper-yarn suction
mouth 35. Simultaneously, the unit control section 50 transmits a drive signal to
the package driving control section 42 and, as illustrated in FIG. 9, rotationally
drives the package 30 at the yarn guiding speed, which is faster than the yarn-end
catching speed, in the unwinding direction A. With the above-described catching operation,
the upper yarn of the package 30 is further sucked and caught by the upper-yarn suction
mouth 35.
[0065] Subsequently, the unit control section 50 controls the upper-yarn catching member
26 to swing the upper-yarn pipe arm 36 and, as illustrated in FIGS. 7 and 9, moves
the upper-yarn suction mouth 35 to the yarn joining region R3. Simultaneously, the
unit control section 50 transmits a drive signal to the package driving control section
42 to decelerate and stop the rotation of the package 30. Consequently, the package
30 stops to be rotationally driven. As described above, the yarn end 30a of the package
30 is caught by the upper-yarn suction mouth 35 and the yarn 20 is guided to the splicer
device 14.
[0066] When the yarn end 30a of the package 30 is guided to the splicer device 14, the guided
yarn end 30a is almost simultaneously guided to the clearer 15 as well. Since the
clearer 15 is arranged along a path in which the yarn 20 travels at the time of yarn
winding operation, when the upper yarn is guided to the splicer device 14, which is
also arranged along the yarn travelling path, by the upper-yarn catching member 26,
the upper yarn is simultaneously guided to the clearer 15. The clearer 15 is thus
used as a yarn detecting device adapted to determine whether or not the yarn from
the package 30 has been guided to the splicer device 14 by the upper-yarn catching
member 26. More specifically, in a case where the clearer 15 can detect the upper
yarn that has been guided after a completion of the guiding operation, a determination
can be made that the yarn end 30a of the package 30 has been successfully guided to
the splicer device 14. On the contrary, in a case where the clearer 15 cannot detect
the upper yarn that has been guided after the completion of the guiding operation,
a determination can be made that guiding of the yarn end 30a of the package 30 to
the splicer device 14 has failed. The guiding failure may be a failure in the catching
operation, a failure in the guiding operation, or the like. In the case where the
determination is made that the guiding has failed, the unit control section 50 controls
the upper-yarn catching member 26 to perform the catching operation, the standby operation
and the guiding operation again, and causes the yarn end 30a of the package 30 to
be guided to the splicer device 14.
[0067] As described above, in the winder unit 10 of the present embodiment, the unit control
section 50 controls the upper-yarn catching member 26 to perform the catching operation
at the catching region R1 to suck and catch the yarn end 30a of the package 30, and
then to perform the standby operation to stop and be under standby at the standby
region R2 where the upper-yarn catching member 26 is farther away from the package
30 than the catching region R1. The standby operation of the upper-yarn catching member
26 is adjusted according to the diameter of the package 30, the length of the yarn
defect included in the yarn 20 and the rotational speed of the package 30. Accordingly,
this allows prevention of a double withdrawal in the winder unit 10 in which a yarn
20 on the surface of the package 30 is also sucked and caught when the yarn end 30a
is sucked from the package 30. In addition, the yarn end 30a of the package 30 can
be reliably caught. In the winder unit 10, defect in the package 30 thus can be prevented.
[0068] In the present embodiment, when the upper-yarn catching member 26 is located at the
standby region R2 after catching at the catching region R1, the yarn end 30a of the
package 30 rotating at the yarn-end catching speed, the unit control section 50 controls
the package driving motor 41 to rotationally drive the package 30 at the yarn guiding
speed that is faster than the yarn-end catching speed. Consequently, in the winder
unit 10, the yarn 20 can be guided to the splicer device 14 at a high speed by the
upper-yarn catching member 26, thereby allowing reduction in time. In the winder unit
10, operation efficiency thus can be improved.
[0069] In the present embodiment, the unit control section 50 controls the package driving
motor 41 to rotationally drive the package 30 at the yarn-end catching speed the number
of rotations set by the setting section 91. Then, after the package 30 is rotated
the number of rotations, the unit control section 50 controls the package driving
motor 41 to proceed to the operation of rotationally driving the package 30 at the
yarn guiding speed. In this manner, in the winder unit 10, since an assumption is
made without using a sensor or the like that the upper-yarn catching member 26 has
caught the yarn end 30a of the package 30, switching from the yarn-end catching speed
to the yarn guiding speed can be performed with a simple configuration and control.
[0070] In the present embodiment, when continuation of the yarn 20 is disconnected, the
unit control section 50 controls the traverse arm 74 to be under standby at one end
in the traverse direction. Therefore, in the winder unit 10, when performing the yarn
joining operation or the like upon the disconnection of the yarn 20, the yarn 20 can
be prevented from being caught in the traverse arm 74. Consequently, damage on the
traverse arm 74 and/or a disconnection of the yarn 20 guided by the upper-yarn catching
member 26 can be prevented.
[0071] In the present embodiment, when the upper-yarn catching member 26 catches the yarn
end 30a of the package 30, in other words, when the upper-yarn suction mouth 35 of
the upper-yarn catching member 26 is located at the catching region R1, the air cylinder
60 of the winder unit 10 brings the package 30 and the contact roller 29 into a non-contact
state. Consequently, in the winder unit 10, when catching the yarn end 30a of the
package 30, the yarn end 30a can be prevented from being sandwiched between the package
30 and the contact roller 29 and from sticking to the surface of the package 30. In
the winder unit 10, the yarn end 30a of the package 30 thus can be reliably caught.
[0072] In the present embodiment, the upper-yarn catching member 26 is driven by the independently
provided motor 38. In the winder unit 10, operation of the upper-yarn catching member
26 thus can be independently and accurately controlled.
[0073] The present invention is not limited to the above-described embodiment. As illustrated
in FIG. 10, the unit control section 50 may control the package driving motor 41 such
that the rotational speed of the package 30 at the yarn-end catching speed is changed
in two stages. The yarn-end catching speed includes the first speed at which the upper-yarn
catching member 26 starts catching the yarn end 30a of the package 30 and a second
speed that is faster than the first speed.
[0074] The unit control section 50 controls the package driving motor 41 such that the package
30 is rotated at the second speed after being rotationally driven at the first speed.
Consequently, the yarn end 30a of the package 30 can be further reliably caught by
the upper-yarn suction mouth 35 of the upper-yarn catching member 26.
[0075] As illustrated in FIG. 11, the unit control section 50 rotationally drives the package
30 at the yarn-end catching speed in the unwinding direction A, and causes the upper-yarn
suction mouth 35 of the upper-yarn catching member 26 to be located at the catching
region R1 to catch the yarn end 30a of the package 30. After rotationally driving
the package 30 in the unwinding direction A a predetermined number of times, the unit
control section 50 moves the upper-yarn suction mouth 35 of the upper-yarn catching
member 26 in the direction to be located away from the package 30, and rotationally
drives the package 30 in the winding direction. Then, after rotationally driving the
package 30 in the winding direction a predetermined number of times, the unit control
section 50 rotationally drives the package 30 at the yarn-end catching speed in the
unwinding direction A, and causes the upper-yarn suction mouth 35 of the upper-yarn
catching member 26 to be located at the catching region R1 again.
[0076] Subsequently, the unit control section 50 rotationally drives the package 30 at the
yarn guiding speed in the unwinding direction A, and causes the upper-yarn suction
mouth 35 of the upper-yarn catching member 26 to be located at the standby region
R2. Consequently, since a slack of the yarn 20 can be eliminated on the package 30,
the upper-yarn catching member 26 can be prevented from catching the yarn 20 that
exists on a surface layer of the package 30.
[0077] As illustrated in FIG. 12, when the upper-yarn catching member 26 is located at the
catching region R1 and the standby region R2, the unit control section 50 may control
the rotational speed of the package driving motor 41 to be constant.
[0078] In the above-described embodiment, the package 30 is rotationally driven directly
by the package driving motor 41, however, in the present invention, a method in which
the contact roller 29 is rotationally driven to rotate the package 30 may be also
employed. In this case, if the package 30 is moved to the non-contact position Q1
and is rotated in the unwinding direction A, a mechanism for rotating the package
30 in the unwinding direction A is further provided in the winder unit 10. In the
case of the method in which the contact roller 29 is rotationally driven to rotate
the package 30, the rotational speed of the package 30 is not directly controlled,
but rotational speed of the contact roller 29 is controlled.
[0079] In the above-described embodiment, although the arm-type traverse device 70 is described
as an example, the traverse device may be a drum having a traverse groove, a belt-type
traverse or a rod-type traverse. In a case of traversing with the drum having the
traverse groove, the package driving motor 41 directly drives the drum having the
traverse groove. In this case, by making contact with the driven drum having the traverse
groove, the package 30 rotates in response to drive force from the drum having the
traverse groove. Therefore, at the time of the above-described withdrawal operation
of the upper yarn, the package 30 is rotated in the unwinding direction A while being
in contact with the drum having the traverse groove.
[0080] The above-described embodiment allows prevention of the double withdrawal from the
package 30, however, the double withdrawal is not completely resolved. In particular,
in a case where after the double withdrawal occurs, the yarn 20 is cut and a yarn
waste, which is a cut yarn end 30a, is wound around the package 30, a serious problem
may occur in subsequent processing. In addition, in a case where the upper yarn of
the package 30 cannot be sucked and caught by the upper-yarn suction mouth 35 in the
catching operation or in a case where a sucking and catching error occurs in which,
e.g., the upper yarn sucked and caught by the upper-yarn suction mouth 35 disengages
from the upper-yarn suction mouth 35, a yarn joining cycle (the catching operation,
the standby operation and the guiding operation) needs to be repeated as described
above, which is not preferable since operation efficiency is reduced.
[0081] Description will be made on an upper-yarn withdrawal operation for preventing repetition
of the yarn joining cycle in the case where the upper yarn of the package 30 cannot
be sucked and caught by the upper-yarn suction mouth 35 or in the case where the sucking
and catching error in which, e.g., the upper yarn sucked and caught by the upper-yarn
suction mouth 35 disengages from the upper-yarn suction mouth 35 occurs. Redundant
description of a configuration in common with the above-described embodiment will
be omitted.
[0082] As illustrated in FIGS. 13 and 15, the unit control section 50 rotationally drives
the package 30 at the yarn-end catching speed in the unwinding direction A, and causes
the upper-yarn suction mouth 35 of the upper-yarn catching member 26 to be located
at the catching region R1 to perform a first catching operation to catch the yarn
end 30a of the package 30 (FIG. 15A). Subsequently, after rotationally driving the
package 30 in the unwinding direction A a predetermined number of times in the first
catching operation, the unit control section 50 causes a separating operation to move
the upper-yarn suction mouth 35 in a direction to be located away from the package
30 (FIG. 15B) to be performed. In the present embodiment, the upper-yarn suction mouth
35 is moved to the standby region R2 in the separating operation. The yarn end 30a
of the package 30, which sticks to the surface of the package 30, can be peeled from
the surface of the package 30 by this movement. Although the upper-yarn withdrawal
operation can be performed by the separating operation, the above-described yarn cut
after the double withdrawal may occur according to a yarn type or a yarn state. Furthermore,
the case where the upper yarn cannot be sucked and caught by the upper-yarn suction
mouth 35 or the sucking and catching error in which the upper yarn that has been sucked
and caught by the upper-yarn suction mouth 35 disengage from the upper-yarn suction
mouth 35 may occur.
[0083] The unit control section 50 thus controls the upper-yarn suction mouth 35 to perform
a second catching operation, which is a catching operation for the second time, after
the separating operation and before the standby operation (FIG. 15C). In the second
catching operation, the upper-yarn suction mouth 35 is moved to the catching region
R1 again and is caused to perform the catching operation. In the present embodiment,
the first catching operation that is a catching operation for the first time and the
second catching operation that is the catching operation for the second time are performed.
Since, also in the second catching operation, a catching operation is performed by
the upper-yarn suction mouth 35 at the catching region R1 as in the first catching
operation, the yarn waste, which has been generated by the yarn cut after the double
withdrawal, can be sucked and removed by the upper-yarn catching member 26. In addition,
in a case where the sucking and catching error occurs in the first catching operation,
the yarn end 30a that could not be caught can be caught.
[0084] Subsequently, the unit control section 50 controls the upper-yarn catching member
26 to perform the standby operation to stop and be under standby at the standby region
R2 where the upper-yarn catching member 26 is located farther away from the package
30 than the catching region R1 (FIG. 15D). The standby operation of the upper-yarn
catching member 26 is adjusted according to the diameter of the package 30, the length
of the yarn defect included in the yarn 20 and the rotational speed of the package
30. This allows prevention of the double withdrawal in the winder unit 10 in which
a yarn 20 on the surface of the package 30 is also sucked and caught when sucking
the yarn end 30a from the package 30 and removing the yarn defect. In addition, the
yarn end 30a of the package 30 can be reliably caught. Then, the unit control section
50 performs the guiding operation (FIG. 15E).
[0085] Although, in the above-described embodiment, the upper-yarn suction mouth 35 is stopped
at the standby region R2 in the separating operation, the separating operation merely
needs to peel the yarn end 30a of the package 30, which sticks to the surface of the
package 30, from the surface of the package 30 by the movement. Therefore, a separating
region in which the upper-yarn suction mouth 35 is stopped in the separating operation
may be provided separately from the standby region R2. The separating region is a
region where the yarn end 30a can be peeled from the surface of the package 30 and,
if the separating region is a position where the yarn end 30a sucked and caught by
the upper-yarn suction mouth 35 does not disengage from the upper-yarn suction mouth
35, an operator can decide the separating region at his/her discretion.
[0086] In the present embodiment, a control value relating to adjustment of the second catching
operation can be set in detail by the setting section 91 to reliably remove the yarn
waste and catch the yarn end in the second catching operation.
[0087] As illustrated in FIG. 14, the unit control sections 50 of a plurality of the winder
units 10 are connected to the machine setting device 90 that includes the setting
section 91. In FIG. 14, although merely two winder units 10 are described, several
tens of winder units 10 can be connected. As described above, the motor 38 is connected
to the unit control section 50, and the upper-yarn catching member 26 is driven by
the motor 38. In the present embodiment, the machine setting device 90 includes the
setting section 91, however, a configuration in which each unit control section 50
includes an own setting section may be employed.
[0088] The setting section 91 includes a time setting section 911 adapted to set a period
of time in which the second catching operation is performed, and a number-of-rotation
setting section 912 adapted to set the number of rotations for the second catching
operation. The unit control section 50 controls the upper-yarn catching member 26
to perform the second catching operation based on at least either one of the period
of time set by the time setting section 911 or the number of rotations set by the
number-of-rotation setting section 912.
[0089] In a case where both the period of time and the number of rotations are set in the
setting section 91 as the control value relating to the adjustment of the second catching
operation, a determination can be made which setting is to be applied on a priority
basis. In a case, e.g., where production efficiency is considered important, the period
of time is applied on a priority basis and, in a case where product quality is considered
important, the number of rotations is applied on a priority basis. In a case the number
of rotations is applied on a priority basis, a yarn waste can be reliably removed
by rotating a predetermined number of rotations. Furthermore, since the diameter of
the package 30 becomes large as the yarn 20 is wound, as the winding operation proceeds,
time for rotating the package one time becomes longer. Thus, the number of rotations
may be applied at the time of a small diameter in which a wound amount of the package
30 is small and thereby the time for one rotation of the package 30 is short. The
period of time may be applied at the time of a large diameter in which the wound amount
of the package 30 is large and thereby the time for one rotation of the package 30
is long.
[0090] When the clearer 15 cannot detect the upper yarn that has been guided after the completion
of the guiding operation, the determination can be made that guiding of the yarn end
30a of the package 30 to the splicer device 14 has failed. The guiding failure may
be a failure in the first catching operation, a failure in the second catching operation,
a failure in the guiding operation, or the like. In a case where the determination
is made that the guiding has failed, the unit control section 50 controls the upper-yarn
catching member 26 to perform a repeating operation in which the catching operation,
the standby operation and the guiding operation are repeated. With this configuration,
since there is performed the repeating operation in which each of the operations is
repeated by the upper-yarn catching member 26 in the case where guiding of the yarn
20 from the package 30 to the yarn joining device 14 has failed, guiding of the yarn
20 from the package 30 can be performed again without manual operation by the operator.
The unit control section 50 is configured capable of setting the control value relating
to the adjustment of the second catching operation of the upper-yarn catching member
26 in performing the repeating operation. With this configuration, in the case where
guiding of the yarn 20 from the package 30 to the splicer device 14 has failed, the
second catching operation by the upper-yarn catching member 26 can be controlled under
a different condition when the repeating operation to repeat each of the above-described
operations is being performed. The period of time or the number of rotations of the
second catching operation, e.g., can be sufficiently large. Consequently, success
rate of the guiding of the yarn 20 from the package 30 can be improved. Furthermore,
since the repeating operation is performed only at the time of the guiding failure,
even if the period of time and the number of rotations are sufficiently large, operation
time is not considerably extended.
[0091] In the above-described embodiment, the diameter of the package 30 is detected by
detecting the swing angle of the cradle 23 with the angle sensor 44. However, the
diameter of the package 30 may be detected by another method. The diameter of the
package 30 can be acquired based on, e.g., a total length of the yarn 20 wound around
the package 30, a winding speed of the yarn 20 and a yarn type (a thickness or the
like of the yarn 20).
[0092] The diameter of the package 30 may also be acquired by measuring time from the start
of winding the yarn 20. In a case where the winding speed and the yarn type (the thickness
or the like of the yarn 20) are known, the diameter of the package 30 can be acquired
by calculating based on the time elapsed from the start of winding the yarn 20. By
storing in the unit control section 50 in advance, a relation between the time elapsed
from the start of winding and the diameter of the package 30, the diameter of the
package 30 can be acquired based on the elapsed time. When the winding is interrupted
by the yarn disconnection, the yarn joining operation, or the like, measurement of
the time elapsed from the start of winding is interrupted.
[0093] The diameter of the package 30 may also be calculated based on a travelling speed
of the yarn 20. Specifically, a traverse angle is calculated by the travelling speed
and a traverse speed of the yarn 20. Furthermore, a peripheral speed of the package
30 is acquired based on the traverse angle and the yarn travelling speed. Then, the
diameter of the package 30 is calculated based on the rotational speed and the peripheral
speed of the package 30.