The present invention relates to a method and to a system comprising an apparatus for loading and transferring tubular products on a toe-closer machine and a toe-closer machine. The invention relates to the technical sector of machines and equipment for the production of tights and other hosiery articles, starting from tubular textile products and relates in particular to the loading, cutting and transfer of the tubular products on a toe-closer machine.
As is known, tights are produced starting from two tubular textile products, identical to one another and each constituting a leg of the tights, and typically involves a toe-closer machine, and a further machine, known as a line-closer, for combining the two legs to form the tights. The toe-closer machine is deputed to the closing of the toes of each of the above-mentioned tubular products, i.e. the toe-tip of each leg of the tights.
A toe-closer usually comprises a plurality of support tubes on which the tubular products are singly loaded; the machine adapts the open toe of the leg to the curvature that is to be obtained for the sewing and carries out the sewing so as to close the toe, after which the product is unloaded from the support.
Line-closer machines comprise a carousel structure rotating about a vertical axis and provided with a plurality of supports. The two tubular products destined to make up the tights are loaded on a pair of adjacent supports and, in a successive station of the line-closer, are subjected to a longitudinal cut at a portion which in the finished product constitutes the trunk (or panty and gusset part) and, following this, to sewing so as to join the previously-cut flaps. The sewing of the trunk part between the two legs is typically carried out by a "four-needle" sewing machine; four-needle sewing necessary requires a manual intervention (the known automatic means are not usable on tights that require a four-needle manual sewn seam).
The toe-closer machine can be positioned upstream of the line-closer (in this case the sewing of the trunk is done on the legs which already have a closed toe) or downstream thereof.
Examples of line-closer and toe-closer machines are described, for example, in patent documents
In the production of low-quality articles and/or articles without portions having particular colours, weft or designs, the cutting of the upper end of the tubular product (which is then joined to the trunk) can be random. In fact, when the tights are uniform it is not important where the cut is made, i.e. it is not necessary to axially orientate the tubular product to make the cut in a particular position. In the same way, for low-cost tights, the cut is done randomly, i.e. in any position of the upper end of the tubular element, and the following step of sewing the toe is completely unconnected to the cutting operation (in substance, the line-closer and toe-closer machines operate autonomously, in two successive moments, without taking account of the relative position between the cut and the sewing of the toe). In this situation the tubular product can be randomly loaded and the cut can be automatically performed by the machine.
Instead, with regard to high-quality articles (progressively more in demand in the hosiery market for tights), highly sophisticated articles and articles with graphic figures or patterns or special designs, or a variety of colours or thickness or embellishments, it is important to realise a precise cut of the upper ends of the tubular products; the cut must be done in a specific position of the product (for example perfectly at the centre of the leg) and terminate in a certain point.
Further, tubular products are provided with a ladderproof portion at which the cut terminates; this prevents, at the end of the cutting line, ladders from developing in the tubular product. Tubular products destined to be loaded and worked automatically are typically provided with a ladderproof portion in a band form all around the tubular product, as the cut is random and it is not possible to know the exact position but only the length thereof. Tubular products for high-quality tights and/or tights provided with particular design graphics are typically provided with a small ladderproof area located exactly at the desired termination for the cutting line of the product. For this reason, the loading of tubular products for high quality tights on the cutting device is done manually, as it is necessary to arrange the product precisely with respect to the cutting device, with the aim of obtaining a cutting line in a determined position on the tubular product.
The known methods for the production of high-quality tights include first carrying out the step of sewing the tip of the tubular product, and then performing the cut of the opposite end. In greater detail, an operator loads the tubular product on a holder of the toe-closer machine, and the loading is done according to a precise orientation, as the sewing of the tip must have a determined progression (for both aesthetic and comfort reasons when the tights are worn, as well as to reproduce correctly the graphic design of the tights).
The use of automatic loaders for the toe-closer machine (for example pick and place devices, which collect the tubular products from a container and load them automatically on a holder) is possible only for low-quality articles and/or which do not require a loading with a precision orientation of the tubular product; in fact, pick and place loaders are not able to load with high precision.
Following the sewing of the tips, the tubular product is unloaded from the toe-closer machine and a further operator loads the product (previously sewn at the tips) onto a cutting holder: this operation is also performed manually as, as mentioned above, the leg of the tight must be precisely positioned so as to be cut along a specific cutting line and with a correct orientation with respect to the sewing line of the toe-tip (for example at an angle of 90°). After the cut, the tubular product is unloaded from the cutting holder and sent to a machine for manual sewing, in which the coupling of two tubular products (each being a leg of the tights) is done so as to complete the production of the tights.
The known methods do not include the making of the cut before the sewing of the toe-tips, as a cut tubular product (at the upper end thereof, opposite the bottom end, which constitutes the toe-tip) no longer has a continuous upper edge (or elastic) since the cutting operation creates two flaps of open textile; the flaps are difficult to manage in the following steps, as they are free to move and make the upper end of the tubular product difficult to associated to a work holder (because the continuous edge is no longer there). For this reason, the toes are usually sewn and then the cutting of the opposite end, then to proceed with the sewing of the trunk part; alternatively the cut can be begun as long as the following step is the sewing of the trunk and the combining of the two legs of the tights, then to conclude with the sewing of both the toe-tips of the tights. In substance, the step of cutting is always followed by the step of sewing the trunk, with the aim of preventing transfers of the tubular products with the cut and open upper end; a transfer of this type would be very difficult, both manually and - even more - automatically, and it would also be difficult to do it while guaranteeing a precise positioning of the tubular product.
From the above it emerges that the known methods, and the relative machines, for production of high quality articles or articles having graphic patterns or special designs are characterised by a very complex working cycle, which typically requires a large use of personnel. For example, considering that pick and place loaders are typically usable only for low-quality production (which does not require precise positionings of the tubular products), the known methods require three distinct manual operations for the toe sewing, the upper end cutting and the trunk sewing (the assembly of two tubular products to form the tights, with a four-needle sewing). This involves the use of three different operators, with a consequent increase in production costs. Further, the productivity of these methods is necessarily low, as the three manual operations require long times and cannot be parallelized: at the end of each operation the tubular product is unloaded from the machine that has carried out the operation and reloaded manually on the following machine. In particular, the cutting operation constitutes a "bottleneck" in know processes: in fact, the operator waits for the sewing of the toes, removes a sewn tubular product and loads it manually on the cutting holder; then he waits for the cutting operation to finish and proceeds to unloading the cut tubular product from the cutting holder. The next tubular product can then be subjected to cutting only after the preceding tubular product has been unloaded.
In substance, the Applicant has found that the methods and apparatus of known type are characterised by slow productivity and/or high production costs for the single pair of tights and/or by significant complexity of the production cycle and/or the means which carry out the cycle. Further, the known production methods and apparatus require large use of personnel, with a consequent increase in times and costs of production.
The Applicant has also found that the known methods and apparatus are difficult to use for the production of textile articles such as tights, which are of high quality and/or are provided with special graphic patterns, designs, colours and/or weft, and in general cannot be used for realizing tights that require cutting and sewing done with precision in specific portions of tubular products that they are constituted by. Further, a drawback of the methods and apparatus of known type lies in the difficulty of obtaining textile articles, such as tights, having uniform aesthetic and functional characteristics, i.e. in the difficulty of guaranteeing a high repeatability in the production process.
Other examples of machines are known.
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An aim of the present invention is to obviate one or more of the above-cited drawbacks.
An aim of the invention is to provide a method and a system comprising an apparatus for loading and transferring tubular textile products on a toe-closer machine which enable realizing textile articles of high quality and substantially without imperfections.
A further aim of the invention is to provide a method and a system comprising an apparatus for loading and transferring tubular textile products on a toe-closer machine which enable reducing production waste.
A further aim of the invention is to provide a method and a system comprising an apparatus for loading and transfer of tubular textile products on a toe-closer machine which enable realising the cut and the sewing of tubular products constituting the leg of a pair of tights, guaranteeing a precise positioning and/or orientation both of the sewing line of the toe-tip, in particular for high-quality tights and/or tights provided with portions having special graphic designs and/or various colours and/or wefts.
A further aim of the invention is to disclose a method and a system comprising an apparatus for loading and transferring tubular textile products on a toe-closer machine which enable reducing the use of personnel for the production of tights, in particular high-quality tights.
A further aim of the invention is to disclose a method and a system comprising an apparatus for loading and transferring tubular textile products on a toe-closer machine, which enable increasing the productivity and/or reducing the time necessary for the production of tights, in particular high-quality tights.
A further aim is to disclose a method and a system comprising an apparatus for loading and transferring tubular textile products on a toe-closer machine which enable obtaining highly-uniform production among the various articles produced.
A further aim of the invention is to disclose a method and a system comprising an apparatus for loading and transferring tubular textile products on a toe-closer machine which enable realising tights in a way that is simple, rapid and/or automatic.
A further aim of the invention is to provide a system comprising an apparatus for loading and transferring tubular textile products on a toe-closer machine which is simple and/or sturdy and/or economical to realise.
A further aim of the invention is to provide a system comprising an apparatus for loading and transfer of tubular textile products on a toe-closer machine, usable with existing toe-closer machines and/or integratable in already-existing plants for the production of textile articles.
These and other aims, which will more fully emerge during the course of the following description, are substantially attained by a method and a system comprising an apparatus for loading and transferring tubular textile products on a toe-closer machine according to the appended claims, in any combination among them and/or with one or more of the aspects set down in the following.
In a first aspect the present invention relates to a loading and transferring method of tubular textile products onto a toe-closer machine for production of tights, each of the tubular products extending longitudinally between an upper end and a lower end, both ends being open, the lower end being destined to be sewn by means of a toe-closer machine in order to form the tip of a leg of a pair of tights and the upper end being destined to be cut in order to be subsequently joined to the respective upper end, also cut, of a further tubular product for forming a pair of legs of the tights
In an aspect, the method comprises steps of:
In an aspect, the loading step of a tubular product onto the at least a hose loader is done manually or automatically, preferably by means of a pick and place device configured and predisposed for picking up a tubular product and for enveloping the product externally on the at least a hose loader, and/or wherein the reference position of the tubular product is a line and/or a band and/or a graphic sign and/or a pattern and/or one or more stop points, the reference position being destined to define a cutting line of the tubular product starting from the upper end thereof or an end of the cutting line.
In an aspect, during the step of loading the tubular product onto the hose loader the upper end is enveloped on the hose loader and the lower end freely hangs from the hose loader.
In an aspect, the step of transferring the tubular product from the hose loader to the hose holder comprises a step of aspirating the portion of tubular product freely hanging from the hose loader, starting from the lower end of the tubular product, internally of an internal cavity of the hose loader or internally of a respective internal cavity of the hose holder of the toe-closer machine.
In an aspect, the at least a hose loader comprises a support bar and at least a mobile element translatably associated to the support bar such as to operate at least between a retracted position, in which it substantially envelops the support bar, and an advanced position, in which it extends beyond the support bar and defines internally thereof a longitudinal cavity counter-shaped to at least a portion of the hose holder.
In an aspect, during the loading step - the tubular product is enveloped on the mobile element in the retracted position, and the step of transferring the tubular product from the hose loader to the hose holder comprises a step of bringing the at least a mobile element of the hose loader into the advanced position such that the hose holder of the toe-closer machine inserts at least partially internally of the longitudinal cavity of the mobile element and, consequently, the portion of tubular product previously-loaded on the mobile element is transferred, turned inside-out, onto the hose holder, being enveloped externally thereof
In an aspect, the step of transferring the tubular product from the hose loader to the hose holder comprises a step of gripping, by means of mobile gripping organs, the portion of tubular product previously loaded on the hose loader, or at least the upper end of the tubular product, unloading such portion from the hose loader and enveloping the tubular product, turned inside-out, externally on the hose holder.
In an aspect, the method comprises a step of cutting the upper end of the tubular product, preferably at the reference position.
In an aspect, the step of cutting the tubular product occurs along a cutting line which starts from the upper end and proceeds along, or up to, the reference position of the tubular product having a shape of a line and/or a band and/or a graphic sign and/or a pattern and/or one or more stop points.
In an aspect, the reference portion of the hose loader houses, enveloped thereon, the portion of tubular product subjected to the cutting step, and/or wherein the cutting step is carried out subsequently to the loading step and/or previously to the transferring step, and/or wherein the cutting step is carried out by means of a cutting device preferably having a blade or using ultrasound or a hot wire, and/or wherein the cutting step comprises a step of selecting and/or regulating a length and/or a shape of the cutting line.
In an aspect, the loading step is carried out in a loading station, the step of automatically transferring is carried out in a transfer station, distinct and separate from the loading station, and the at least a hose loader, during the positioning step, is moved between the loading station and the transfer station.
In an aspect, the cutting step is carried out in the loading station or in the transfer station or during the positioning step and/or in an intermediate position between the loading station and the transfer station.
In an aspect, when the hose loader is moved from the loading station to the transfer station, a further hose loader is predisposed in the loading station for carrying out a further loading step of a further tubular product.
In an aspect the method comprises, at an end of the transfer step, a step of returning the at least a hose loader, or a plurality of hose loaders in succession, into the loading station, such as to cyclically repeat the steps of the method on successive tubular products.
In an aspect, the method comprises a step of predisposing one or more locking plates operatively and movably associated to the mobile element and operable between an open configuration, in which they are externally distanced with respect to the mobile element, and a closed configuration, in which they are neared to the mobile element.
In an aspect, during the loading step the locking plates are in the open configuration in order to allow loading of the tubular product on the hose loader and are brought into the closed configuration when loading is complete.
In an aspect, the locking plates are maintained in the closed configuration during and/or successively to the cutting step, such as to maintain two flaps of product created by the cutting step enveloped on the hose loader, and/or wherein during the transfer step the locking plates are returned into the open configuration in order to allow transfer of the tubular product onto the hose loader.
In an aspect, the method comprises, possibly, a step of selecting or replacing the at least a hose loader, or the mobile element of the hose loader, according to the conformation of the hose holder and/or according to the type of tubular product.
In an aspect, the method comprises, once transfer is complete, a step of returning the mobile element of the hose loader, without the tubular product, into the retracted position, leaving the product, orientated and/or cut, on the hose holder of the toe-closer machine.
In an aspect, the method comprises a step of moving the at least a hose loader from the position in which the transfer step is performed to the position in which the loading step is performed, such as to enable loading of a successive tubular product.
In an aspect, the method comprises a step of completing the transfer of the whole tubular product onto the hose holder, preferably using loading rollers, so that the previously-aspirated portion in the internal cavity of the product hose holder exits from the cavity and is wound externally of the hose holder.
In an aspect, the method comprises a step of maintaining two flaps of tubular product created by the step of cutting wound on the hose holder of the toe-closer, by means of one or more pads acting on the hose-holder.
In an aspect, the method comprises a step of
In an aspect, the method comprises a step of combining a pair of tubular products, each subjected to a respective cutting step of each, preferably subjected to a respective sewing step of the tip, and subjecting the pair of tubular products to a line-closer machine for sewing a trunk part and completion of the tights.
In a further independent aspect, the present invention relaters to a system comprising an apparatus for loading and transfer of tubular products on a toe-closer machine for the production of tights, each of the tubular products extending longitudinally between an upper end and a lower end, both open, the lower end being destined to be sewn by a toe-closer machine in order to form the tip of a leg of the tights and the upper end being destined to be cut in order subsequently to be joined to the respective cut upper end of a further tubular product such as to form a pair of legs of a pair of tights.
In an aspect the apparatus comprises at least a hose loader provided with at least a reference portion and cyclically mobile, by means of movement means, at least between:
In an aspect the apparatus is configured and predisposed for automatically transferring, at the transfer station, the tubular product from the hose-loader to the hose-holder, by turning the tubular product inside-out and enveloping the product externally of the hose-loader, while maintaining the respective reference position of the tubular product aligned to, and/or orientated with, and/or corresponding with, the specific portion of the hose-holder.
In an aspect, in the loading station the upper end of the tubular product is wound on the hose loader and the lower end freely hangs from the hose loader.
In an aspect, the apparatus comprises aspirating means configured such as to aspirate, at least at the transfer station, the portion of tubular product hanging freely from the hose-loader, starting from the lower end of the tubular product, internally of an internal cavity of the hose-loader.
In an aspect, the at least a hose loader comprises a support bar and at least a mobile element translatably associated to the support bar such as to operate at least between a retracted position, in which it substantially envelops the support bar, and an advanced position, in which it extends beyond the support bar and defines internally thereof a longitudinal cavity counter-shaped to at least a portion of the hose holder.
In an aspect, the apparatus comprises a pusher organ, located at the transfer station, configured such as to cooperate with the mobile element of the hose-loader and cause passage thereof between the retracted configuration and the advanced configuration.
In an aspect, the passage of the mobile element into the advanced position determines insertion of a hose-loader of the toe-closer machine at least partially internally of the longitudinal cavity of the mobile element and, consequently, a transfer, with an inside-out turning, of the portion of tubular product, previously loaded on the mobile element, onto the hose-holder.
In an aspect, the mobile element comprises a coupling element configured such as to cooperate, when the hose-loader is positioned in the transfer station, with the pusher organ, such as to receive there-from a motion necessary for determining the passage of the mobile element between the retracted and advanced configurations.
In an aspect the mobile element comprises a pair of translatable portions, preferably identical to one another, arranged on opposite sides of the support bar and movable, preferably together, with respect to the support bar in the passage of the mobile element between the retracted and advanced configurations, the translatable portions being each conformed in such a way as to internally define a respective seating counter-shaped to a respective lateral tab of the hose-holder of the toe-closer machine, and to define between them the longitudinal cavity that is complementarily-shaped to the toe-closer machine.
In an aspect, the apparatus comprises a cutting device configured and predisposed to cut the upper end of the tubular product loaded on the hose-loader along a cutting line.
In an aspect, the cutting device performs a cutting on the portion of tubular product positioned at the reference position.
In an aspect, the cutting device is configured such as to select and/or regulate a length and/or a shape of the cutting line.
In an aspect, the cutting line starts from the upper end and proceeds along, or up to, the reference position of the tubular product having a shape of a line and/or a band and/or a graphic sign and/or a pattern and/or one or more stop points.
In an aspect, the cutting device is configured such as to perform the cutting of the tubular product at the loading station or the transfer station or during the transfer of the hose-loader between the loading station and the transfer station or into an intermediate position between the loading station and the transfer station or at a cutting station, or it is mounted directly onto the hose-loader.
In an aspect, the hose-loader comprises one or more locking plates operatively and movably associated to the mobile element and operable between an open configuration, in which the locking plates are externally distanced with respect to the mobile element, and a closed configuration, in which they are neared to the mobile element, wherein the locking plates are configured such as to enable, in the open configuration, the loading and/or transfer of the tubular product onto and/or from the hose-loader and, in the closed configuration, such as to maintain two flaps of product created by the cutting device enveloped on the hose-loader.
In an aspect, the apparatus comprises two or three or four, or a number greater than four, of the hose-loaders, preferably equidistanced from one another and cyclically moved at least between the loading station and/or the cutting station and/or the transfer station by means of the movement means.
In an aspect, the movement means comprise a closed belt, to which the hose-loaders are fixed, and an actuator, the closed belt being moved selectively by means of the actuator, in such a way as to position the hose-loaders of the loading station and/or the cutting station and/or the transfer station according to a predetermined operating cycle.
In an aspect, the apparatus comprises a set of mobile elements comprising at least two interchangeable different mobile elements for the hose holder and/or a set of hose holders comprising at least two different interchangeable hose holders, each mobile element or each hose holder being complementarily shaped to a specific hose holder of the toe-closer and/or to a specific type of tubular product.
In a further independent aspect thereof, the present invention relates to a machine for production of tights, comprising an apparatus for loading and transferring tubular products according to any one of the claims and/or the aspects and/or configured and predisposed to implement the method according to any one of the claims and/or aspects, and further comprising a toe-closer machine and/or a line-closer machine.
In an aspect, the apparatus of the present invention can be a part of, i.e. can be integrated into, a toe-closer machine and/or a line-closer machine.
Each of the aspects of the invention can be taken alone or in combination with any one of the claims or the other aspects described.
Further characteristics and advantages will more fully emerge from the detailed description of a preferred but not exclusive embodiment, according to the accompanying figures, in which:
With reference to the
The apparatus of the system of the present invention is configured to operate on tubular textile machines, in particular for tubular products typically used for the production of tights and each destined to constitute a leg of a pair of tights. By way of example, each tubular product extends longitudinally between an upper end and a lower end, both open: the lower end is destined to be sewn by a toe-closer machine 50 for forming the tip of a leg of the tights, while the upper end is destined to be cut, then to be joined at the respective cut upper end to the respective cut upper end of a further tubular product for forming a pair of legs of the tights.
The apparatus 1 comprises at least a hose loader 2 provided with at least a reference portion 3 and cyclically mobile, by movement means 40, at least among:
The apparatus 1 is structured for automatically transferring, at the transfer station 12, the tubular product from the hose-loader 2 to the hose-holder 51, by turning the tubular product inside-out and enveloping the product externally of the hose-holder, while maintaining the respective reference position of the tubular product aligned to, and/or orientated with, and/or corresponding with, the specific portion of the hose-holder 51.
The apparatus comprises a frame 1a to which the movement means 40 are associated to the movement means 40 are associated, which support and move the hose-loaders 2. As shown by way of example in the figures, the frame comprises a support structure and a command panel which controls the functioning of the whole apparatus.
In the loading station 11, the upper end of the tubular product is preferably enveloped on the hose loader 2 and the lower end hangs freely from the hose loader. In a possible embodiment that is not illustrated, the apparatus preferably comprises aspirating means able to aspirate, at least at the transfer station, the portion of tubular product hanging freely from the hose loader, starting from the lower end of the tubular product, internally of an internal cavity of the hose loader. In this way the lower end of the product will not interfere with elements of the apparatus or the toe-closer machine and further the tubular product is predisposed for the following transfer step on the holder of the toe-closer.
The hose loader 2 preferably comprises a support bar 5 and at least a mobile element 6 translatably associated to the support bar and operable at least between a retracted position, in which it surrounds the support bar, and an advanced position, in which it extends beyond the support bar and defines internally thereof a longitudinal cavity 4 counter-shaped to at least a portion of the hose-holder.
As shown by way of example the figures, the passage between the retracted position and the advanced position, and vice versa, is done by means of a to and fro translation of the mobile element along a longitudinal development direction of the hose loader.
The apparatus preferably comprises a pusher organ 15, located at the transfer station 12, configured such as to cooperate with the mobile element 6 of the hose-loader 2 and cause passage thereof between the retracted configuration and the advanced configuration. The passage of the mobile element 6 into the advanced position preferably determines insertion of a hose-loader 51 of the toe-closer machine 50 at least partially internally of the longitudinal cavity 4 of the mobile element 6 and, consequently, a transfer, with a tilting, of the portion of tubular product, previously loaded on the mobile element 6, onto the hose-holder.
The mobile element 6 preferably comprises (solidly constrained thereto) a coupling element 16 configured such as to cooperate, when the hose-loader 51 is positioned in the transfer station 12, with the pusher organ 15, such as to receive there-from a motion necessary for determining the passage of the mobile element between the retracted and advanced configurations.
In the embodiment illustrated in the figures, the pushing organ consists of a linear actuator, for example a pneumatic cylinder, associated to the frame 1a of the apparatus 1 at the transfer station.
The pushing organ preferably comprises a fixed part 15a mounted to the frame 1a and a mobile part 15b (or stem) translatable in advancement and retraction with respect to the fixed part. The pusher organ 15 is positioned in such a way that when the hose loader 2 reaches the transfer station the coupling element 16 of the hose loader 2 is perfectly aligned with the pusher organ: in this situation, the mobile part 15b - when it exits from the fixed part 15a - encounters the coupling element 16 and connects to it, transferring the advancement motion to it and drawing it towards the advanced configuration. In this way, the hose-loader 2 reaches the hose-holder 51 of the toe-closer machine and envelops it externally.
Considering that the tubular product is enveloped with the upper end thereof externally of the mobile element 6 of the hose loader, the inlet of the hose holder 51 internally of the cavity 4 of the mobile element (into which the remaining portion of tubular product not enveloped externally of the hose-loader 2 is preferably aspirated) causes a push on the part of the hose-holder 51 on the tubular product, which is transferred, inside-out with respect to the loading step, externally of the hose-holder. The transfer with the present apparatus 1 enables maintaining the orientation of the tubular product unvaried between the hose-loader 2 and the hose-holder 51.
The mobile element 6 preferably comprises a pair of translatable portions 7, preferably identical to one another, arranged on opposite sides of the support bar 5 and movable, preferably together, with respect to the support bar in the passage of the mobile element between the retracted and advanced configurations.
As shown in the figures, the two translatable portions 7 are preferably located on two opposite sides of the support bar 5 (substantially one above and one below the bar) and are connected and solidly constrained by means of two connecting plates, preferably one on each of the two sides of the support bar.
One of the connecting plates preferably bears the coupling element 16: in this way the pusher organ acts on the coupling element and then draws the whole mobile element 6 (preferably comprising two portions 7).
The translatable portions 7 are preferably conformed each in such a way as to internally define a respective seating 7a counter-shaped to a respective lateral tab 53 of the hose-holder 51 of the toe-closer machine 50, and such as to define between them the longitudinal cavity 4 counter-shaped to a central tube 52 of the hose-holder 51 of the toe-closer machine.
The hose-loaders 2 of the apparatus of the present invention are structured in such a way as to cooperate correctly with hose holders 51 typically used in toe-closer machines: the toe-holders usually comprise a central tube 52, about which the tubular product to be toe-stitched is wound, and possibly a pair of lateral tabs which stretch the tubular product wound on the hose holder 51 to the sides of the central tube, so as to facilitate the sewing operation of the toe-tip. For this reason, the translating portions 7 of the mobile element 6 of the hose-loader 2 are provided with seatings 7a specially conformed to enable insertion of the tabs 53 of a hose-holder 51.
The hose-loader 2 is further preferably positionable by movement means 40 in a cutting station 13, in which a cutting operation of the upper end of the tubular product is made (the end being destined to be joined by a trunk to the other leg of the tights). For this purpose, the apparatus can comprise a cutting device 30 configured to as to cut the upper end of the tubular product loaded on the hose-loader along a cutting line. In
The cutting device 30 preferably performs the cut on the portion of tubular product at the reference position. The cutting line preferably starts from the upper end of the tubular product and proceeds along, or up to, the reference position having a shape of a line and/or a band and/or a graphic sign and/or a weft and/or one or more halt points. The cutting device 30 can perform the cut of the tubular product at the hose loader 11 or the transfer station or during the transfer of the hose loader between the loading station and the transfer station or in an intermediate position between the loading station and the transfer station. As shown in the figures, the cutting device preferably carries out the cut at the cutting station 13. Each hose loader can also be provided with a cutting device of its own mounted directly on it and mobile, among the various stations, solidly in constraint with it. In this way the cut can be made without halting the motion of the hose loaded between the various stations.
The cutting device can be of the blade or ultrasound or hotwire type.
As shown by way of example in the figures, the reference portion 3 of the hose loader 2 preferably consists in a straight gully on an external surface of the hose loader (the surface is preferably facing upwards when the hose loader 2 is in the loading station). The gulley is preferably configured so as to receive a cutting blade (or equivalent means) and enable the cut of the portion of tubular product superposed to the gully. In substance, the gully functions as an abutment, or guide, for a cutting blade: the portion of tubular product, enveloped on the hose loader, which is interposed between the gully and the cutting blade is cut. The extension of the reference portion (i.e. the gully) and/or the trajectory of the cut carried out by the cutting device define the shape and/or the length of the cutting line of the tubular product.
The hose loader 2 preferably comprises one or more blocking plates 8 operatively and movably associated to the mobile element 6 and operable between an open configuration, in which they are distanced externally with respect to an open configuration and a closed configuration, in which they are neared to the mobile element. The blocking plates 8 enable, in the open configuration, the loading and/or transfer of the tubular product on and/or from the hose loader while, in the closed configuration, they maintain the two flaps of product created by the cutting device enveloped on the hose loader. The hose loader can preferably comprise two blocking plates, one for each side of the mobile element. Still more preferably, as shown in the figures, the hose loader 2 comprises two pairs of blocking plates 8 (for a total of four plates), a pair for each side of the hose loader. In more detail, each side of the hose loader comprises a blocking plate for each of the two translatable portions 7.
The blocking plates are preferably movable between the respective open and closed configurations by means of appropriate actuators, for example of pneumatic or electrical type. All the blocking plates of a hose loader are preferably moved to open and close together, i.e. simultaneously (for example by means of a single actuator active on all the blocking plates of the loader). This means that (typically in the loading station and so as to complete the transfer), the blocking plates are all brought into the open configuration so as to enable loading and transfer of the tubular product, while with the loading completed and up to the transfer onto the toe-closer, the blocking plates maintain the tubular product correctly and stably enveloped on the hose loader, in particular during and after the cutting operation; the blocking plates prevent the tubular product loaded on the hose loader from becoming dealigned and/or losing the original orientation receive during the loading step, which orientation is to be conserved up to the transfer onto the toe-closer machine.
The apparatus 1 preferably comprises two or three or four, or a number greater than four, of the hose loaders 2; in the embodiment shown in the figures, the apparatus comprises four distinct hose loaders 2. This enables arranging a number hose loaders greater than the number of stations (loading 11, cutting 13 and transfer 12) and therefore enables the operations to be "parallelized": in fact, following the loading of a tubular product on a first hose loader, it is not necessary to wait for the holder to complete the cycle and return availably to the starting point, although a second hose loader is immediately available (i.e. free of tubular products and not engaged in any station) and arrives in the loading station to receive a further tubular product. At working speed each hose loader of the apparatus substantially passes through successive operating stations and at least one of the loaders is always available, with a short waiting time for the operation who does the initial loading. Imagining a photograph of the state of the apparatus at a given instant (as shown by way of example in
It is obviously possible to increase the number of hose loaders of the apparatus and the distance between the stations: the greater the number of holders, the greater the number of tubular products contemporaneously working in the apparatus. The hose loaders 2 are preferably equidistanced and cyclically moved at least between the above-mentioned loading and/or cutting and/or transfer stations by means of the movement means 40. The movement means 40 preferably comprise a closed belt 41 (or a chain or a conveyor belt or the like) to which the hose loaders are fixed, and an actuator (not shown), for example comprising an electric motor and a drive pulley, activated by the electric motor, on which the belt 41 is mounted. The closed belt 41 is moved selectively by means of being advanced in such a way as to position the hose loader in the loading and/or cutting and/or transfer stations in a predetermined operating cycle. The movement means are configured so as to move the hose loaders between the various stations by means of continuous motion, with selectable velocity, or discontinuously, providing on need one or more paused, for example at the loading and/or cutting and/or transfer stations.
In the embodiment of the figures, the movement means are configuration so as to move the hose loaders in horizontal trajectories, an outward trajectory (from the loading station to the transfer station) and an opposite return station, connected by two tracts of circular connections. However, according to needs (for example taking account of ergonomic criteria), the movement of the hose loaders can take place along inclined trajectories, i.e. the position of the different stations of the apparatus is on different levels (for example, for the sake of ease of operation, the loading station and the transfer station can be vertically dealigned, with the loading station in a lower position so as to facilitate the enveloping of the tubular product on the hose loader by an operator.
Overall the figures (in particular
In this station, the hose loader 2 is positioned perfectly aligned and headed with the hose holder 51 of the toe-closer machine. Note that in
In the figures it can also be seen how the hose loader 2 in the transfer station has the respective mobile element 6 in an advanced configuration (by means of the action of the pusher organ 15), with the aim of enabling transfer to the hose holder of the toe-closer, while the remaining hose loaders 2 are in the retracted configuration, enabling the loading and/or the cutting of the tubular product (see
The above-described apparatus is particular, though not exclusively, suitable for implementing the method for loading and transferring the tubular products on a toe-closer machine for the production of tights of the present invention.
As described above, and clearly illustrated in the figures, the method comprises steps of:
The loading step is preferably carried out in the above-mentioned loading station 11, the step of automatically transferring is carried out in a transfer station 12, distinct and separate from the loading station 11, and the hose loader 2, during the positioning step, is moved between the loading station 11 and the transfer station 12. The cutting step is preferably carried out in the loading station 11 or in the transfer station 11 or during the positioning step or in an intermediate position between the loading station and the transfer station.
As shown by way of example in
When a hose loader 2 is moved from the loading station to the transfer station, a further hose loader 2 is preferably predisposed in the loading station 11 for carrying out a further loading step of a further tubular product.
The method preferably comprises, at an end of the transfer step, a step of returning the at least a hose loader 2, or a plurality of hose loaders 2 in succession, into the loading station 11, such as to cyclically repeat the steps of the method on successive tubular products.
The method preferably comprises a step of completion of the transfer of the whole tubular product onto the hose holder 51, preferably by means of loading rollers 55 (see
In an aspect, the method comprises a step of sewing, by means of the toe-closer machine 50, the lower end of the tubular product wound to the hose holder, in such a way as to close the lower end and realize the toe-tip of a leg of the tights. Using the present method and apparatus, and thanks to the maintaining of a precise orientation unchanged from the loading on the hose loader to the transfer onto the hose holder, the sewing of the toe of each tubular product is carried out along a sewing line having a predetermined orientation (for example 90°) with respect to the cutting line of the upper end of the tubular product.
The sewing machine (not illustrated) of the toe-closer can be a machine of the overlock cut-and-sew type, for example a machine of the type produced by UNION SPECIAL ® in one of series 9M or the like.
Various aspects of the method, corresponding to the further aspects described above and/or actuable using above-illustrated components of the apparatus, are not repeated here. The further aspects of the production process of tights, for example relating to toe-closer and line-closer machines not described in detail in the present description and not deriving from special characteristics of the apparatus as described in the foregoing, are understood to be of conventional type.
The invention as it is conceived is susceptible to numerous modifications and variants, all falling within the inventive concept and the cited components are replaceable by other technically-equivalent element.
The invention offers important advantages.
Firstly, the invention enables obviating at least some of the drawbacks of the prior art. The invention further enables automatically producing tights of high quality and/or provided with particular graphic designs, wefts or designs and/or, in general, requiring a cut and sew having a determined orientation and/or position.
The invention further enables realizing textile articles, in particular tights, with high precision and/or substantially free of imperfections and/or reducing production waste.
The invention further enables automatically transferring a tubular product, already subjected to a cutting operation of the upper end, to a toe-closer machine for sewing the toe-tips.
The invention further enables realizing a continuous automatic cycle comprising the loading and cutting of tubular products and the transfer thereof on a toe-closer machine in a completely automatic way, without any intermediate unloading and with a single apparatus.
The invention further provides a method and a relative system in which a tubular product is initially loaded with a determined orientation and/or positioning and the orientation and/or positioning are maintained unchanged along all the successive stations up to the passage to a successive toe-closer machine, on which they are transferred while maintaining unchanged the said orientation and/or positioning.
Further, within the production cycle of tights, the invention anticipates the cutting operation of the tubular products upstream of the closing operations of the toes and sewing of the trunk.
The invention also enables increasing the velocity of execution of the cutting and/or transfer and/or sewing operations of tubular products for tights, and in general increasing the velocity of the whole production cycle, and thus increasing productivity.
The invention further enables improving the quality and/or obtaining productions of great uniformity among the various tights produced.
The invention further enables simplifying the production process of tights with respect to the known methods. The invention further enables reducing the need for personnel (one only or even no operator is required) with respect to the known methods.
The invention further obviates unloading of tubular products from the cutter holders and the successive manual re-loading on the toe-closer machine holders, typically required in the known methods and apparatus.
The invention further enables parallelising the cutting and sewing operations of tubular products for tights, reducing the dead times and enabling loading in succession a plurality of tubular products without having to wait for the completion of the production cycle.
The invention further facilitates the initial loading of tubular products on a machine for production of tights and/or improving the ergonomics of the loading.
The invention further enables realizing loading and transfer of tubular products on a toe-closer machine in a simple, rapid and automatic way, in particular also by integrating the apparatus described in an automatic machine for assembly of textile articles of known type.
Furthermore, the system of the present invention is simple and/or sturdy and/or economic to realize.
This list of references cited by the applicant is for the reader's convenience only. It does not form part of the European patent document. Even though great care has been taken in compiling the references, errors or omissions cannot be excluded and the EPO disclaims all liability in this regard.