YARN WINDING DEVICE, YARN WINDING METHOD, AND YARN WINDING SYSTEM

Abstract

 A yarn winding device (1) of an automatic winder comprises a yarn supplying section (11) adapted to hold a yarn supplying bobbin (8) ; a winding section (13, 60) adapted to wind a yarn unwound to one side in an axial direction from the yarn supplying bobbin (8) ; a winding control section (26) adapted to control the winding section (13, 60) ; an unwinding position detecting section (26) adapted to detect a yarn unwinding position of the yarn supplying bobbin (8) ; and an abnormality information storage section (51) adapted to store information related to an unwinding abnormality including the yarn unwinding position when the unwinding abnormality of the yarn is generated. The winding control section (26) is adapted to specify a drawback of a spinning device that spun the yarn supplying bobbin (8), in which the unwinding abnormality generates, from the abnormality information stored in the abnormality information storage section (51).

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

[0001] The present invention relates to a yarn winding device, a yarn winding method, and a yarn winding system adapted to wind a yarn to form a package.

2. Description of the Related Art

[0002] Japanese Patent Publication No. 3564817 discloses an automatic winder including a plurality of winding units. One winding unit winds a yarn, which is unwound from a yarn supplying bobbin, around a winding tube, which is supported by a cradle, while traversing with a winding drum including a traverse groove to form a package.

[0003] As the remaining amount of the yarn of the yarn supplying bobbin reduces, the unwound yarn and the yarn supplying bobbin tend to easily rub against each other thus increasing the unwinding resistance, and hence problems in that the tension of the yarn increases and unwinding abnormality such as yarn breakage, sloughing (hoop drop-out), and the like easily generates arise. In the automatic winder described in Japanese Patent Publication No. 3564817, when the remaining amount of the yarn becomes less than or equal to a prescribed amount, the tension to be applied on the yarn with the tensor is lowered. When the remaining amount of the yarn further reduces and cannot be responded by simply reducing the tension with the tensor, the rotation speed of the traverse drum is lowered to decelerate the winding speed. In Japanese Patent Publication No. 3564817, the set value of the winding speed is constant in a state that there is a great amount of yarn remaining on the yarn winding bobbin (until becoming less than or equal to the prescribed amount).

BRIEF SUMMARY OF THE INVENTION

[0004] The behavior (hereinafter referred to as yarn unwinding property) of the yarn often differs depending on the yarn supplying bobbin even if the yarn is unwound with the same condition for the unwinding speed, and the like. For example, if there is an area where the yarn is softly wound in the yarn supplying bobbin, sloughing, in which the yarn becomes a ring-shaped clump and drops off, may occur at the portion where the winding is soft if the yarn is unwound at high speed in the automatic winder. Furthermore, if the winding manner is common among the plurality of yarn supplying bobbins such as when a great number of yarn supplying bobbins are simultaneously manufactured with a spinning device, abnormality such as sloughing easily occurs at substantially the same yarn unwinding position when unwinding the yarn from the plurality of yarn supplying bobbins. Thus, the unwinding abnormality tends to easily generate at the same yarn unwinding position among the yarn supplying bobbins in which a specific condition is the same.

[0005] In regards to this, in the conventional automatic winder such as described in Japanese Patent Publication No. 3564817, the winding speed in a state there is a great amount of yarn remaining on the yarn supplying bobbin is set constant. Thus, when using the yarn supplying bobbin in which the sloughing and the like may possibly occur at a specific yarn unwinding position, the unwinding of the yarn of the entire yarn supplying bobbin is carried out with the winding speed sufficiently lowered so that abnormality does not generate at the relevant specific yarn unwinding position. In other words, abnormality does not generate even if the yarn is wound at a higher winding speed in a normal situation when unwinding the yarn at a position other than the specific yarn unwinding position, but in the prior art, the yarn is unwound at a low speed corresponding to the specific yarn unwinding position even at such a position, and as a result, the productivity is lowered.

[0006] It is an object of the present invention to enhance the productivity by setting an appropriate winding speed in accordance with the yarn unwinding property of the yarn supplying bobbin.

[0007] A yarn winding device of an aspect not part of the claimed invention includes a yarn supplying section adapted to hold a yarn supplying bobbin; a winding section adapted to wind a yarn unwound to one side in an axial direction from the yarn supplying bobbin; a speed setting section adapted to set a winding speed of the winding section; and a winding control section adapted to control the winding section based on the winding speed set by the speed setting section; wherein the winding control section functions as an unwinding position detecting section adapted to detect a yarn unwinding position of the yarn supplying bobbin; the speed setting section divides a winding range in which the yarn is wound in the yarn supplying bobbin to a plurality of individual setting ranges and sets the winding speed of the winding section for each of the plurality of individual setting ranges; and the winding control section controls the winding section to wind the yarn at the winding speed set with respect to the range in which the yarn unwinding position is located in accordance with in which range of the plurality of individual setting ranges the detected yarn unwinding position is located.

[0008] The yarn is unwound to one side in the axial direction from the yarn supplying bobbin, and the yarn is wound by the winding section. In the present invention, the winding range in which the yarn is wound in the yarn supplying bobbin is divided into a plurality of individual setting ranges, and the winding speed of the winding section is set for each of the plurality of individual setting ranges. Therefore, for example, the winding speed can be set in accordance with the yarn unwinding property such that the yarn is unwound at a high winding speed at the portion where the yarn is wound at a defined strength, and the yarn is unwound at a low winding speed at a portion where the yarn is wound looser than the defined strength so that the unwinding abnormality such as sloughing does not generate. That is, if the unwinding abnormality easily generates at a specific yarn unwinding position within the winding range of the yarn supplying bobbin, the winding speed is set to be slow when unwinding at such a specific yarn unwinding position and the winding speed is set fast when unwinding at other positions. Thus, the yarn can be wound as high speed as possible in a range the unwinding abnormality does not generate, which enhances the productivity.

[0009] A yarn winding device of another aspect not part of the claimed invention further includes a yarn detecting sensor adapted to detect an end on the yarn unwinding side of a yarn layer wound around the yarn supplying bobbin; an unwinding assisting device, which includes a tube body and which is adapted to assist the unwinding of the yarn while moving in the axial direction of the yarn supplying bobbin accompanying the advancement of the unwinding of the yarn; a stepping motor adapted to move the tube body toward a side opposite to the yarn unwinding side along the axial direction of the yarn supplying bobbin in accordance with the detection of the yarn by the yarn detecting sensor; and a count section adapted to count number of pulses transmitted to the stepping motor to drive the stepping motor; wherein the unwinding position detecting section detects the current yarn unwinding position from the number of pulses counted by the count section when the tube body is moved.

[0010] As the yarn is unwound from the yarn supplying bobbin, the position of the end on the yarn unwinding side of the yarn layer lowers. The tube body of the unwinding assisting device is moved in the axial direction of the yarn supplying bobbin accompanying the advancement of the unwinding of the yarn from the yarn supplying bobbin to regulate the expansion (balloon) of a yarn Y being unwound and to stabilize the unwinding tension. More specifically, the tube body is moved toward the side opposite to the yarn unwinding side along the axial direction of the yarn supplying bobbin by the stepping motor in accordance with the detection of the yarn by the yarn detecting sensor. In this case, where the current yarn unwinding position is at, that is, at which position in the axial direction of the yarn supplying bobbin the end on the yarn unwinding side of the yarn layer is at can be detected from the movement amount of the tube body. The movement amount of the tube body can be grasped by counting the number of pulses transmitted to the stepping motor when the tube body is moved. Therefore, the yarn unwinding position of the yarn supplying bobbin can be detected.

[0011] In a yarn winding device of another aspect not part of the claimed invention, the speed setting section includes an input section adapted to input a set value of the winding speed with respect to each of the plurality of individual setting ranges.

[0012] According to the present invention, the operator may input from the input section to set the winding speed for each of the plurality of individual setting ranges of the yarn supplying bobbin.

[0013] A yarn winding device of another aspect not part of the claimed invention further includes an abnormality information storage section adapted to store information related to frequency of an unwinding abnormality generated when the yarn is unwound in each of the plurality of individual setting ranges; wherein the speed setting section references the information related to the frequency of the unwinding abnormality stored in the abnormality information storage section to set the winding speed for each of the plurality of individual setting ranges.

[0014] According to the present invention, the winding speed for each of the plurality of individual setting ranges is set from the information related to the frequency of the unwinding abnormality at the time of yarn winding in the past for each of the plurality of individual setting ranges. Therefore, the winding speed can be appropriately set according to the generation tendency of the unwinding abnormality such as at which yarn unwinding position the unwinding abnormality easily generates.

[0015] A yarn winding device of another aspect not part of the claimed invention further includes a package forming section adapted to wind the yarn unwound from the yarn supplying bobbin around a winding tube to form a package; wherein the winding section is a yarn accumulating device arranged between the yarn supplying section and the package forming section to wind and temporarily accumulate the yarn unwound from the yarn supplying bobbin; and the package forming section winds the yarn unwound from the yarn accumulating device around the winding tube.

[0016] The yarn accumulating device is arranged between the yarn supplying section and the package forming section to temporarily accumulate the yarn unwound from the yarn supplying bobbin, so that the yarn accumulated in the yarn accumulating device can be supplied to the package forming section even under a situation where the yarn is not supplied from the yarn supplying bobbin such as when replacing the yarn supplying bobbin, when yarn breakage occurs, and the like. The interruption of the winding operation of the package forming section is thus suppressed as much as possible, and the productivity of the package enhances. According to the present invention, in the yarn winding device including the yarn accumulating device, the winding speed of the yarn accumulating device is controlled according to the yarn unwinding position of the yarn supplying bobbin. That is, the winding speed of the yarn accumulating device located between the yarn supplying section and the package forming section is controlled to control the yarn unwinding speed of the yarn from the yarn supplying bobbin, so that the lowering in the quality of the package is suppressed compared to when controlling the winding speed of the package forming section.

[0017] A yarn winding method of another aspect not part of the claimed invention relates to a yarn winding method for winding a yarn unwound from a yarn supplying bobbin, the method including the steps of dividing a winding range in which the yarn is wound in the yarn supplying bobbin into a plurality of individual setting ranges and setting a winding speed corresponding to a yarn unwinding property for each of the plurality of individual setting ranges; and winding the yarn unwound from the yarn supplying bobbin at the set winding speed.

[0018] In the present invention, the winding speed is set in accordance with the yarn unwinding property of the individual range, for each of the plurality of individual setting ranges of the winding range of the yarn supplying bobbin. Thus, the yarn can be wound as high speed as possible in a range that the unwinding abnormality does not generate, which enhances the productivity.

[0019] A yarn winding device of a first aspect includes a yarn supplying section adapted to hold a yarn supplying bobbin; a winding section adapted to wind a yarn unwound to one side in an axial direction from the yarn supplying bobbin; a winding control section adapted to control the winding section; an unwinding position detecting section adapted to detect a yarn unwinding position of the yarn supplying bobbin; and an abnormality information storage section adapted to store information related to an unwinding abnormality including the yarn unwinding position when the unwinding abnormality of the yarn is generated; wherein the winding control section specifies a drawback of a spinning device that spun the yarn supplying bobbin, in which the unwinding abnormality generates, from the abnormality information stored in the abnormality information storage section.

[0020] In the present invention, since the spinning device that spun the yarn supplying bobbin in which the unwinding abnormality generates can be specified in the yarn winding device, the drawbacks can be quickly responded.

[0021] A yarn winding device of a second aspect further includes a notifying section adapted to notify a specification result when the winding control section specifies the drawback of the spinning device that spun the yarn supplying bobbin in which the unwinding abnormality generates.

[0022] In the present invention, since the specification result of the drawback of the spinning device is notified by the notifying section, the operator can be quickly notified of the drawback of the spinning device.

[0023] A yarn winding system of a third aspect including the yarn winding device according to the first or second aspect, a spinning device including a plurality of spinning units adapted to spin the yarn supplying bobbin; and a tray transporting device adapted to transport the yarn supplying bobbin between the yarn winding device and the spinning device; wherein the tray transporting device includes a transportation tray adapted to mount and transport the yarn supplying bobbin, and a storage section arranged in the transportation tray; the storage section stores information related to the spinning unit that spun the yarn supplying bobbin mounted on the transportation tray; and the winding control section specifies the spinning unit that spun the yarn supplying bobbin, in which the unwinding abnormality generates, and specifies a spinning step that became the cause of generation of the unwinding abnormality in the spinning unit from the information stored in the storage section and the abnormality information stored in the abnormality information storage section.

[0024] In the present invention, since the spinning step in which the unwinding abnormality is generated in the relevant spinning unit can be specified, the operator can grasp more detailed drawback information and the maintenance performance enhances.

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] 

FIG. 1 is a perspective view of an automatic winder according to the present embodiment;

FIG. 2 is a front view of one winding unit of the automatic winder;

FIG. 3 is a block diagram schematically illustrating an electrical configuration of the automatic winder;

FIG. 4 is a front view of a yarn supplying bobbin;

FIG. 5 is a graph illustrating one example of a winding speed control of an accumulating device corresponding to a yarn unwinding position;

FIG. 6 is an explanatory view on determining weighting coefficients of seven individual setting ranges according to an alternative embodiment; and

FIG. 7 is a front view of one winding unit of an automatic winder according to another alternative embodiment.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0026] An embodiment of the present invention will now be described. The present embodiment is an example in which the present invention is applied to an automatic winder including a plurality of winding units adapted to wind a yarn unwound from a yarn supplying bobbin around a winding tube to form a package. FIG. 1 is a front view of an automatic winder according to the present embodiment, and FIG. 2 is a front view of one winding unit 2 of the automatic winder.

[0027] As illustrated in FIG. 1, the automatic winder 1 (yarn winding device) includes a plurality of winding units 2 arranged in a line in a right and left direction of FIG. 1, a doffing device 3 arranged in a freely travelling manner in a direction the plurality of winding units 2 are arranged, and a machine control device 4 adapted to perform an overall control of the automatic winder 1. The machine control device 4 is arranged at one end in the direction the winding units 2 are arranged in a line.

[0028] The automatic winder 1 is configured to transmit a command to each of the plurality of winding units 2 from the machine control device 4, and wind a yarn Y unwound from a yarn supplying bobbin 8 around a winding tube 17 (see FIG. 2) to form a package P in each winding unit 2. When a fully-wound package P is formed in a certain winding unit 2, the doffing device 3 moves to above the relevant winding unit 2 and changes the fully-wound package P with an empty winding tube 17. The machine control device 4 controls the operation of each winding unit 2, and also performs monitoring of the operation state, the setting and storing of the operation parameters, and the like. The machine control device 4 includes a display operation section 50. The display operation section includes a display section adapted to indicate the operation states of each winding unit 2 and the doffing device 3, a button and a switch adapted to perform the setting of the operation parameters, and the like of each winding unit 2, and the like.

[0029] The detailed configuration of each winding unit 2 will now be described. The winding unit 2 illustrated in FIG. 2 winds the spun yarn Y unwound from the yarn supplying bobbin 8 around the winding tube 17 while traversing to form into the package P of a prescribed shape.

[0030] The winding unit 2 includes a unit machine 10, a yarn supplying section 11 adapted to unwind the yarn Y of the yarn supplying bobbin 8 and supply the yarn Y, a yarn processing executing section 12 adapted to perform various processing on the yarn Y supplied from the yarn supplying section 11, and a winding section 13 adapted to wind the yarn Y processed by the yarn processing executing section 12 around the winding tube 17 to form the package P. The unit machine 10 includes an operation panel 25 having a display unit, an operation button, and the like, and a unit control section 26 (see FIG. 3). The yarn supplying section 11, the yarn processing executing section 12, and the winding section 13 are arranged in this order in a line from top to bottom.

[0031] The yarn supplying section 11 includes a peg 15 adapted to replaceably hold the yarn supplying bobbin 8, and an unwinding assisting device 16 adapted to assist the unwinding of the yarn Y from the yarn supplying bobbin 8. The peg 15 is in a vertical state illustrated in FIG. 2 at the time of unwinding of the yarn Y (time of yarn winding). The peg 15 tilts forward and backward (direction perpendicular to the plane of drawing of FIG. 2) when driven by a peg driving section 28 (see FIG. 3), so that the empty yarn supplying bobbin 8 can be discharged and a new yarn supplying bobbin 8 can be received from a magazine (not illustrated).

[0032] The unwinding assisting device 16 lowers a tube body 30, which is placed over the yarn supplying bobbin 8 from the upper side, as the unwinding of the yarn Y advances to regulate the expansion (balloon) of the yarn Y being unwound and stabilize the unwinding tension. More specifically, the unwinding assisting device 16 includes the tube body 30, a holding member 35 adapted to hold the tube body 30, and an optical sensor 36 attached to the holding member 35. The holding member 35 is raised and lowered up and down by a tube body drive motor 37 including a stepping motor, so that the tube body 30 and the optical sensor 36 also move up and down with the holding member 35. The optical sensor 36 includes a light emitting element 36a and a light receiving element 36b arranged on both sides of the yarn supplying bobbin 8, and the optical sensor 36 detects a chess section 8a of the yarn supplying bobbin 8 (a tapered end on the yarn unwinding side of a yarn layer of the yarn supplying bobbin 8: see FIG. 4).

[0033] When the position (yarn unwinding position) of the chess section 8a lowers with the advancement of the unwinding of the yarn Y, the chess section 8a is no longer detected by the optical sensor 36. A signal for driving the tube body drive motor 37 and lowering the tube body 30 is then transmitted from the unit control section 26 to a motor driver 38. The motor driver 38 receiving the signal transmits a pulse signal to the tube body drive motor 37, and moves the holding member 35 toward a side (lower side) opposite to the yarn unwinding side up to a position where the chess section 8a is detected by the optical sensor 36. In this case, a count section arranged in the motor driver 38 counts the number of pulse signals transmitted to the tube body drive motor 37 to lower the tube body 30. The tube body 30 thus lowers following the change in the yarn unwinding position, and the position relationship of the tube body 30 and the chess section 8a is maintained constant. When the yarn Y of the yarn supplying bobbin 8 becomes considerably small, the balloon of the unwound yarn Y becomes small and hence does not need to be regulated with the tube body 30, whereby the tube body 30 is configured so as not to further lower when reaching a prescribed lower limit position.

[0034] The winding section 13 includes a cradle (not illustrated) adapted to rotatably grip the winding tube 17, and a traverse drum 18 rotatably driven by the drum driving section 27 (see FIG. 3). A spiral-shaped traverse groove 18a is formed on the circumferential surface of the traverse drum 18, so that the yarn Y is traversed by the traverse groove 18a. Since the traverse drum 18 is rotatably driven while making contact with the package P formed on the winding tube 17 while traversing the yarn Y with the traverse groove 18a, the package P is rotated by a contacting friction with the traverse drum 18, and the yarn Y unwound from the yarn supplying bobbin 8 is wound around the winding tube 17.

[0035] The yarn processing executing section 12 includes a yarn filler 19, a tension applying device 20, a yarn joining device 21, and a yarn clearer 22.

[0036] The yarn filler 19 is adapted to detect presence or absence of the yarn Y between the unwinding assisting device 16 and the tension applying device 20. The tension applying device 20 is adapted to apply a predetermined tension on the travelling yarn Y. FIG. 2 illustrates a gate-type including a fixed comb tooth 20a and a movable comb tooth 20b driven by a tension applying device driving section 30 (see FIG. 3), by way of example.

[0037] The yarn joining device 21 joins a lower yarn Y1 from the yarn supplying bobbin 8 and an upper yarn Y2 from the package P at the time of yarn cut by a cutter 22a when a yarn defect is detected by the yarn clearer 22, to be described later, at the time of yarn breakage during the winding, or at the time of replacing the yarn supplying bobbin 8. One example of the yarn joining device 21 is an air splicer adapted to perform the yarn joining operation by generating an airflow and entangling the fibers of the lower yarn Y1 and the upper yarn Y2.

[0038] A lower yarn catching and guiding member 23 adapted to catch the lower yarn Y1 from the yarn supplying bobbin 8 and guide the lower yarn Y1 to the yarn joining device 21, and an upper yarn catching and guiding member 24 adapted to catch the upper yarn Y2 from the package P and to guide the upper yarn Y2 to the yarn joining device 21 are arranged on the lower side and the upper side of the yarn joining device 21, respectively. The lower yarn catching and guiding member 23 and the upper yarn catching and guiding member 24 both have one end rotatably attached to the unit machine 10. Furthermore, the lower yarn catching and guiding member 23 and the upper yarn catching and guiding member 24 are respectively driven by a lower yarn guiding member driving section 31 and an upper yarn guiding member driving section 32 (both illustrated in FIG. 3) to be swung up and down.

[0039] A suction port 23a of the lower yarn catching and guiding member 23 sucks and catches the yarn end of the lower yarn Y1, and swings from the lower side to the upper side to guide the lower yarn Y1 to the yarn joining device 21. At the same time, the upper yarn catching and guiding member 24 has a suction mouth 24a swung to a yarn end catching position proximate to a contacting point of the package P and the traverse drum 18, and again swung to the lower side after sucking and catching the yarn end of the upper yarn Y2 from the package P at the yarn end catching position to guide the upper yarn Y2 to the yarn joining device 21. The yarn joining device 21 joins the yarn end of the lower yarn Y1 guided by the lower yarn catching and guiding member 23 and the yarn end of the upper yarn Y2 guided by the upper yarn catching and guiding member 24 to obtain one yarn Y. The winding of the yarn Y by the winding section 13 is thereby resumed.

[0040] The yarn clearer 22 acquires information on a thickness of the travelling yarn Y on a constant basis. In other words, the yarn clearer 22 corresponds to a yarn thickness detecting section in the invention of the present application. Furthermore, the yarn clearer 22 detects an abnormality portion at where the yarn thickness is thicker or thinner by a constant amount or more existing in the yarn Y as a yarn defect based on the information of the yarn thickness. The yarn clearer 22 includes a cutter 22a, and the cutter 22a immediately cuts the yarn Y when the yarn defect is detected by the yarn clearer 22.

[0041] The yarn defect remains in the upper yarn Y2 if the yarn Y is cut after the detection of the yarn defect of the yarn clearer 22 , but the lower yarn Y1 and the upper yarn Y2 are joined after removing the yarn defect from the upper yarn Y2 in the yarn joining device 21.

[0042] The electrical configuration of the automatic winder 1 will now be described. As illustrated in FIG. 3, the machine control device 4 of the automatic winder 1 is communicably connected to the unit control section 26 of the plurality of winding units 2 and the control section 52 of the doffing device 3. The machine control device 4 monitors the operation state of each winding unit 2 and the operation state of the doffing device 3. The machine control device 4 includes a display operation section 50, and a winding condition storage section 51 adapted to store the winding condition of each winding unit 2 set from the display operation section 50.

[0043] The unit control section 26 of each winding unit 2 is configured by a CPU (Central Processing Unit), which is an arithmetic processing unit, a ROM (Read-Only Memory) storing programs to be executed by the CPU and data to be used in the programs, a RAM (Random Access Memory) adapted to temporarily store the data at the time of program execution, an input/output interface adapted to perform input/output of data with the outside, and the like. The unit control section 26 controls the operation of each device of the winding unit 2 described above based on the winding condition transmitted from the machine control device 4. The unit control section 26 is also communicable with the control section 52 of the doffing device 3, and outputs a signal for causing the doffing device 3 to perform the doffing operation when the fully-wound package P is obtained.

[0044] The display operation section 50 includes a display 50a (correspond to "notifying section" in the present invention) adapted to display various information, and an operation button group 50b (correspond to "input section" in the present invention) enabling the operator to perform various setting. When the operator operates the operation button group 50b of the display operation section 50 of the machine control device 4 to input, the various winding conditions for each winding unit 2 can be set and changed. The winding condition set (changed) in the display operation section 50 is stored in the winding condition storage section 51. In particular, in the present embodiment, the setting of the winding condition by the display operation section 50 includes the setting of the package winding speed (i.e., unwinding speed of the yarn Y from the yarn supplying bobbin 8) of the winding section 13 corresponding to the yarn unwinding property of the yarn supplying bobbin 8. In the present embodiment, the display operation section 50 of the machine control device 4 corresponds to the "speed setting section" in the present invention.

[0045] The unit control section 26 (winding control section) adapted to control the winding operation of the winding section 13 references the set value of the winding speed stored in the winding condition storage section 51 to control the rotation speed of the traverse drum 18 in accordance with the yarn unwinding position of the yarn supplying bobbin 8 (position of chess section 8a).

[0046] The setting of the package winding speed according to the yarn unwinding property of the yarn supplying bobbin 8 will be described in detail below. FIG. 4 is a front view of the yarn supplying bobbin 8. A core tube 8b of the yarn supplying bobbin 8 has a tapered tube shape in which the diameter of one end (upper end in the figure) in the axial direction is smaller than the diameter of the other end (lower end in the figure). A range excluding both ends of the core tube 8b is the winding range in which the yarn Y is wound. If the yarn Y is wound around the entire region of the winding range illustrated in FIG. 4, the yarn supplying bobbin 8 is in a fully-wound state. However, the yarn supplying bobbin used in the automatic winder 1 is not limited to the yarn supplying bobbin 8 in the fully-wound state, and the yarn supplying bobbin 8 in which the yarn is only wound up to the middle from the lower end of the winding range may be used.

[0047] As illustrated in FIG. 4, the winding range of the yarn supplying bobbin 8 is divided to a first range A1 and a second range A2. The first range A1 is a range located on the yarn unwinding side (upper side) of the winding range. If the chess section 8a is located within the first range A1, the chess section 8a is detected by the optical sensor 36 (see FIG. 2) that moves up and down (axial direction of the yarn supplying bobbin 8) with the tube body 30 of the unwinding assisting device 15. The second range A2 is a range located on the opposite side of the yarn unwinding side in the winding range, and is located further on the lower side than the detecting position of the optical sensor 36 when the tube body 30 of the unwinding assisting device 15 is at the lower limit position. That is, the chess section 8a is in the first range if the chess section 8a can be detected by the optical sensor 36, and the chess section 8a is in the second range if the chess section 8a cannot be detected with the optical sensor 36.

[0048] When the yarn Y is unwound from the yarn supplying bobbin 8, the yarn Y wound in the first range A1 is first unwound, and after all the yarn Y in the first range A1 is unwound, the yarn Y in the second range A2 is unwound. That is, a state the yarn Y is unwound from the first range A1 is a state in which the yarn Y of the yarn supplying bobbin 8 is sufficiently remained, and a state the yarn Y is unwound from the second range A2 is a state the yarn Y is barely remained.

[0049] When the yarn Y is unwound from the first range A1 located on the yarn unwinding side, the unwound yarn Y forms a big balloon, so that the yarn y does not rub against the yarn supplying bobbin 8 at the time of unwinding and the unwinding resistance is small. Thus, abnormality such as yarn breakage and sloughing is less likely to occur even if the unwinding speed of the yarn Y (winding speed of the winding section 13) is increased. If the yarn Y is unwound from the second range A2 on the opposite side of the yarn unwinding side, the balloon becomes small, and thus the unwound yarn Y easily rubs against the yarn supplying bobbin 8 and the unwinding resistance becomes large. Thus, yarn breakage and sloughing easily occur if the unwinding speed of the yarn Y is high. The winding speed of the winding section 13 when the yarn unwinding position (chess section 8a) is in the second range A2 is set to a value lower than in the first range A1 by the display operation section 50.

[0050] Furthermore, as illustrated in FIG. 4, the first range A1 is divided into seven individual setting ranges A1a to A1g in the axial direction of the core tube 8b in order from the top. The winding speed of the winding section 13 is individually set for each of the seven ranges A1a to A1g by the display operation section 50. The unit control section 26 controls the winding section 13 such that the yarn is wound at a predetermined winding speed corresponding to the individual setting range in which the yarn unwinding position is located when the yarn Y is unwound at a certain position of the yarn supplying bobbin 8.

[0051] In which one of the seven ranges A1a to A1g of the first range A1 the current yarn unwinding position (position of chess section 8a) is at can be detected in the following manner. The optical sensor 36 for detecting the chess section 8a is attached to the holding member 35 (see FIG. 2), and the rising/lowering amount from the original position of the holding member 35 when the chess section 8a is detected by the optical sensor 36 can be acquired from the number of pulses transmitted from the motor driver 38 to the tube body drive motor 37 including the stepping motor. The transmitted number of pulses is stored in the count section of the motor driver 38. The unit control section 26 acquires the lowering amount from the original position of the holding member 35 (optical sensor 36) from the number of pulses transmitted from the motor driver 38 to the tube body drive motor 37, and detects the height position of the chess section 8a (axial position of the yarn supplying bobbin 8), that is, yarn unwinding position therefrom. In the present embodiment, the optical sensor 36 for detecting the chess section 8a of the yarn supplying bobbin 8 corresponds to the "yarn detecting sensor" in the present invention. The unit control section 26 that detects the position of the chess section 8a from the number of pulses transmitted to the tube body drive motor 37 corresponds to the "unwinding position detecting section" in the present invention adapted to detect the position (yarn unwinding position) of the chess section 8a of the yarn supplying bobbin 8. In the present embodiment, the count section is arranged in the motor driver, but the count section may be arranged in the unit control section 26.

[0052] The winding speed of the seven ranges A1a to A1g of the first range A1 is set from the display operation section 50 based on the information related to the yarn unwinding property such as at which position of the yarn supplying bobbin 8 the yarn Y is unwound when the abnormality such as yarn breakage and sloughing easily generates. More specifically, if conditions such as the shape of the yarn supplying bobbin 8 (shape of the core tube 8b and the shape of the yarn layer), the yarn type, or the winding manner (tight or loose winding manner) of the yarn in the spinning device when manufacturing the yarn supplying bobbin 8 differ, the position of the yarn supplying bobbin 8 the yarn Y is unwound when the abnormality easily generates changes. Thus, the winding speeds of the seven ranges A1a to A1g of the first range A1 are respectively set based on the various types of conditions that influence the yarn unwinding property. Alternatively, the machine control device 51 may automatically set the winding speeds with respect to the seven ranges A1a to A1g based on such conditions when the operator inputs the various types of conditions from the display operation section 50.

[0053] FIG. 5 illustrates a set example of a winding speed control corresponding to the yarn unwinding position. This is an example of when using the yarn supplying bobbin 8 in which abnormality easily generates the most in the range A1f and the range A1g and the abnormality easily generates next in the range A1a and the range A1b. In this case, as illustrated in FIG. 5, the winding speed VA of the range A1f and the range A1g is set to be the smallest, and the winding speed VB of the range A1a and the range A1b is set to be the next smallest, and the winding speed VC of other ranges A1c to A1e is set to be the largest. The winding speed of the second range A2 is set to V2 that is further lower than the VA, which is the lowest speed in the first range A1.

[0054] In the present embodiment described above, the winding speed of the winding section 13 can be set and changed by the display operation section 50 in accordance with the yarn unwinding property of the yarn supplying bobbin 8. Thus, the yarn can be wound as high speed as possible in a range the unwinding abnormality does not generate, which enhances the productivity.

[0055] More specifically, the winding range (first range A1) in which the yarn of the yarn supplying bobbin 8 is wound is divided into seven individual setting ranges A1a to A1g, and the winding speed of the winding section is set for each of the seven individual setting ranges A1a to A1g. Thus, even if the unwinding abnormality easily generates at a specific yarn unwinding position in the first range A1 of the yarn supplying bobbin 8, the winding speed can be lowered when unwinding the yarn at the yarn unwinding position and the winding speed can be increased when unwinding the yarn at other yarn unwinding positions. Thus, the yarn can be wound as high speed as possible in the range the unwinding abnormality does not generate, which enhances the productivity of the package P.

[0056] An alternative embodiment in which various changes are made on the embodiment described above will now be described. The same reference numerals are denoted on the components having a configuration similar to the embodiment described above, and the description will be appropriately omitted.

1] The winding speed for each of the seven ranges A1a to A1g may be set based on the data of the yarn unwinding position of when the abnormality actually generated and the winding speed collected at the time of bobbin use in the past. The setting of the winding speed based on the past abnormality information will be described below using an example.

[0057] The winding speed V1x of the winding section 13 with respect to the range A1x (x is any of a to g) of the first range A1 is calculated with the equation V1x = V0 + wx x ΔV, where V0 is the reference speed, wx is the weighting coefficient, and ΔV is the increasing speed. The information on the frequency of abnormality generation of when the yarn Y is unwound from the range A1x, which is collected from the data at the time of yarn winding in the past, is directly input from the display operation section 50 by the operator and stored in the winding condition storage section 51 of the machine control device 4. The machine control device 4 determines the weighting coefficient wx based on the information on the frequency of the abnormality generation. In this aspect, the winding condition storage section 51 of the machine control device 4 corresponds to the "abnormality information storage section" in the present invention adapted to store the information related to the frequency of the unwinding abnormality on each individual setting range A1a to A1g. Furthermore, in this aspect, the display operation section 50 of the machine control device 4 that determines the weighting coefficient wx corresponds to the "speed setting section" in the present invention adapted to set the winding speed with reference to the information related to the frequency of the unwinding abnormality. The unit control section 26 of each winding unit 2 may determine the weighting coefficient wx with reference to the information related to the frequency of the unwinding abnormality stored in the winding condition storage section 51.

[0058] The setting method of the weighting coefficient wx is not particularly limited, but may be set in the following manner, for example. FIG. 6 is an explanatory view on determining the weighting coefficients of the seven individual setting ranges. First, initial values of all weighting coefficients wx are set to 0. In other words, the initial value of the winding speed of each range = reference speed V0.

[0059] The winding of the package P is started at the initial value, and information on the presence/absence of generation of the unwinding abnormality in the relevant yarn supplying bobbin 8 as well as in which range the unwinding abnormality is generated if the unwinding abnormality is generated are acquired every time one yarn supplying bobbin 8 is used up. The weighting coefficient wx is increased by one in the range in which the unwinding abnormality does not generate and the weighting coefficient wx is reduced by one in the range in which the unwinding abnormality is generated in the seven individual setting ranges A1a to A1g. In the example of FIG. 6, the abnormality is generated once in the ranges A1a and A1b and the abnormality is generated twice in the ranges A1f, A1g while five yarn supplying bobbins are used up. This is repeated to acquire the limit speed at which the unwinding abnormality does not generate for each of the seven ranges A1a to A1g.

[0060] In the present embodiment, the embodiment in which the winding of the package P is started, the information on the presence/absence of generation of the unwinding abnormality in the relevant yarn supplying bobbin 8 as well as in which range the unwinding abnormality is generated if the unwinding abnormality is generated are acquired every time one yarn supplying bobbin 8 is used up, and the weighting coefficient in the range in which the unwinding abnormality is generated is changed to change the setting speed of the individual setting range has been described, but this is not the sole case. The information on the presence/absence of generation of the unwinding abnormality in the relevant yarn supplying bobbin 8 detected in the above manner and in which range the unwinding abnormality is generated if the unwinding abnormality is generated are acquired, and the information may be used to perform maintenance on the spinning device. If the unwinding abnormality is generated, the information on in which range the unwinding abnormality is generated is acquired, so that the cause the yarn supplying bobbin 8, in which the unwinding abnormality generates, is spun may be estimated or specified in the step of spinning one yarn supplying bobbin 8 in the spinning device. The cause the yarn supplying bobbin 8, in which the unwinding abnormality generates, is spun includes stopping of the spinning device due to blackout, end of lifespan of the consumable articles, and the like.

[0061] If a tray transporting device adapted to transport the yarn supplying bobbin 8 from the spinning device to the winding unit 2 with the transportation tray is arranged, the storage section is attached to the transportation tray, and the information on the spinning unit that spun the yarn supplying bobbin is recorded in such storage section so that the spinning unit that spun the yarn supplying bobbin 8 in which the unwinding abnormality is generated can be specified. Furthermore, since in which range of the one yarn supplying bobbin 8 the unwinding abnormality is generated is acquired as the information of the unwinding abnormality, the spinning step that became the cause of generation of the unwinding abnormality (spinning length from the start of spinning of the yarn supplying bobbin to the area where the yarn of the unwinding abnormality portion is spun) can be specified when the spinning unit that spun the yarn supplying bobbin 8, in which the unwinding abnormality is generated, spins the yarn supplying bobbin 8. Furthermore, the unit control section 26 includes a notifying section 50a adapted to notify the specification result when specification of the spinning unit that spun the yarn supplying bobbin 8 in which the unwinding abnormality is generated and the step that became the cause of occurrence of drawback is carried out.

2] In the embodiment described above, the first range A1 of the winding range is divided into a plurality of (seven) individual setting ranges, and then the winding speed is set for each of the plurality of individual setting ranges. In other words, a plurality of discrete winding speeds is set with respect to the first range A1. On the contrary, a continuous function expression between the yarn unwinding position of the yarn supplying bobbin 8 and the winding speed of the winding section 13 may be obtained, and the winding speed may be continuously calculated from the detected yarn unwinding position in accordance with the function expression.

3] In the embodiment described above, the chess section 8a is not detected with the optical sensor 36 in the second range A2, but if the remaining amount of the yarn can be detected even in the second range A2, the winding speed can be controlled in accordance with the yarn unwinding position for the second range A2 as well, similar to the first range A1. In order to detect the yarn unwinding position in the second range A2, for example, image analysis by a camera may be used.
Alternatively, a plurality of optical sensors 36 may be fixedly installed in a line vertically at the side of the yarn supplying bobbin 8, and the position of the chess section 8a may be detected with the plurality of optical sensors 36. In this variant, the chess section 8a can be detected not only in the second range A2 but in the entire winding range including the first range A1 by vertically arranging the plurality of optical sensors 36 over the entire winding range including the first range A1.

4] The detection of the yarn unwinding position of the yarn supplying bobbin 8 can be carried out without using sensors such as the optical sensor 36. For example, the yarn unwinding position of the yarn supplying bobbin 8 may be detected (presumed) from the winding time of the package P by the winding section 13. The yarn unwinding position of the yarn supplying bobbin 8 may be detected (presumed) from the length of yarn wound into the package P. The length of the yarn wound into the package P can be detected from the number of rotations of the traverse drum 18, for example. Alternatively, detection may be directly made by a yarn length detecting sensor arranged on a yarn travelling path.

5] As illustrated in FIG. 7, a yarn accumulating roller 60 (yarn accumulating device) adapted to wind the yarn unwound from the yarn supplying bobbin and temporarily accumulate the yarn may be arranged between the yarn supplying section 11 and the winding section 13 (package forming section). The winding section 13 winds the yarn Y unwound from the yarn accumulating roller 60 around the winding tube 17 to form the package P. With such a configuration, the yarn accumulated in the yarn accumulating roller 60 can be supplied to the winding section 13 even under a situation where the yarn Y is not supplied from the yarn supplying bobbin 8 such as when replacing the yarn supplying bobbin 8, when yarn breakage occurs, and the like. The interruption of the winding operation of the winding section 13 is thus suppressed as much as possible, and the productivity of the package P enhances.
When applying the present invention on the winding unit 2 including the yarn accumulating roller 60, the winding speed of the yarn accumulating roller 60 is set in accordance with the yarn unwinding position of the yarn supplying bobbin 8. That is, the unwinding speed of the yarn Y from the yarn supplying bobbin 8 is controlled by controlling the winding speed of the yarn accumulating roller 60 located between the yarn supplying section 11 and the winding section 13. In this case, the lowering in the quality of the package P is suppressed compared to when controlling the winding speed of the winding section 13 that forms the package P.

6] In the embodiment described above, the fact that the yarn unwinding position where the unwinding abnormality tends to easily generate differs among the yarn supplying bobbins 8 is seen as a problem, and hence the winding speed of the winding section 13 is set in accordance with the yarn unwinding position of the yarn supplying bobbin 8. However, the winding speed may be set according to the difference in other yarn unwinding properties. For example, in the spinning device, the unwinding abnormality such as yarn breakage and sloughing tends to easily generate overall in the yarn supplying bobbin 8 in which the yarn is loosely wound at low tension, compared to the yarn supplying bobbin 8 in which the yarn is tightly wound at a defined tension. Thus, if the yarn of the yarn supplying bobbin 8 is loosely wound, the winding speed is suppressed low overall.

[0062] The tube body 30 arranged in the unwinding assisting device 16 of the present invention also includes a tube body with a slit, in which a slit for passing the yarn is formed at one portion.

[0063] The following points are also part of the disclosure:

1. A yarn winding device (1) comprising:

a yarn supplying section (11) adapted to hold a yarn supplying bobbin (8);

a winding section (13, 60) adapted to wind a yarn unwound to one side in an axial direction from the yarn supplying bobbin (8);

a speed setting section (50) adapted to set a winding speed of the winding section (13, 60); and

a winding control section (26) adapted to control the winding section (13, 60) based on the winding speed set by the speed setting section (50); characterized in that:

the winding control section (26) functions as an unwinding position detecting section (26) adapted to detect a yarn unwinding position of the yarn supplying bobbin (8);

the speed setting section (50) divides a winding range in which the yarn is wound in the yarn supplying bobbin (8) to a plurality of individual setting ranges (A1a to A1g) and sets the winding speed of the winding section (13, 60) for each of the plurality of individual setting ranges (A1a to A1g); and

the winding control section (26) controls the winding section (13, 60) to wind the yarn at the winding speed set with respect to the range in which the yarn unwinding position is located in accordance with in which range of the plurality of individual setting ranges (A1a to A1g) the detected yarn unwinding position is located.

2. The yarn winding device (1) according to point 1, further comprising:

a yarn detecting sensor (36) adapted to detect an end on the yarn unwinding side of a yarn layer wound around the yarn supplying bobbin (8) ; an unwinding assisting device, which includes a tube body and which is adapted to assist the unwinding of the yarn while moving in the axial direction of the yarn supplying bobbin (8) accompanying the advancement of the unwinding of the yarn;

a stepping motor (37) adapted to move the tube body toward a side opposite to the yarn unwinding side along the axial direction of the yarn supplying bobbin (8) in accordance with the detection of the yarn by the yarn detecting sensor (36); and

a count section (38) adapted to count number of pulses transmitted to the stepping motor (37) to drive the stepping motor (37); characterized in that the unwinding position detecting section (26) detects the current yarn unwinding position from the number of pulses counted by the count section (38) when the tube body is moved.

3. The yarn winding device (1) according to point 1 or 2, characterized in that the speed setting section (50) includes an input section (50b) adapted to input a set value of the winding speed with respect to each of the plurality of individual setting ranges (A1a to A1g).

4. The yarn winding device (1) according to point 1 or 2, further comprising an abnormality information storage section (51) adapted to store information related to frequency of an unwinding abnormality generated when the yarn is unwound in each of the plurality of individual setting ranges (A1a to A1g); characterized in that
the speed setting section (50) references the information related to the frequency of the unwinding abnormality stored in the abnormality information storage section (51) to set the winding speed for each of the plurality of individual setting ranges (A1a to A1g).

5. The yarn winding device (1) according to any one of points 1 to 4, further comprising a package forming section (13) adapted to wind the yarn unwound from the yarn supplying bobbin (8) around a winding tube to form a package; characterized in that
the winding section (60) is a yarn accumulating device (60) arranged between the yarn supplying section (11) and the package forming section (13) to wind and temporarily accumulate the yarn unwound from the yarn supplying bobbin (8); and
the package forming section (13) winds the yarn unwound from the yarn accumulating device (60) around the winding tube.

6. A yarn winding method for winding a yarn unwound from a yarn supplying bobbin (8), the method comprising the steps of:

dividing a winding range in which the yarn is wound in the yarn supplying bobbin (8) into a plurality of individual setting ranges (A1a to A1g) and setting a winding speed corresponding to a yarn unwinding property for each of the plurality of individual setting ranges (A1a to A1g); and

winding the yarn unwound from the yarn supplying bobbin (8) at the set winding speed.

7. A yarn winding device (1) comprising:

a yarn supplying section (11) adapted to hold a yarn supplying bobbin (8);

a winding section (13, 60) adapted to wind a yarn unwound to one side in an axial direction from the yarn supplying bobbin (8);

a winding control section (26) adapted to control the winding section (13, 60);

an unwinding position detecting section (26) adapted to detect a yarn unwinding position of the yarn supplying bobbin (8); and

an abnormality information storage section (51) adapted to store information related to an unwinding abnormality including the yarn unwinding position when the unwinding abnormality of the yarn is generated; characterized in that

the winding control section (26) specifies a drawback of a spinning device that spun the yarn supplying bobbin (8), in which the unwinding abnormality generates, from the abnormality information stored in the abnormality information storage section (51).

8. The yarn winding device (1) according to point 7, further comprising a notifying section (50a) adapted to notify a specification result when the winding control section (26) specifies the drawback of the spinning device that spun the yarn supplying bobbin (8) in which the unwinding abnormality generates.

9. A yarn winding system comprising:

the yarn winding device (1) according to point 7 or 8;

a spinning device including a plurality of spinning units adapted to spin the yarn supplying bobbin (8); and

a tray transporting device adapted to transport the yarn supplying bobbin (8) between the yarn winding device (1) and the spinning device; characterized in that

the tray transporting device includes a transportation tray adapted to mount and transport the yarn supplying bobbin (8), and a storage section arranged in the transportation tray;

the storage section stores information related to the spinning unit that spun the yarn supplying bobbin (8) mounted on the transportation tray; and

the winding control section (26) specifies the spinning unit that spun the yarn supplying bobbin (8), in which the unwinding abnormality generates, and specifies a spinning step that became the cause of generation of the unwinding abnormality in the spinning unit from the information stored in the storage section and the abnormality information stored in the abnormality information storage section (51).

Claims

1. A yarn winding device (1) comprising:

a yarn supplying section (11) adapted to hold a yarn supplying bobbin (8);

a winding section (13, 60) adapted to wind a yarn unwound to one side in an axial direction from the yarn supplying bobbin (8);

a winding control section (26) adapted to control the winding section (13, 60);

an unwinding position detecting section (26) adapted to detect a yarn unwinding position of the yarn supplying bobbin (8); and

an abnormality information storage section (51) adapted to store information related to an unwinding abnormality including the yarn unwinding position when the unwinding abnormality of the yarn is generated; characterized in that

the winding control section (26) is configured to specify a drawback of a spinning device that spun the yarn supplying bobbin (8), in which the unwinding abnormality generates, from the abnormality information stored in the abnormality information storage section (51).

2. The yarn winding device (1) according to claim 1, further comprising a notifying section (50a) adapted to notify a specification result when the winding control section (26) specifies the drawback of the spinning device that spun the yarn supplying bobbin (8) in which the unwinding abnormality generates.

3. A yarn winding system comprising:

the yarn winding device (1) according to claim 1 or 2;

a spinning device including a plurality of spinning units adapted to spin the yarn supplying bobbin (8); and

a tray transporting device adapted to transport the yarn supplying bobbin (8) between the yarn winding device (1) and the spinning device; characterized in that

the tray transporting device includes a transportation tray adapted to mount and transport the yarn supplying bobbin (8), and a storage section arranged in the transportation tray;

the storage section stores information related to the spinning unit that spun the yarn supplying bobbin (8) mounted on the transportation tray; and

the winding control section (26) is configured to specify the spinning unit that spun the yarn supplying bobbin (8), in which the unwinding abnormality generates, and to specify a spinning step that became the cause of generation of the unwinding abnormality in the spinning unit from the information stored in the storage section and the abnormality information stored in the abnormality information storage section (51).

Drawing