BACKGROUND OF THE INVENTION
[0001] The present invention relates to a false-twist texturing machine including an empty
take-up tube supplier configured to supply an empty take-up tube to a winding device.
[0002] Patent Literature 1 (
Japanese Laid-Open Patent Publication No. 2011-47074) discloses a false-twist texturing machine configured to false-twist a yarn. The
false-twist texturing machine of Patent Literature 1 includes a yarn supplying unit,
a feed roller causing a yarn supplied from the yarn supplying unit to run, a winding
device winding the running yarn, and a heater, a cooler, and a false-twisting device
that are provided on a yarn path from the yarn supplying unit to the winding device.
[0003] In the false-twist texturing machine, a package is formed in such a way that a yarn
supplied from the yarn supplying unit is false-twisted by members such as the false-twisting
device and the yarn is then wound onto a take-up tube by the winding device. The completed
package is detached from the winding device. After an empty take-up tube on which
no yarn is wound is attached to the winding device, winding of another yarn is performed
again by the winding device.
[0004] Patent Literature 2 (
Japanese Laid-Open Patent Publication No. H10-279188) discloses an empty take-up tube supplier (bobbin replacement device) which is configured
to supply an empty take-up tube (empty bobbin) to a winding device such as a false-twist
texturing machine. The empty take-up tube supplier is able to accommodate an empty
take-up tube therein. When a yarn is wound onto a take-up tube by the winding device
and a fully-wound package is formed, the fully-wound package is detached and an empty
take-up tube is supplied from an empty take-up tube supplying rail to the winding
device.
SUMMARY OF THE INVENTION
[0005] To the empty take-up tube supplier, an empty take-up tube is accordingly supplied
by an operator, an automatic robot, or the like. When the empty take-up tube supplier
runs out of empty take-up tubes but replenishment of the empty take-up tubes has not
been done, the empty take-up tube supplier cannot supply an empty take-up tube to
the winding device. To the false-twist texturing machine, a yarn is continuously supplied
from the yarn supplying unit. On this account, when no empty take-up tube is supplied
to the winding device after a fully-wound package is detached from the winding device,
malfunction such as entanglement of the yarn onto the winding device may occur on
account of continuous supply of the yarn from the yarn supplying unit.
[0006] In addition to the above, when yarn breakage occurs while the yarn is being wound
or yarn threading to the winding device is not successfully done, the winding performed
by the winding device may be canceled in the middle and supply of the next empty take-up
tube may be requested at an early time. In such a case, when the empty take-up tube
supplier does not accommodate empty take-up tubes, the malfunction above may occur.
It is therefore very important to grasp the timing to replenish empty take-up tubes
to the empty take-up tube supplier.
[0007] In particular, in a false-twist texturing machine having plural winding devices,
it is difficult to grasp the timing to replenish empty take-up tubes to each of all
empty take-up tube suppliers corresponding to the respective winding devices. On this
account, replenishment of empty take-up tubes tends to be forgotten.
[0008] An object of the present invention is to provide a false-twist texturing machine
that prevents an operator, an automatic robot, or the like from forgetting to replenish
empty take-up tubes to an empty take-up tube supplier and also prevents the occurrence
of a failure in winding of a yarn by a winding device.
[0009] The present invention relates to a false-twist texturing machine comprising: winding
devices each of which is configured to form a package by winding a yarn onto a take-up
tube; empty take-up tube suppliers which are provided for the respective winding devices
and each of which supplies an empty take-up tube to each of the winding devices; and
a control unit, each of the empty take-up tube suppliers includes a stocker portion
capable of accommodating empty take-up tubes and at least one sensor configured to
detect that the number of the empty take-up tubes accommodated in the stocker portion
is equal to or less than a predetermined number, when the at least one sensor detects
that the number of the empty take-up tubes accommodated in the stocker portion is
equal to or less than the predetermined number, the control unit generating a notification
signal indicating necessity of replenishment of the empty take-up tubes to the stocker
portion.
[0010] According to the present invention, because replenishment of empty take-up tubes
to the stocker portion is performed based on the notification signal, it is possible
to grasp a timing to replenish the empty take-up tubes to each of all empty take-up
tube suppliers corresponding to the winding devices. On this account, the operator
or the like is prevented from forgetting to replenish empty take-up tubes to an empty
take-up tube, and also the occurrence of a failure in winding of a yarn by a winding
device is prevented.
[0011] In the present invention, preferably, the at least one sensor includes a first sensor
which is configured to detect that the number of the empty take-up tubes accommodated
in the stocker portion is equal to or less than a first predetermined number that
is the predetermined number and is one or more.
[0012] When the number of winding devices is large, supply of empty take-up tubes to a winding
device by the empty take-up tube supplier may not be timely performed if empty take-up
tubes are replenished to the stocker portion after the number of empty take-up tubes
accommodated in the stocker portion becomes zero. According to the present invention,
it is possible to generate the notification signal in advance before the number of
empty take-up tubes accommodated in the stocker portion becomes zero. It is therefore
possible to prevent the delay of replenishment of empty take-up tubes to the stocker
portion.
[0013] In the present invention, preferably, the at least one sensor includes a second sensor
which is configured to detect that the number of the empty take-up tubes accommodated
in the stocker portion is zero.
[0014] According to the present invention, the notification signal is generated when the
number of empty take-up tubes accommodated in the stocker portion becomes zero. Therefore,
it is possible to grasp a timing of urgent need of replenishment of empty take-up
tubes as the number of empty take-up tubes accommodated in the stocker portion becomes
zero.
[0015] In the present invention, preferably, the notification signal includes a priority
notification signal which notifies that, when the second sensor detects that the number
of the empty take-up tubes accommodated in one of stocker portions of the empty take-up
tube suppliers is 0, replenishment of empty take-up tubes to the one of the stocker
portions accommodating no empty take-up tube must be prioritized over replenishment
to the other stocker portions.
[0016] According to the present invention, because the replenishment of the empty take-up
tubes is performed based on the priority notification signal, the replenishment of
the empty take-up tubes to the stocker portion in which the number of accommodated
empty take-up tubes is zero is prioritized over the replenishment to the other stocker
portions. It is therefore possible to avoid a situation in which the supply of take-up
tubes from the empty take-up tube supplier to the winding device is not performed.
[0017] In the present invention, preferably, when the number of the empty take-up tubes
accommodated in one of the stocker portions is 0, the control unit controls the winding
device corresponding to the one of the stocker portions not to perform winding again
after the winding device completes formation of the package.
[0018] According to the present invention, when the number of empty take-up tubes accommodated
in a stocker portion becomes 0, the winding device corresponding to that stocker portion
does not resume the winding after the completion of the formation of the wound package.
It is therefore possible to avoid the occurrence of malfunction, that is, entanglement
of the yarn onto the winding device that resumed winding in the absence of a take-up
tube.
[0019] In the present invention, preferably, the at least one sensor includes two or more
sensors, and each of the two or more sensors is a sensor configured to detect that
the number of the accommodated take-up tubes is equal to or less than the predetermined
number that is different from each other.
[0020] According to the present invention, with two or more sensors, it is possible to grasp
the number of empty take-up tubes accommodated in the stocker portion, in a detailed
manner. On this account, it is easy to adjust at which timing the necessity of replenishment
of empty take-up tubes notified, in accordance with, for example, the situation.
[0021] In the present invention, preferably, the false-twist texturing machine further comprises
a notification unit which is capable of performing a notification operation of notifying
an operator of the necessity of replenishment of the empty take-up tubes to the stocker
portion, the control unit causing the notification unit to perform the notification
operation by sending the notification signal to the notification unit.
[0022] According to the present invention, when replenishment of empty take-up tubes to
the stocker portion is performed by an operator, the operator is able to grasp, by
the notification operation by the notification unit, a timing to replenish the empty
take-up tubes.
[0023] In the present invention, preferably, the false-twist texturing machine further comprises
an empty take-up tube replenishment robot which is capable of automatically performing
a replenishment operation of replenishing the empty take-up tubes to the stocker portion,
the control unit causing the empty take-up tube replenishment robot to perform the
replenishment operation by sending the notification signal to the empty take-up tube
replenishment robot.
[0024] According to the present invention, when replenishment of empty take-up tubes to
the stocker portion is automatically done by the empty take-up tube replenishment
robot, the timing of the replenishment operation can be suitably controlled.
[0025] In the present invention, preferably, the at least one sensor includes a third sensor
which is capable of detecting that the number of the empty take-up tubes accommodated
in the stocker portion is at the maximum, and when the third sensor detects that the
number of the empty take-up tubes accommodated in the stocker portion is at the maximum,
the control unit controls the empty take-up tube replenishment robot not to perform
the replenishment operation.
[0026] According to the present invention, when the replenishment of empty take-up tubes
to the stocker portion is automatically done by the empty take-up tube replenishment
robot, it is possible to prevent the replenishment operation from being performed
when the maximum number of empty take-up tubes are accommodated in the stocker portion.
It is therefore possible to prevent the empty take-up tubes from overflowing from
the stocker portion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027]
FIG. 1 is a profile of a false-twist texturing machine related to an embodiment.
FIG. 2 shows the false-twist texturing machine viewed in the direction II in FIG.
1.
FIG. 3 is a schematic diagram of a winding unit.
FIG. 4 is a schematic diagram of an empty bobbin supplier.
FIG. 5 is a block diagram illustrating the electrical structure of the false-twist
texturing machine.
FIG. 6 is a block diagram illustrating the electrical structure of a false-twist texturing
machine of a modification.
FIG. 7 is a schematic diagram of an empty bobbin supplier of a modification.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] The following will describe an embodiment of the present invention with reference
to figures.
(Overall Structure of False-Twist Texturing Machine 1)
[0029] FIG. 1 is a profile showing the overall structure of a false-twist texturing machine
1 of the present embodiment. Hereinafter, a vertical direction to the sheet of FIG.
1 is defined as a base longitudinal direction, and a left-right direction to the sheet
is defined as a base width direction. A direction orthogonal to the base longitudinal
direction and the base width direction is defined as the up-down direction (vertical
direction) in which the gravity acts. These definitions of the directions will be
suitably used hereinbelow.
[0030] The false-twist texturing machine 1 can perform false twisting of yarns Y made of,
for example, synthetic fibers such as nylon (polyamide fibers). The false-twist texturing
machine 1 includes a yarn supplying unit 2 for supplying the yarns Y, a processing
unit 3 which performs false twisting of the yarns Y supplied from the supplying unit
2, a winding unit 4 which winds the yarns Y processed by the processing unit 3 onto
winding bobbins Bw (take-up tubes of the present invention), and a control unit 40
(see FIG. 5). The yarn supplying unit 2, the processing unit 3, and the winding unit
4 include structural elements (described later), and the structural elements are provided
to form plural lines in a base longitudinal direction orthogonal to a yarn running
surface (surface orthogonal to the direction in which FIG. 1 is viewed) in which yarn
paths are provided to reach the winding unit 4 from the yarn supplying unit 2 via
the processing unit 3.
[0031] The yarn supplying unit 2 includes a creel stand 7 retaining yarn supply packages
Ps, and supplies the yarns Y to the processing unit 3. In the processing unit 3, the
following members are provided in this order from the upstream in a yarn running direction:
first feed rollers 11; a twist-stopping guide 12; a first heater 13; a cooler 14;
a false-twisting device 15; second feed rollers 16; an interlacing device 17; third
feed rollers 18; a second heater 19; and fourth feed rollers 20. The winding unit
4 winds the yarns Y for which the false winding has been performed at the processing
unit 3 onto the winding bobbins Bw by winding devices 21, and forms wound packages
Pw (packages of the present invention).
[0032] The false-twist texturing machine 1 includes a main base 8 and a winding base 9 which
are placed apart from each other in the base width direction. The main base 8 and
the winding base 9 are provided to extend in a substantially same length in the base
longitudinal direction, and placed to oppose each other. An upper part of the main
base 8 is connected to an upper part of the winding base 9 by a supporting frame 10.
Each device forming the processing unit 3 is mainly attached to the main base 8 or
the supporting frame 10. The main base 8, the winding base 9, and the supporting frame
10 form a working space 22 in which an operator performs an operation such as the
yarn threading to each device. The yarn paths are formed so that the yarns Y mainly
run around the working space 22.
[0033] The false-twist texturing machine 1 includes units which are termed spans, each
of which includes a pair of the main base 8 and the winding base 9 placed to oppose
each other. In one span, each device is placed so that the yarns Y running while being
aligned in the base longitudinal direction can be false-twisted at the same time.
For example, twelve winding devices 21 are provided for one winding base 9 (as shown
in FIG. 2). In the false-twist texturing machine 1, the spans are placed in a left-right
symmetrical manner to the sheet, with a center line C of the base width direction
of the main base 8 as a symmetry axis (main base 8 is shared between the left span
and the right span), and the spans are aligned in the base longitudinal direction.
(Processing Unit)
[0034] The following will describe each element of the processing unit 3. Each first feed
roller 11 sends the yarns Y supplied from the yarn supplying unit 2 to the first heater
13. The first feed rollers 11 are placed above the winding base 9 (as shown in FIG.
1). The first feed rollers 11 are aligned in the base longitudinal direction.
[0035] Each twist-stopping guide 12 prevents twisting which has been applied to the yarn
Y at the later-described false-twisting device 15 from being propagated to the upstream
of each twist-stopping guide 12 in the yarn running direction. The twist-stopping
guides 12 are placed downstream of the first feed rollers 11 in the yarn running direction,
and placed upstream of the first heater 13 in the yarn running direction. The twist-stopping
guides 12 are, for example, provided for the yarns Y supplied from the yarn supplying
unit 2, respectively, and aligned in the base longitudinal direction.
[0036] Each first heater 13 heats the yarns Y sent from the first feed rollers 11, and are
placed at the supporting frame 10 (as shown in FIG. 1). The first heaters 13 are provided
for the yarns Y supplied from the yarn supplying unit 2, and aligned in the base longitudinal
direction.
[0037] Each cooler 14 cools the yarns Y heated at each first heater 13. The coolers 14 are
placed downstream of each first heater 13 in the yarn running direction, and placed
upstream of the false-twisting devices 15 in the yarn running direction. The coolers
14 are provided for the yarns Y supplied by the yarn supplying unit 2, and aligned
in the base longitudinal direction.
[0038] Each false-twisting device 15 is configured to twist the yarn Y. The false-twisting
devices 15 are placed directly downstream of the coolers 14 in the yarn running direction.
The false-twisting devices 15 are aligned in the base longitudinal direction. For
example, twelve false-twisting devices 15 are provided in one span.
[0039] The second feed rollers 16 are rollers for sending the yarn Y twisted by the false-twisting
device 15 toward the interlacing device 17. The second feed rollers 16 are provided
on the downstream side in the yarn running direction of the false-twisting device
15 in the main base 8. The conveyance speed of conveying the yarn Y by the second
feed rollers 16 is higher than the conveyance speed of conveying the yarn Y by the
first feed rollers 11. The yarn Y is therefore drawn between the first feed rollers
11 and the second feed rollers 16.
[0040] The interlacing device 17 is configured to interlace the yarn Y by injecting air
thereto. The interlacing device 17 is provided below the second feed rollers 16 in
the main base 8.
[0041] The third feed rollers 18 are rollers for sending the yarn Y interlaced by the interlacing
device 17 toward the second heater 19. The third feed roller 18 are provided below
the interlacing device 17 in the main base 8. The conveyance speed of conveying the
yarn Y by the third feed rollers 18 is lower than the conveyance speed of conveying
the yarn Y by the second feed rollers 16. The yarn Y is therefore relaxed between
the second feed rollers 16 and the third feed rollers 18.
[0042] The second heater 19 is a device for heating the yarns Y supplied from the third
feed rollers 18. The second heater 19 is provided below the third feed rollers 18
in the main base 8. The second heater 19 extends along the vertical direction, and
one second heater 19 is provided in one span.
[0043] The fourth feed rollers 20 are provided to feed the yarn Y thermally treated by the
second heater 19 toward the winding device 21. The fourth feed rollers 20 are provided
at a lower part of the winding base 9. The conveyance speed of conveying the yarn
Y by the fourth feed rollers 20 is lower than the conveyance speed of conveying the
yarn Y by the third feed rollers 18. The yarn Y is therefore relaxed between the third
feed rollers 18 and the fourth feed rollers 20.
[0044] In the processing unit 3 arranged as described above, the yarn Y drawn between the
first feed rollers 11 and the second feed rollers 16 is twisted by the false-twisting
device 15. The twist formed by the false-twisting device 15 is propagated to the twist-stopping
guide 12, but is not propagated to the upstream in the yarn running direction of the
twist-stopping guide 12. The yarn Y which is twisted and drawn is heated at each first
heater 13 and thermally set. After that, the yarn Y is cooled at each cooler 14. The
yarn Y is untwisted at the downstream of the false-twisting device 15. However, each
filament is maintained to be wavy in shape on account of the thermal setting described
above. After being false-twisted by the false-twisting device 15, the yarn Y is interlaced
by the interlacing device 17 while being relaxed between the second feed rollers 16
and the third feed rollers 18, and then the yarn Y is guided to the downstream side
in the yarn running direction. Furthermore, the yarn Y is thermally set at the second
heater 19 while being relaxed between the third feed roller 18 and the fourth feed
roller 20. Finally, the yarn Y sent from each fourth feed roller 20 is wound by each
winding device 21, and form each wound package Pw.
(Structure of Winding Unit 4)
[0045] The structure of the winding unit 4 will be described with reference to FIG. 2 and
FIG. 3. As shown in FIG. 3, the winding unit 4 includes winding devices 21 configured
to form wound packages Pw by winding the yarns Y onto winding bobbins Bw, empty bobbin
suppliers 23 (empty take-up tube suppliers of the present invention), and storage
units 24. The empty bobbin suppliers 23 and the storage units 24 are provided for
the respective winding devices 21. Each winding device 21 includes a single cradle
31 that rotatably supports the winding bobbin Bw. The winding bobbin Bw which is supported
by the cradle 31 is rotationally driven by, for example, an unillustrated motor. By
rotationally driving the winding bobbin Bw, the winding device 21 winds the yarn Y
onto the winding bobbin Bw and forms the wound package Pw.
[0046] The empty bobbin supplier 23 is a device for supplying, to the winding device 21,
an empty winding bobbin Bw on which no yarn Y is wound. The empty winding bobbin Bw
(hereinafter, empty bobbin Bw) is equivalent to an empty take-up tube of the present
invention. The empty bobbin supplier 23 will be detailed later.
[0047] The storage unit 24 is configured to store a fully-wound package Pw formed by the
winding device 21. When the formation of the wound package Pw is completed, the winding
bobbin Bw supported by the cradle 31 is detached from the winding device 21 as the
cradle 31 rotates about the rotational axis extending in the base longitudinal direction,
and the wound package Pw is then supplied to the storage unit 24. For example, the
storage unit 24 is able to store three wound packages Pw at the maximum. When, for
example, yarn breakage occurs while the winding device 21 is winding the yarn Y, the
wound package Pw may be supplied to the storage unit 24 even though the formation
of the package has not been completed.
(Structure of Empty Bobbin Supplier 23)
[0048] Now, the structure of the empty bobbin supplier 23 will be described with reference
to FIG. 4. The empty bobbin supplier 23 is a device configured to supply an empty
bobbin Bw to the winding device 21 after a wound package Pw is detached from the winding
device 21 and supplied to the storage unit 24. Each empty bobbin supplier 23 includes
a stocker portion 51 capable of accommodating four empty bobbins Bw, a first sensor
52, a second sensor 53, and a leading end portion 54.
[0049] The stocker portion 51 has a supporting member 51a and side walls 51b. The supporting
member 51a supports empty bobbins Bw from below and is inclined downward toward the
side in the base width direction on which the winding device 21 is provided. The length
in the base longitudinal direction of the supporting member 51a is arranged to be
slightly longer than the length along the axial center of the empty bobbin Bw. The
side walls 51b extend upward from one end portion and the other end portion in the
base longitudinal direction of the supporting member 51a, respectively. Although FIG.
4 shows only the side wall 51b that is, for a viewer of the figure, on the far side
of the empty bobbins Bw supported by the supporting member 51a, actually the other
side wall 51b is provided on the near side of the empty bobbins Bw. In the present
embodiment, the stocker portion 51 is able to accommodate four empty bobbins Bw at
the maximum. In the present embodiment, replenishment of empty bobbins Bw to the stocker
portion 51 is manually done by an operator. Each empty bobbin Bw replenished to the
stocker portion 51 by the operator moves toward the side in the base width direction
on which the winding device 21 is provided, along the supporting member 51a that is
inclined downward. The first empty bobbin Bw to be accommodated in the stocker portion
51 moves along the inclination of the supporting member 51a and is then accommodated
at an end portion of the stocker portion 51, which is on the side in the base width
direction on which the winding device 21 is provided. After the first empty bobbin
Bw is accommodated in the stocker portion 51, the subsequent second to fourth empty
bobbins Bw move along the inclination of the stocker portion 51, with the result that
the second, third, and fourth empty bobbins Bw are positioned next to the first empty
bobbin Bw, in this order. Hereinafter, the empty bobbin Bw that is closest to the
winding device 21 will be referred to as a first empty bobbin Bw, the empty bobbin
Bw that is second closest to the winding device 21 will be referred to as a second
empty bobbin Bw, the empty bobbin Bw that is third closest to the winding device 21
will be referred to as a third empty bobbin Bw, and the empty bobbin Bw that is fourth
closest to the winding device 21 will be referred to as a fourth empty bobbin Bw.
[0050] The first sensor 52 is a microswitch having a detection piece 52a which slightly
protrudes upward from the bottom surface of the supporting member 51a. The second
sensor 53 is a microswitch having a detection piece 53a which slightly protrudes upward
from the bottom surface of the supporting member 51a. The first sensor 52 is in an
ON state when the empty bobbin Bw is in contact with the detection piece 52a, and
is in an OFF state when the empty bobbin Bw is not in contact with the detection piece
52a. The second sensor 53 is in an ON state when the empty bobbin Bw is in contact
with the detection piece 53a, and is in an OFF state when the empty bobbin Bw is not
in contact with the detection piece 53a. The first sensor 52 and the second sensor
53 may not be microswitches, and may be infrared light sensors configured to detect
empty bobbins Bw by applying infrared light thereto.
[0051] The detection piece 52a of the first sensor 52 is positioned to be in contact with
the third empty bobbin Bw. On this account, when the first sensor 52 is in the ON
state, the number of empty bobbins Bw accommodated in the stocker portion 51 is three
or more. Meanwhile, when the first sensor 52 is in the OFF state, the number of accommodated
empty bobbins Bw is two or less. As such, the first sensor 52 of the present embodiment
is able to detect that the number of empty bobbins Bw accommodated in the stocker
portion 51 is two or less, and is equivalent to a first sensor of the present invention.
[0052] The detection piece 53a of the second sensor 53 is positioned to be in contact with
the second empty bobbin Bw. On this account, when the second sensor 53 is in the ON
state, the number of empty bobbins Bw accommodated in the stocker portion 51 is two
or more. Meanwhile, when the second sensor 53 is in the OFF state, the number of accommodated
empty bobbins Bw is one or less. The second sensor 53 of this case is able to detect
that the number of empty bobbins Bw accommodated in the stocker portion 51 is one
that is a predetermined number or less, and can be regarded as a first sensor of the
present invention.
[0053] In addition to the above, based on the timing to switch on and off the second sensor
53, the control unit 40 is able to determine whether the number of empty bobbins Bw
accommodated in the stocker portion 51 is one or 0. The following will describe how
the control unit 40 determines the number of accommodated empty bobbins Bw based on
the detection by the second sensor 53.
[0054] The empty bobbins Bw are supplied from the empty bobbin supplier 23 to the winding
device 21 one by one. Once the empty bobbin Bw is supplied from the empty bobbin supplier
23 to the winding device 21, the next supply of the empty bobbin Bw is not performed
until the formation of the wound package Pw is completed and the wound package Pw
is detached from the winding device 21. For example, the control unit 40 measures
in advance, as a predetermined time, a period of time from the supply of the empty
bobbin Bw from the empty bobbin supplier 23 to the winding device 21 to the supply
of the next empty bobbin Bw to the winding device 21 after the completion of the formation
of the wound package Pw and the detachment of the wound package Pw from the winding
device 21. The predetermined time may not be measured by the control unit 40, and
may be input by an operator in advance.
[0055] When the second sensor 53 is in the OFF state and was switched off during the immediately
preceding predetermined time, the control unit 40 determines that the number of empty
bobbins Bw accommodated in the stocker portion 51 became one from two during the immediately
preceding predetermined time. The control unit 40 is therefore able to determine that
the number of empty bobbins Bw accommodated in the stocker portion 51 is one.
[0056] Meanwhile, when the second sensor 53 has been in the OFF state for at least the predetermined
time, the control unit 40 determines that, after the number of empty bobbins Bw accommodated
in the stocker portion 51 became one from two, the empty bobbin Bw was further supplied
to the winding device 21 and the number of accommodated bobbins Bw became 0. The control
unit 40 is therefore able to determine that the number of empty bobbins Bw accommodated
in the stocker portion 51 is 0. As such, the second sensor 53 of the present embodiment
is able to detect that the number of empty bobbins Bw accommodated in the stocker
portion 51 is 0, and is equivalent to a second sensor of the present invention.
[0057] In the present embodiment, when the first sensor 52 does not detect the empty bobbin
Bw whereas the second sensor 53 detects the empty bobbin Bw, it is determined that
the number of empty bobbins Bw accommodated in the stocker portion 51 is two.
[0058] The leading end portion 54 is provided at a leading end of the stocker portion 51,
which is on the side in the base width direction on which the winding device 21 is
provided. An empty bobbin Bw moving along the supporting member 51a which is inclined
downward makes contact with the leading end portion 54. In this way, supply of the
bobbin to the winding device 21 from the leading end of the stocker portion 51 on
the side on which the winding device 21 is provided is prohibited.
[0059] The following will describe how an empty bobbin Bw is supplied from the empty bobbin
supplier 23 to the winding device 21. While the yarn Y is being wound by the winding
device 21, the empty bobbin supplier 23 is at a standby position where the leading
end portion 54 is able to prohibit the movement of the empty bobbin Bw (see FIG. 3).
When the wound package Pw formed by the winding device 21 is detached from the winding
device 21 by the rotation of the cradle 31, the empty bobbin supplier 23 moves to
a supply position where an empty bobbin Bw can be supplied to the winding device 21.
To be more specific, the empty bobbin supplier 23 moves to the supply position where
the cradle 31 is provided, by rotating about a rotational axis (not illustrated) that
is below the stocker portion 51 and extends along the base longitudinal direction.
As the empty bobbin supplier 23 moves to the supply position, the prohibition of the
movement of the empty bobbin Bw by the leading end portion 54 is canceled, and hence
the empty bobbin Bw passes through the leading end of the stocker portion 51 on the
side on which the winding device 21 is provided, and reaches the cradle 31. The empty
bobbin Bw is then supported by the cradle 31. This is the end of the supply of the
empty bobbin Bw from the empty bobbin supplier 23 to the winding device 21. The empty
bobbin supplier 23 is rotationally driven by an unillustrated motor.
[0060] The false-twist texturing machine 1 of the present embodiment includes a notification
unit 61 which is capable of performing a notification operation of notifying an operator
of the necessity of the replenishment of empty bobbins Bw to the stocker portion 51
(see FIG. 5). The notification unit 61 is, for example, a display electrically connected
to each empty bobbin supplier 23. The notification unit 61 performs the notification
operation by displaying, on the display, a message that empty bobbins Bw need to be
replenished to the stocker portion 51. A timing at which the notification unit 61
performs the notification operation will be described later.
(Electric Structure)
[0061] FIG. 5 is a block diagram illustrating an electric structure of the false-twist texturing
machine 1. The control unit 40 controls the elements that are the yarn supplying unit
2, the processing unit 3, and the winding unit 4. For the sake of space, FIG. 5 shows
that the control unit 40 is connected to one winding device 21 and one empty bobbin
supplier 23 among the winding devices 21 and the empty bobbin suppliers 23. In reality,
the control unit 40 is connected to the other winding devices 21 and the other empty
bobbin suppliers 23, too. The control unit 40 may be provided for each of the winding
devices 21 and each of the empty bobbin suppliers 23.
[0062] The control unit 40 is electrically connected to the first sensor 52, the second
sensor 53, and the notification unit 61. Information indicating whether the first
sensor 52 and the second sensor 53 of the empty bobbin supplier 23 are in the ON state
or the OFF state, i.e., information indicating whether the first sensor 52 and the
second sensor 53 detect empty bobbins Bw, is supplied to the control unit 40. Based
on the information supplied from the first sensor 52 and the second sensor 53, the
control unit 40 causes the notification unit 61 to perform the notification operation
at a timing set in advance.
(Notification Operation)
[0063] The following will describe the timing at which the control unit 40 causes the notification
unit 61 to perform the notification operation.
[0064] When the first sensor 52 detects that the number of empty bobbins Bw accommodated
in the stocker portion 51 is two or less, the control unit 40 generates a notification
signal by which the necessity of replenishment of empty bobbins Bw to the stocker
portion 51 is notified. The control unit 40 then causes the notification unit 61 to
perform the notification operation by sending the notification signal to the notification
unit 61.
[0065] When the second sensor 53 detects that the number of empty bobbins Bw accommodated
in the stocker portion 51 is one or less, the control unit 40 generates another notification
signal. The control unit 40 then causes the notification unit 61 to perform the notification
operation again by sending the notification signal to the notification unit 61. In
this case, the control unit 40 may differentiate the notification operation performed
by the notification unit 61 when the number of empty bobbins Bw accommodated in the
stocker portion 51 is two or less from the notification operation performed by the
notification unit 61 when the number of accommodated empty bobbins Bw is one or less.
To be more specific, the control unit 40 changes the content of display by the notification
unit 61 that is a display, in accordance with the number of empty bobbins Bw accommodated
in the stocker portion 51.
[0066] When the second sensor 53 detects that the number of empty bobbins Bw accommodated
in the stocker portion 51 is 0, the control unit 40 generates a priority notification
signal. The priority notification signal is a notification signal for performing notification
in such a way that, when it is detected that the number of empty bobbins Bw accommodated
in one of the stocker portions 51 of the empty bobbin suppliers 23 is 0, replenishment
of empty bobbins Bw to that stocker portion 51 accommodating no empty bobbin Bw must
be prioritized over the replenishment to the other stocker portions 51. The control
unit 40 then causes the notification unit 61 to perform the notification operation
by sending the priority notification signal to the notification unit 61.
[0067] The control unit 40 controls the notification operations performed by the notification
unit 61 such that the notification operation performed by the notification unit 61
when the priority notification signal is sent is discerned from the notification operation
performed by the notification unit 61 when a normal notification signal which is not
the priority notification signal is sent. For example, the control unit 40 differentiates
the content of display on the notification unit 61 that is a display, between the
case where the priority notification signal is sent and the case where the normal
notification signal is sent.
[0068] As described above, when the first sensor 52 does not detect the empty bobbin Bw
whereas the second sensor 53 detects the empty bobbin Bw, it is detected that the
number of empty bobbins Bw accommodated in the stocker portion 51 is two. In addition
to the notification operation, the control unit 40 may control the notification unit
61 so that information indicating that the number of empty bobbins Bw accommodated
in the stocker portion 51 is two is displayed on the display. When the first sensor
52 detects that the number of empty bobbins Bw accommodated in the stocker portion
operating is three or more, the control unit 40 may control the notification unit
61 so that information indicating that the number of empty bobbins Bw accommodated
in the stocker portion 51 is three or more is displayed on the display, in addition
to the notification operation.
[0069] When the second sensor 53 detects that the number of empty bobbins Bw accommodated
in the stocker portion 51 is 0, the control unit 40 controls the winding device 21
corresponding to that stocker portion 51 not to perform winding again after the completion
of the formation of the wound package Pw.
(Effects)
[0070] In the false-twist texturing machine 1 of the present embodiment, when the first
sensor 52 and the second sensor 53 detect that the number of empty bobbins Bw accommodated
in the stocker portion 51 is equal to or less than a predetermined number, the control
unit 40 generates a notification signal by which the necessity of the replenishment
of empty bobbins Bw to the stocker portion 51 is notified. In the present embodiment,
the predetermined number is two, one, or zero. By sending the notification signal
to the notification unit 61, the control unit 40 causes the notification unit 61 to
perform the notification operation of notifying an operator of the necessity of the
replenishment of empty bobbins Bw to the stocker portion 51. With this arrangement,
when replenishment of empty bobbins Bw to the stocker portion 51 is performed by an
operator, the operator is able to grasp, by the notification operation by the notification
unit 61, a timing to replenish the empty bobbins Bw to each of all empty bobbin suppliers
23 corresponding to the winding devices 21. On this account, the operator or the like
is prevented from forgetting to replenish empty bobbins Bw to the stocker portion
51 of the empty bobbin supplier 23n and also the occurrence of a failure in winding
of a yarn Y by the winding device 21is prevented.
[0071] In the present embodiment, the empty bobbin supplier 23 includes the first sensor
52 configured to detect that the number of empty bobbins Bw accommodated in the stocker
portion 51 is two or less and the second sensor 53 configured to detect that the number
of accommodated empty bobbins Bw is one or less. With this arrangement, the control
unit 40 is able to generate the notification signal in advance before the number of
empty bobbins Bw accommodated in the stocker portion 51 becomes 0. It is therefore
possible to prevent the delay of replenishment of empty bobbins Bw to the stocker
portion 51.
[0072] In the present embodiment, the empty bobbin supplier 23 includes the second sensor
53 configured to detect that the number of empty bobbins Bw accommodated in the stocker
portion 51 is 0. This makes it possible to generate the notification signal when the
number of empty bobbins Bw accommodated in the stocker portion 51 becomes 0. On this
account, it is possible to grasp a timing of urgent need of replenishment of empty
bobbins Bw as the number of empty bobbins Bw accommodated in the stocker portion 51
becomes 0.
[0073] In the present embodiment, when it is detected that the number of empty bobbins Bw
accommodated in one of the stocker portions 51 is 0, the control unit 40 generates
the priority notification signal for the stocker portion 51 in which the number of
accommodated empty bobbins Bw is 0. With this arrangement, because the replenishment
of the empty bobbins Bw is performed based on the priority notification signal, the
replenishment of the empty bobbins Bw to the stocker portion 51 in which the number
of accommodated empty bobbins Bw is 0 is prioritized over the replenishment to the
other stocker portions 51. It is therefore possible to avoid a situation in which
the supply of empty bobbins Bw from the empty bobbin supplier 23 to the winding device
21 is not performed.
[0074] In the present embodiment, when the number of empty bobbins Bw accommodated in the
stocker portion 51 is 0, the control unit 40 controls the winding device 21 corresponding
to that stocker portion 51 not to perform winding again after the completion of the
formation of the wound package Pw. With this arrangement, when the number of empty
bobbins Bw accommodated in a stocker portion 51 becomes 0, the winding device 21 corresponding
to that stocker portion 51 does not resume the winding after the completion of the
formation of the wound package Pw. It is therefore possible to avoid the occurrence
of malfunction that is entanglement of the yarn Y onto the winding device 21 that
resumed winding in the absence of the winding bobbin Bw.
[0075] In the present embodiment, there are two sensors (the first sensor 52 and the second
sensor) which correspond to different predetermined numbers, respectively, and which
detect that the number of empty bobbins Bw accommodated in the stocker portion 51
is equal to or less than those predetermined numbers, respectively. With these two
sensors, it is possible to grasp the number of empty bobbins Bw accommodated in the
stocker portion 51, in a detailed manner. On this account, it is easy to adjust at
which timing the necessity of replenishment of empty bobbins Bw is notified, in accordance
with, for example, the situation.
(Modifications)
[0076] The following will describe modifications of the above-described embodiment. The
members identical with those in the embodiment above will be denoted by the same reference
numerals, and the explanations thereof are not repeated.
[0077] In the embodiment above, the control unit 40 causes the notification unit 61 to perform
the notification operation by sending the notification signal to the notification
unit 61. Alternatively, the control unit 40 may send the notification signal to a
device different from the notification unit 61. For example, in a false-twist texturing
machine 101, a control unit 140 sends a notification signal to an empty bobbin replenishment
robot 161 (equivalent to an empty take-up tube replenishment robot of the present
invention) (see FIG. 6). The empty bobbin replenishment robot 161 is a device capable
of automatically performing a replenishment operation of replenishing empty bobbins
Bw to a stocker portion 51. For example, the empty bobbin replenishment robot 161
is able to perform reciprocal movement along the base longitudinal direction, and
is able to automatically replenish empty bobbins Bw to each stocker portion 51 by
moving members such as a robotic arm and a conveyor. The control unit 140 causes the
empty bobbin replenishment robot 161 to perform the replenishment operation of replenishing
empty bobbins Bw by sending a notification signal thereto. With this arrangement,
when replenishment of empty bobbins Bw to the stocker portion 51 is automatically
done by the empty bobbin replenishment robot 161, the timing of the replenishment
operation can be suitably controlled.
[0078] In addition to the above, in the false-twist texturing machine 101 having the empty
bobbin replenishment robot 161, a empty bobbin supplier 123 may include a third sensor
154 which is configured to detect that the number of empty bobbins Bw accommodated
in the stocker portion 51 is at the maximum (see FIG. 7). A detection piece 154a of
the third sensor 154 is positioned to be in contact with the fourth empty bobbin Bw.
When the third sensor 154 is in the ON state, the number of empty bobbins Bw accommodated
in the stocker portion 51 is four. Meanwhile, when the third sensor 154 is in the
OFF state, the number of accommodated empty bobbins Bw is three or less. The third
sensor 154 in this case is able to detect that the number of empty bobbins Bw accommodated
in the stocker portion 51 is three that is a predetermined number or less, and can
be regarded as the first sensor of the present invention. Furthermore, the third sensor
154 is able to detect that the number of accommodated empty bobbins Bw is the maximum
four, and is equivalent to a third sensor of the present invention.
[0079] The control unit 140 controls the empty bobbin replenishment robot 161 not to perform
the replenishment operation when the third sensor 154 detects that the stocker portion
51 stores the maximum number of empty bobbins Bw. With this arrangement, when the
replenishment of empty bobbins Bw to the stocker portion 51 is automatically done
by the empty bobbin replenishment robot 161, it is possible to prevent the replenishment
operation from being performed when the maximum number of empty bobbins Bw are accommodated
in the stocker portion 51. It is therefore possible to prevent the empty bobbins Bw
from overflowing from the stocker portion 51.
[0080] When causing the empty bobbin replenishment robot 161 to perform the replenishment
operation, the control unit 140 may continue the replenishment operation until the
third sensor 154 detects that the maximum number of empty bobbins Bw are accommodated.
With this arrangement, when the replenishment of empty bobbins Bw to the stocker portion
51 is automatically done by the empty bobbin replenishment robot 161, it is possible
to replenish the maximum number of empty bobbins Bw by a single replenishment operation.
[0081] In the embodiment above, the third sensor 154 may be provided. In this case, when
the third sensor 154 detects that the stocker portion 51 stores the maximum number
of empty bobbins Bw, the control unit 40 may cause the notification unit 61 to give
a notification indicating that replenishment of empty bobbin Bw to the stocker portion
cannot be done.
[0082] In the embodiment above, the second sensor 53 may be positioned to be able to detect
the first empty bobbin Bw when one or more empty bobbin Bw is accommodated in the
stocker portion 51. In this case, the second sensor 53 is a sensor detecting that
the number of empty bobbins Bw accommodated in the stocker portion 51 is one or more,
or is 0. In other words, in this case, the second sensor 53 is equivalent to the second
sensor of the present invention.
[0083] In the present invention, the empty bobbin supplier 23 may have four sensors. In
this case, the four sensors are provided at four positions where the first, second,
third, and fourth empty bobbins Bw are detectable when four empty bobbins Bw are accommodated
in the stocker portion 51, respectively. Alternatively, the empty bobbin supplier
23 may have only one sensor.
[0084] In the embodiment above, the control unit 40 may generate a notification signal
only when the first sensor 52 detects that the number of empty bobbins Bw accommodated
in the stocker portion 51 is two or less. The control unit 40 may generate a notification
signal only when the second sensor 53 detects that the number of empty bobbins Bw
accommodated in the stocker portion 51 is one or less. Moreover, the control unit
40 may generate a notification signal only when the second sensor 53 detects that
the number of empty bobbins Bw accommodated in the stocker portion 51 is 0. In any
case, the control unit 40 generates a notification signal and causes the notification
unit 61 to perform the notification operation when one of or both of the first sensor
52 and the second sensor 53 detect that the number of empty bobbins Bw accommodated
in the stocker portion 51 is equal to or less than a predetermined number. A timing
at which the control unit 40 generates a notification signal is set in advance at
a timing at which the replenishment of empty bobbins Bw is most unlikely to be forgotten,
in accordance with the number of empty bobbin suppliers 23 per false-twist texturing
machine 1, a current situation such as the number of operators in charge of replenishment
of empty bobbins Bw, etc.
[0085] In the embodiment above, when the second sensor 53 detects that the number of empty
bobbins Bw accommodated in the stocker portion 51 is 0, the control unit 40 generates
a priority notification signal. Alternatively, when the second sensor 53 detects that
the number of empty bobbins Bw accommodated in the stocker portion 51 is 0, the control
unit 40 may generate a normal notification signal that is not the priority notification
signal.
[0086] In the present embodiment, the stocker portion 51 is able to accommodate four empty
bobbins Bw. In this regard, the stocker portion 51 may be able to accommodate two
or three empty bobbins Bw, or may be able to accommodate 5 or more empty bobbins Bw.
The sensors may be provided in accordance with the number of empty bobbins Bw accommodatable
in the stocker portion 51. For example, when the stocker portion 51 is able to accommodate
n (n=two or more) empty bobbins Bw, n sensors may be provided. In this case, the n
sensors are provided at n positions where the first to n-th empty bobbins Bw are detectable
when n empty bobbins Bw are accommodated in the stocker portion 51, respectively.
Alternatively, when the stocker portion 51 is able to accommodate n empty bobbins
Bw, the number of provided sensors may be any number from one to n-1.
[0087] In the embodiment above, the notification unit 61 is a display electrically connected
to each empty bobbin supplier 23. Alternatively, the notification unit 61 may be a
lamp attached to each empty bobbin supplier 23, for example. In this case, the control
unit 40 turns on the lamp of the notification unit 61 corresponding to the stocker
portion 51 in which the number of accommodated empty bobbins Bw becomes equal to or
less than a predetermined number, by sending a notification signal to the notification
unit 61. An operator is able to understand that replenishment of empty bobbins Bw
is necessary at the stocker portion 51 of the empty bobbin supplier 23 corresponding
to the lamp having been turned on. The control unit 40 may differentiate the color
of the lamp turned on by the notification unit 61 between a case where a priority
notification signal is sent to the notification unit 61 and a case where a normal
notification signal that is not the priority notification signal is sent to the notification
unit 61. This makes it possible to discern whether the notification operation by the
notification unit 61 is performed in response to the priority notification signal
or in response to the normal notification signal that is not the priority notification
signal.
[0088] The notification unit 61 may be a device outputting sound, for example. In this case,
the notification unit 61 may be attached to each empty bobbin supplier 23, or may
be a single notification unit 61 shared between plural empty bobbin suppliers 23.
When the notification unit 61 is attached to each empty bobbin supplier 23, the control
unit 40 causes the notification unit 61 corresponding to the stocker portion 51 in
which the number of accommodated empty bobbins Bw becomes equal to or less than a
predetermined number to generate sound, by sending a notification signal to the notification
unit 61. When the notification unit 61 is a single notification unit 61 shared between
plural empty bobbin suppliers 23, the control unit 40 causes the notification unit
61 to generate sound notifying the stocker portion 51 in which the number of empty
bobbins Bw accommodated becomes equal to or less than a predetermined number, by sending
a notification signal to the notification unit 61. The control unit 40 may differentiate
the sound pattern generated by the notification unit 61 between a case where a priority
notification signal is sent to the notification unit 61 and a case where a normal
notification signal that is not the priority notification signal is sent to the notification
unit 61. This makes it possible to discern whether the notification operation by the
notification unit 61 is performed in response to the priority notification signal
or in response to the normal notification signal that is not the priority notification
signal.
1. A false-twist texturing machine (1, 101) comprising:
winding devices (21) each of which is configured to form a package (Pw) by winding
a yarn (Y) onto a take-up tube (Bw);
empty take-up tube suppliers (23, 123) which are provided for the respective winding
devices (21) and each of which supplies an empty take-up tube (Bw) to each of the
winding devices (21); and
a control unit (40, 140),
each of the empty take-up tube suppliers (23, 123) includes a stocker portion (51)
capable of accommodating empty take-up tubes (Bw) and at least one sensor (52, 53,
154) configured to detect that the number of the empty take-up tubes (Bw) accommodated
in the stocker portion (51) is equal to or less than a predetermined number,
when the at least one sensor (52, 53, 154) detects that the number of the empty take-up
tubes (Bw) accommodated in the stocker portion (51) is equal to or less than the predetermined
number, the control unit (40, 140) generating a notification signal indicating necessity
of replenishment of the empty take-up tubes (Bw) to the stocker portion (51).
2. The false-twist texturing machine (1, 101) according to claim 1, wherein, the at least
one sensor (52, 53, 154) includes a first sensor (52, 53, 154) which is configured
to detect that the number of the empty take-up tubes (Bw) accommodated in the stocker
portion (51) is equal to or less than a first predetermined number that is the predetermined
number and is one or more.
3. The false-twist texturing machine (1, 101) according to claim 1 or 2, wherein, the
at least one sensor (52, 53, 154) includes a second sensor (53) which is configured
to detect that the number of the empty take-up tubes (Bw) accommodated in the stocker
portion (51) is 0.
4. The false-twist texturing machine (1, 101) according to claim 3, wherein, the notification
signal includes a priority notification signal which notifies that, when the second
sensor (53) detects that the number of the empty take-up tubes (Bw) accommodated in
one of stocker portions (51) of the empty take-up tube suppliers (23, 123) is 0, replenishment
of empty take-up tubes (Bw) to the one of the stocker portions (51) accommodating
no empty take-up tube (Bw) must be prioritized over replenishment to the other stocker
portions (51).
5. The false-twist texturing machine (1, 101) according to claim 3 or 4, wherein, when
the number of the empty take-up tubes (Bw) accommodated in one of the stocker portions
(51) is 0, the control unit (40, 140) controls the winding device (21) corresponding
to the one of the stocker portions (51) not to perform winding again after the winding
device (21) completes formation of the package (Pw).
6. The false-twist texturing machine (1, 101) according to any one of claims 1 to 5,
wherein,
the at least one sensor (52, 53, 154) includes two or more sensors (52, 53, 154),
and
each of the two or more sensors (52, 53, 154) is a sensor (52, 53, 154) configured
to detect that the number of the accommodated take-up tubes (Bw) is equal to or less
than the predetermined number that is different from each other.
7. The false-twist texturing machine (1, 101) according to any one of claims 1 to 6,
further comprising
a notification unit (61) which is capable of performing a notification operation of
notifying an operator of the necessity of replenishment of the empty take-up tubes
(Bw) to the stocker portion (51),
the control unit (40, 140) causing the notification unit (61) to perform the notification
operation by sending the notification signal to the notification unit (61).
8. The false-twist texturing machine (1, 101) according to any one of claims 1 to 6,
further comprising
an empty take-up tube replenishment robot (161) which is capable of automatically
performing a replenishment operation of replenishing the empty take-up tubes (Bw)
to the stocker portion (51),
the control unit (40, 140) causing the empty take-up tube replenishment robot (161)
to perform the replenishment operation by sending the notification signal to the empty
take-up tube replenishment robot (161).
9. The false-twist texturing machine (1, 101) according to claim 8, wherein,
the at least one sensor (52, 53, 154) includes a third sensor (154) which is capable
of detecting that the number of the empty take-up tubes (Bw) accommodated in the stocker
portion (51) is at the maximum, and
when the third sensor (154) detects that the number of the empty take-up tubes (Bw)
accommodated in the stocker portion (51) is at the maximum, the control unit (40,
140) controls the empty take-up tube replenishment robot (161) not to perform the
replenishment operation.