Field of the Invention
[0001] The present invention relates to a technique for a method and device for unwinding
a yarn from a package, in which a friction roller is contacted with a peripheral surface
of the package to rotate the package, while unwinding the yarn from the package so
that the yarn is unwound in the radial direction of the package.
Background of the Invention
[0002] A yarn unwinding device based on a friction roller system is conventionally known
which is configured so as to unwind a yarn from a package by contacting a friction
roller with a peripheral surface of the package. An example of such an unwinding device
is an elastic yarn supply device 10 disclosed in the Unexamined Japanese Patent Application
Publication (Tokkai) No. 2002-363834 (the reference numeral corresponds to the Unexamined
Japanese Patent Application Publication (Tokkai) No. 2002-363834). As described in
the paragraph 0017 of the Unexamined Japanese Patent Application Publication (Tokkai)
No. 2002-363834), the elastic yarn supply device 10 is provided with a rotating roller
21 that drives a package 20 for an elastic yarn 11. The elastic yarn package 20 contacts
with the rotating roller 21 so as to be subjected to its rotation.
[0003] In a manufacturing stage of the elastic yarn package, "higher yarn layer portions"
may be formed at the opposite ends of the elastic yarn package, and the surface of
yarn layers in the package may be formed to be convex at the opposite ends so as to
project from the surface of the remaining yarn layer part. This occurs when, during
an operation of winding a yarn by traversing the yarn in the axial direction of the
package, a relatively long time is required to guide the yarn around a turning pint,
that is, the time for which yarn is stalled increases at the ends of the package.
[0004] When the friction roller is contacted with the surface of yarn layers in a package
with higher yarn layer portions to rotate the package, the contact pressure acting
on the higher yarn layer portions may collapse the yarn layers constituting the higher
yarn layer portions. This may disturb the vertical arrangement of the overlapping
yarn layers in the traversed yarn to be unwound, thus collapsing the yarn layer, or
may cause latching in which the vertical relationship among the yarn layers in the
yarn to be unwound is reversed. In portions in which the collapse of the package or
latching occurs, the yarn is likely to be broken when the yarn is unwound.
[0005] It is an object of the present invention to provide a method and device for unwinding
a yarn in which a yarn can be successfully unwound from a package with high yarn layer
portions without breaking the yarn.
Summary of the Invention
[0006] A description has been given of the problem to be solved by the present invention.
A description will be given below of means for solving the problem.
[0007] According to Claim 1, the present invention provides a method for unwinding a yarn
from a package, in which a friction roller is contacted with a peripheral surface
of the package to rotate the package, while unwinding the yarn from the package so
that the yarn is unwound in the radial direction of the package, the method being
characterized in that the package is rotated to unwind the yarn in such a way that
opposite ends of the package float from an outer peripheral surface of the friction
roller.
[0008] According to Claim 2, the package is an elastic yarn package into which an elastic
yarn has been wound, and the friction roller drivingly contacts with a central part
of the outer peripheral surface of the package to rotate the package, the central
part being located away from opposite end surfaces of the package by a predetermined
distance within which the package is expected to collapse.
[0009] According to Claim 3, the predetermined distance is larger than the distance of higher
yarn layer portions formed at the opposite ends of the package.
[0010] According to Claim 4, the present invention provides a device for unwinding a yarn
from a package, the device comprising a friction roller that contacts with a peripheral
surface of the package to rotate the package and yarn guiding means for guiding a
yarn unwound and drawn out from the package in the radial direction of the package
as a result of rotation of the friction roller, the device being characterized in
that a convex portion is provided on an axial part of the friction roller so that
the friction roller contacts with only a central part of the package which is located
inside opposite axial ends of the package and which has a substantially fixed outer
diameter, the convex portion of the friction roller having a larger diameter than
other parts of the friction roller and contacting with the central part of the package.
[0011] According to Claim 5, the friction roller comprises a cylinder, and an annular member
which is separate from the cylinder and which is placed radially outside the cylinder,
and the annular member is the convex portion of the friction roller.
[0012] According to Claim 6, the present invention provides a device for unwinding a yarn
from a package, the device comprising a friction roller that contacts with a peripheral
surface of the package to rotate the package and yarn guiding means for guiding a
yarn unwound and drawn out from the package in the radial direction of the package
as a result of rotation of the friction roller, the device being characterized in
that the friction roller is formed so as to be as long as or shorter than an axially
central part of the package in an axial direction so that the friction roller contacts
with only the central part of the package which is located inside opposite axial ends
of the package and which has a substantially fixed outer diameter.
[0013] The present invention produces the effects described below.
[0014] According to Claim 1, inappropriate unwinding is prevented even when a yarn is unwound
while applying unwinding tension.
[0015] According to Claim 2, inappropriate unwinding is prevented even when an elastic yarn
is unwound while applying unwinding tension.
[0016] According to Claim 3, inappropriate unwinding is prevented even when a yarn is unwound
from a package with higher yarn layer portions while applying unwinding tension to
the package.
[0017] According to Claim 4, inappropriate unwinding is prevented even when a yarn is unwound
while applying unwinding tension.
[0018] According to Claim 5, an appropriate friction roller can be easily manufactured to
the shape of a package (the axial length of the package or the diameter of higher
yarn layer portions) from which a yarn is to be unwound.
[0019] According to Claim 6, inappropriate unwinding is prevented even when a yarn is unwound
while applying unwinding tension.
Brief Description of the Drawings
[0020]
Figure 1 is a side view showing an unwinding device in accordance with a first embodiment.
Figure 2 is a front view showing the unwinding device in accordance with the first
embodiment.
Figure 3 is a front view showing an unwinding device in accordance with a second embodiment.
Figure 4 is a front view showing an unwinding device in accordance with a third embodiment.
Figure 5 is a perspective view showing a core yarn manufacturing unit to which the
unwinding device in accordance with the first embodiment is applied.
Detailed Description of the Preferred Embodiments
[0021] A description will be given of three embodiments of an unwinding device for a package
with higher yarn layer portions in accordance with the present invention. The unwinding
device in accordance with the present invention is based on the friction roller system.
A friction roller is contacted with a peripheral surface of a package to rotate the
package, thus unwinding and drawing out the yarn from the package. The package from
which the yarn is to be unwound is a common package with higher yarn layer portions
(the diameter of the package is larger at its axial ends). In the embodiments described
below, the friction roller provided in the unwinding device has different configurations.
[0022] With reference to Figures 1 and 2, a description will be given of an unwinding device
100 that is a first embodiment.
[0023] As shown in Figure 1, the unwinding device 100 comprises a cradle arm 2 that holds
a package 1 and a friction roller 3 contacted with a peripheral surface of the package
1. The unwinding device 100 may also comprise a yarn guide roller 4 that guide an
elastic yarn 5 unwound from the package 1 (in present embodiment, the yarn guide roller
4 is provided.).
[0024] A main frame (not shown in the drawings) of the unwinding device 100 rotatably supports
a roller driving shaft 7 and also supports a cradle support shaft 8. The roller driving
shaft 7 is fixed to the axis of the friction roller 3, and the roller driving shaft
7 rotatively drives and rotates the friction roller 3. The cradle arm 2 is U-shaped
in a plane view and has bobbin holders 2a provided inside the respective ends (upper
right and left portions of the U shape) of the cradle arm 2 to support a bobbin 6
for the package 1. The cradle arm 2 is rotatably supported by the cradle support shaft
8 in its part (lower end of the U shape) located opposite the laterally opposite ends.
The package 1 is a package formed by traversing a yarn around an outer periphery of
the bobbin 6 in a manufacturing stage of the package.
[0025] In the above configuration, the axial direction of the roller driving shaft 7 is
parallel to that of the cradle support shaft 8. The axial direction of the bobbin
6, supported by the bobbin holders 2a, 2a, is also parallel to that of the roller
driving shaft 7 and the cradle support shaft 8. Accordingly, the axial direction of
the friction roller 3 is parallel to that of the package 1, supported by the cradle
arm 2.
[0026] The package 1, supported by the cradle arm 2, can revolve freely around the cradle
support shaft 8, and the weight of the package 1 keeps it in contact with the friction
roller 3. The peripheral surface of the package 1 is in frictional contact with a
peripheral surface of the friction roller 3. The package 1 rotates in unison with
the rotation of the friction roller 3.
[0027] The elastic yarn 5 unwound from the package 1 is guided by the yarn guide roller
4 and drawn out in the radial direction of the package 1. The yarn guide roller 4
is placed on the tangent between the friction roller 3 and the package 1 or at a position
closer to the package 1 than the tangential direction (the position where the unwound
elastic yarn 5 contacts with the peripheral surface of the package 1), in the side
view shown in Figure 1 (as viewed from the axial direction of the package 1). In the
front view shown in Figure 2 (as viewed from the direction of the tangent between
the friction roller 3 and the package 1), the yarn guide roller 4 (not shown in Figure
2) is located in a central part of the package 1 in the axial direction of the package
1.
[0028] As shown in Figure 2, the package 1, from which the yarn is to be unwound by the
unwinding device 100, has higher yarn layer portions in which the diameter of the
package 1 is larger at its axial ends. The package 1 is divided into the following
three parts along its axial direction: opposite axial ends 1a, 1a and a central part
1b. Each of the axial ends 1a of the package 1 includes the higher yarn layer portions.
On the other hand, the central part 1b of the package 1 has a substantially fixed
outer diameter and includes no the higher yarn layer portions.
[0029] The friction roller 3 is composed of a cylindrical drum 10 and a friction belt (for
example, a rubber belt) 11 placed radially outside the drum 10. The friction belt
11 is an annular member formed by connecting the opposite ends of a band-like rubber
member. The friction belt 11 is fitted around the drum 10.
[0030] In connection with the axial length, the drum 10 is formed to be longer than the
package 1, and the friction belt 11 is formed to be shorter than the package 1. Further,
the friction roller 3 has a larger outer diameter by the thickness of the friction
belt 11 at the position where the friction belt 11 is placed, than in a part in which
only the drum 10 is present.
[0031] The friction belt 11 is formed to have an axial length W1 equal to or smaller than
the axial length W0 of central part 1b of the package 1. The radially outward projection
length H1 of the friction roller 11, that is, the difference between the diameter
of the drum 10 and the outer diameter of the friction belt 11 (thickness of the friction
belt 11) is larger than the height H0 of the higher yarn layer portion of the package
1, that is, the difference between the maximum diameter of the axial end 1a of the
package 1 and the diameter of the central part 1b of the package 1. Here, the package
1 and the friction roller 3 are laid out so that the friction belt 11 is located between
boundary surfaces A, A each of which is located between the corresponding axial end
1a and the central part 1b of the package 1.
[0032] In the above configuration, only the central part 1b of the package 1 contacts with
the friction belt 11 of the friction roller 3, and no other parts of the package 1
contact with the friction roller 3. Thus, the higher yarn layer portions do not contact
with the friction roller 3. This prevents the yarn from being inappropriately unwound.
[0033] Now, with reference to Figure 3, a description will be give of an unwinding device
200 that is a second embodiment. The unwinding device 200 has the same configuration
as that of the unwinding device 100 except that a friction roller 103 is used in place
of the friction roller 3. The package from which the yarn is to be unwound by the
unwinding device 200 is the package 1 having higher yarn layer portions in which the
diameter of the package is larger at the axial ends of the package 1. Accordingly,
in the description below of the unwinding device 200, focus will be given to the configuration
of the friction roller 103. In addition, the same reference numbers as those of the
unwinding device 100 are used for those members of the unwinding device 200 which
have the same arrangements of the corresponding members of the unwinding device 100.
The description of these members is omitted.
[0034] The friction roller 103 is composed of a cylindrical drum 110 and a rubber ring 111
placed radially outside the drum 110. The rubber ring 111 is an annular member having
a circular transverse section, and the rubber ring 11 is fitted around the drum 110.
Further, a concave groove 110a is formed in an outer peripheral surface of the drum
110 at an appropriate position in the axial direction, and the concave groove 110a
is formed to the shape of the transverse section of the rubber ring 111. The rubber
ring 111 is fitted and positioned in the concave groove 110a. The roller driving shaft
107 is fixed to the axis of the friction roller 103 (drum 110).
[0035] In connection with the axial length, the drum 110 is formed to be longer than the
package 1, and the rubber ring 111 is formed to be shorter than the package 1. Further,
the friction roller 103 has a larger outer diameter by the thickness of the rubber
belt 111 at the position where the rubber ring 111 is placed, than in a part in which
only the drum 110 is present.
[0036] The rubber ring 111 is formed to have an axial length W2 equal to or smaller than
the axial length W0 of central part 1b of the package 1. The radially outward projection
length H2 of the rubber ring 111, that is , the difference between the maximum diameter
of the drum 110 (not the diameter of the concave groove but of the peripheral surface)
and the outer diameter of the rubber ring 111 is larger than the height H0 of the
higher yarn layer portion of the package 1, that is, the difference between the maximum
diameter of the axial end 1a of the package 1 and the diameter of the central part
1b of the package 1. Here, the package 1 and the friction roller 103 is laid out so
that the rubber ring 111 is located between boundary surfaces A, A, each of which
is located between the corresponding axial end 1a and the central part 1b of the package
1.
[0037] In the above configuration, only the central part 1b of the package 1 contacts with
the rubber ring 111 of the friction roller 103, and no other parts of the package
1 contact with the friction roller 103.
[0038] Now, with reference to Figure 4, a description will be given of an unwinding device
300 that is a third embodiment. The unwinding device 300 has the same configuration
as that of the unwinding device 100 except that a friction roller 203 is used in place
of the friction roller 3. The package from which the yarn is to be unwound by the
unwinding device 300 is the package 1 having higher yarn layer portions in which the
diameter of the package 1 is larger at the axial ends of the package 1. Accordingly,
in the description below of the unwinding device 300, focus will be given to the configuration
of the friction roller 203. In addition, the same reference numbers as those of the
unwinding device 100 are used for those members of the unwinding device 300 which
have the same arrangements of the corresponding members of the unwinding device 100.
The description of these members is omitted.
[0039] The friction roller 203 is a cylindrical drum and is formed to be shorter than that
of the package 1 in the axial direction. The roller driving shaft 7 is fixed to the
axis of the friction roller 203 (drum 110).
[0040] More specifically, the friction roller 203 is formed to have an axial length W3 equal
to or smaller than the axial length WO of central part 1b of the package 1. The difference
(length H3) between the diameter of the friction roller 203 and the diameter of the
roller driving shaft 7 is larger than the height H0 of the higher yarn layer portion
of the package 1, that is, the difference between the maximum diameter of the axial
end 1a of the package 1 and the diameter of the central part 1b of the package 1.
Here, the package 1 and the friction roller 203 are laid out so that the friction
roller 203 is located between the boundary surfaces A, A, each of which is located
between the corresponding axial end 1a and the central part 1b of the package 1.
[0041] In the above configuration, the friction roller 203 contacts with only the central
part 1b of the package 1, and it does not contact with any other parts (axial ends
1a) of the package 1.
[0042] Now, with reference to Figure 5, a description will be given of a core yarn manufacturing
unit 500 to which the unwinding device 100, the first embodiment, is applied. The
core yarn manufacturing unit 500 manufactures a core yarn using one spindle, and the
core yarn manufacturing unit 500 constitutes a part of a core yarn manufacturing apparatus.
The core yarn manufacturing apparatus comprises a large number of core yarn manufacturing
units 500, and driving and control mechanisms for the respective core yarn manufacturing
units 500. The core yarn manufacturing apparatus can simultaneously manufacture a
large number of core yarns using a corresponding number of spindles.
[0043] The core yarn manufacturing unit 500 comprises an elastic yarn supply device that
supplies the elastic yarn 5, constituting a core fiber, a fiber bundle manufacturing
device that manufactures a fiber bundle 505 from a sliver 504, and a spinning device
that covers the periphery of the elastic yarn 5 with the fiber bundle 505 to manufacture
a core yarn 512. In the description below, expressions such as upstream side and downstream
side are used on the basis of the direction in which the sliver 504, the fiber bundle
505, and the core yarn 512 are fed.
[0044] The elastic yarn supply device is the unwinding device 100 provided with the package
1 around which the elastic yarn 5 is wound.
[0045] The fiber bundle manufacturing device comprises a can (not shown in the drawing)
serving as a supplying source of the sliver 504 and a draft device 506 that drafts
(draws) the sliver 504 to form and to arrange a fiber bundle 505. The draft device
506 comprises four roller pairs, that is, a back roller pair 507, a third roller pair
508, a second roller pair 509, and a front roller pair 510, arranged in this order
along the direction in which the sliver 504 is conveyed. An apron belt is wound around
the rollers of the second roller pair 509 to enlarge a nip area for the sliver 504.
[0046] The elastic yarn 5 is supplied to between the front roller pair 510 and the second
roller pair 509 of the draft device 506 so as to join the fiber bundle 505. The following
are provided on a route for the elastic yarn 5 which extends from the unwinding device
100 to the draft device 506: a funnel portion 560 into which the elastic yarn 5 is
inserted, an air sucker device 558, an elastic yarn detecting sensor 532, a clamp
cutter device 533, and an elastic yarn supply guide cylinder 559. The elastic yarn
5 is supplied to the draft device 506 through these devices.
[0047] A pneumatic spinning device 513 as the above spinning device is provided downstream
side of the draft device 506. The pneumatic spinning device 513 contains a pneumatic
spinning nozzle that carries out spinning by causing whirling currents of compressed
air to act on the elastic yarn 11 supplied from the unwinding device 100 and on the
fiber bundle 505 drafted by the draft device 506. The pneumatic spinning device 513
manufactures a core yarn 12 composed of the elastic yarn 11 as a core fiber and covered
with the fibers of the fiber bundle 5.
[0048] A delivery roller 514 is provided downstream side of the pneumatic spinning device
513 to exert a feeding force on the core yarn 512 manufactured by the pneumatic spinning
device 513. A winding device 516 is provided downstream side of the delivery roller
514 to wind the core yarn 512 around a package 515. Further, the following are arranged
on a route for the core yarn 512 which extends from the delivery roller 514 to the
package 515: a slab catcher (thickness defect detector) 517 that detects yarn defects
and a cutter 563 that cuts the core yarn 512 on the basis of the detection of a yarn
defect carried out by the slab catcher 517.
[0049] A summary will be given of the unwinding device for a package in accordance with
the present invention.
[0050] The unwinding device for a package, corresponding to a first device invention, comprises
a friction roller that contacts with a peripheral surface of the package to rotate
the package and yarn guiding means for guiding the yarn unwound and drawn out from
the package in the radial direction of the package as a result of rotation of the
friction roller. Further, a convex portion is provided on an axial part of the friction
roller so that the friction roller contacts with only a central part of the package
which is located inside opposite axial ends of the package and which has a substantially
fixed outer diameter, the convex portion of the friction roller having a larger diameter
than other parts of the friction roller and contacting with the central part of the
package.
[0051] In the first and second embodiments, the yarn guiding means is the yarn guide roller
4. In the first and second embodiments, the package 1 is divided into the following
three parts along the axial direction, that is, the opposite axial ends 1a, 1a and
the central part 1b. The central part 1b of the package 1 has a substantially fixed
outer diameter. The friction roller 3 in the first embodiment comprises the friction
belt 11 placed radially outside the drum 10 and serving as the convex portion. The
friction roller 103 in the second embodiment comprises the rubber ring 111 placed
radially outside the drum 110 and serving as the convex portion.
[0052] The convex portion need not necessarily be separated from the drum 10, 110, like
the friction belt 11 on the drum 10 or the rubber ring 111 on the drum 110. The convex
portion may be integrated with the drum 10, 110. Further, the present embodiment uses
the elastic yarn but is not limited to it provided that the unwinding device configured
as described above is used.
[0053] Thus, the higher yarn layer portions of the package do not contact with the friction
roller. This prevents inappropriate unwinding even when a yarn is unwound while applying
unwinding tension.
[0054] An unwinding device for a package corresponding to a second device invention is the
first device invention configured as described below. The friction roller is composed
of a cylinder and an annular member which is separate from the cylinder and which
is placed radially outside the cylinder. The annular member is the convex portion
of the friction roller.
[0055] In the first embodiment, the cylinder is the drum 10 and the annular member is the
friction belt 11. In the second embodiment, the cylinder is the drum 110 and the annular
member is the rubber ring 111.
[0056] Thus, in the friction roller having the convex portion, the convex portion is separate
from the cylinder. This allows an appropriate friction roller to be manufactured to
the shape (the axial length or the diameter of the higher yarn layer portions) of
the package from which the yarn is to be unwound.
[0057] An unwinding device for a package corresponding to a third device invention comprises
a friction roller that contacts with a peripheral surface of the package to rotate
the package and yarn guiding means for guiding a yarn unwound and drawn out from the
package in the radial direction of the package as a result of rotation of the friction
roller. The friction roller is formed so as to be as long as or shorter than an axially
central part of the package in the axial direction so that the friction roller contacts
with only the central part of the package which is located inside opposite axial ends
of the package and which has a substantially fixed outer diameter.
[0058] In the third embodiment, the yarn guiding means is the yarn guide roller 4. In the
third embodiment, the package 1 is divided into the following three parts along the
axial direction, that is, the opposite axial ends 1a, 1a and the central part 1b.
The central part 1b of the package 1 has a substantially fixed outer diameter. The
friction roller 203 in the third embodiment is formed to be shorter than the central
part 1b of the package 1 in the axial direction.
[0059] Thus, the higher yarn layer portions do not contact with the friction roller. This
prevents inappropriate unwinding even when a yarn is unwound while applying unwinding
tension.
[0060] Now, a description will be given of a method for unwinding a yarn from a package
in accordance with the present invention.
[0061] A method for unwinding a yarn from a package which method corresponds to a first
method invention uses an unwinding device based on a friction roller system and comprises
the steps described below. In a first step, a friction roller is contacted with a
peripheral surface of the package. In a second step, the friction roller is driven
to rotate the package, while unwinding the yarn from the package so that the yarn
is unwound in the radial direction of the package. In particular, the friction roller
contacts with the peripheral surface of the package in such a way that the opposite
ends of the package float from an outer peripheral surface of the friction roller.
[0062] In this case, the friction roller may be contacted with the peripheral surface of
the package in any part of the package except its opposite ends. For example, any
part of the package except its opposite ends, that is, any part within the central
part of the package, may be used as a contacting part with the friction roller regardless
of whether it is located at a central position of the package or closer to one of
the opposite ends than to the axially central position. That is, the contact between
the friction roller and the package may be similar to a point contact rather than
a line contact, along the axis of the package. Of course, a line contact may be achieved
in which the entire central part of the package except the opposite ends contacts
with the friction roller.
[0063] With the above configuration, the higher yarn layer portions do not contact with
the friction roller. This prevents inappropriate unwinding even when a yarn is unwound
while applying unwinding tension.
[0064] A method for unwinding a yarn from a package which method corresponds to a second
method invention is the first method invention configured as described below. The
package is an elastic yarn package into which an elastic yarn has been wound. The
friction roller drivingly contacts with a central part of the outer peripheral surface
of the package to rotate the package, the central part being located away from opposite
end surfaces of the package by a predetermined distance within which the package is
expected to collapse.
[0065] Even with an elastic yarn package in which package is more likely collapse than in
the case of normal yarns, the above configuration prevents the higher yarn layer portions
of the package from contacting with the friction roller. This prevents inappropriate
unwinding even when a yarn is unwound while applying unwinding tension.
[0066] A method for unwinding a yarn from a package which method corresponds to a third
method invention is the second method invention configured as described below. The
predetermined distance is larger than the length of higher yarn layer portions formed
at the opposite ends of the package.
[0067] Even if a package with higher yarn layer portions, higher yarn layer portions, in
which the collapse of the package or latching is likely to occur, do not contact with
the friction roller. This prevents inappropriate unwinding even when a yarn is unwound
from a package with the higher yarn layer portions while applying unwinding tension
to the package.