BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The present invention relates to a yarn winding machine including a plurality of
winding units.
2. Description of the Related Art
[0002] In an automatic winder disclosed in Japanese Patent Application Laid-Open No.
2009-46269, a tray on which a yarn supplying bobbin has been mounted is supplied from a bobbin
replacement unit to a mainline and then supplied from the mainline to winding units.
A tray that is transported to a downstream end of the mainline without being supplied
to any of the winding units is returned to an upstream end of the mainline via a bypass
line.
[0003] In the case of the automatic winder disclosed in Japanese Patent Application Laid-Open
No.
2009-46269, when a sufficient number of trays are being supplied to every winding unit, the
tray that was not supplied to any winding unit is needlessly repeatedly transported
from the mainline to the bypass line and vice versa. In such an automatic winder,
usually, to enable in the winding unit finding of a yarn end of a yarn that has been
wound on a yarn supplying bobbin, in the bobbin replacement unit the yarn end of the
yarn is inserted into a hole formed in an upper end of a core tube of the yarn supplying
bobbin. Therefore, the tray is supplied from the bobbin replacement unit to the winding
unit in a state in which the yarn end has been inserted in the hole formed in the
upper end of the core tube of the yarn supplying bobbin mounted thereon. When the
tray is needlessly transported as explained above, the yarn end of the yarn wound
on the yarn supplying bobbin drops (comes out of the hole formed in the upper end
of the core tube) due to vibration and the like of the tray during transportation
of the tray so that it may not be possible to find the end of the yarn when the tray
is supplied to the winding unit. Moreover, if the tray is transported in a state in
which the yarn end has dropped, it is possible that the dropped yarn end is disadvantageously
caught in a member that constitutes a transportation path of the tray.
SUMMARY OF THE INVENTION
[0004] An object of the present invention is to provide a yarn winding machine in which
it is possible to supply necessary trays to each of the winding units and that can
suppress transportation of unnecessary trays as much as possible.
[0005] This object is achieved by a yarn winding machine according to claim 1.
[0006] A yarn winding machine according to one aspect of the present invention includes
a plurality of winding units; a bobbin processing device; a tray transporting device;
and a control device. Each of the winding units unwinds a yarn from a yarn supplying
bobbin and winds the unwound yarn into a package. The bobbin processing device performs
pre-processing on the yarn supplying bobbin that is mounted on a tray and collects
the tray on which an empty bobbin from which the yarn has been unwound in the winding
unit is mounted. The tray transporting device transports the tray between the winding
units and the bobbin processing device. The tray transporting device includes a supply
path; a collection path; a return path; a conveyor device; and a tray controlling
device. The supply path is a path on which the tray on which the yarn supplying bobbin
has been mounted is transported to the winding units. The collection path is a path
on which the tray that has been discharged from the winding units is transported to
the bobbin processing device. The return path is a path on which the tray that has
been transported to a downstream end of the supply path is transported so as to be
returned to an upstream end of the supply path. The conveyor device transports the
tray along the supply path, the collection path, and the return path. The tray controlling
device is arranged on the return path and sends the tray present on the return path
to the upstream end of the supply path. The bobbin processing device supplies the
tray to any one of the supply path and the return path. The control device causes
the tray controlling device to perform a sending operation of sending the tray at
a first sending pace that corresponds to a difference between a pace at which the
trays are discharged from the winding units to the collection path and a pace at which
the trays are supplied from the bobbin processing device directly to the supply path
or to a portion in the return path that is downstream than the tray controlling device.
[0007] The above and other objects, features, advantages and technical and industrial significance
of this invention will be better understood by reading the following detailed description
of presently preferred embodiments of the invention, when considered in connection
with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008]
FIG. 1 is a schematic configurational diagram of a yarn winding machine according
to a first embodiment.
FIG. 2A is a plan view of a tray stopper in a state in which the tray stopper has
stopped sending of trays and FIG. 2B is a plan view of the tray stopper in a state
in which the tray stopper permits sending of trays.
FIG. 3 is a block diagram of an electrical configuration of the yarn winding machine.
FIG. 4 is a flowchart indicating a process procedure of a control that causes the
tray stopper to send the trays.
FIG. 5 is a flowchart indicating a process procedure of a normal sending control.
FIG. 6 is a view for explaining specific examples of the normal sending control.
FIG. 7 is a schematic configurational diagram of a yarn winding machine according
to a second embodiment.
FIG. 8 is a flowchart of a process procedure that causes to perform an additional
sending operation in the second embodiment.
FIG. 9 is a schematic configurational diagram of a yarn winding machine according
to a third embodiment.
FIG. 10 is a schematic configurational diagram of a yarn winding machine according
to a fourth embodiment.
FIG. 11 is a schematic configurational diagram of a yarn winding machine according
to a fifth embodiment.
FIG. 12 is a schematic configurational diagram of a yarn winding machine according
to a sixth embodiment.
DETAILED DESCRIPTION
First Embodiment
[0009] A preferred first embodiment of the present invention is explained below. Note that,
the explanation will be given while appropriately referring to the directions shown
in the drawings.
Overall Configuration of Yarn Winding Machine
[0010] As shown in FIG. 1, a yarn winding machine 1 includes a plurality of winding units
11 arranged in a left-right direction, a bobbin processing device 12 arranged at a
right end, a control box 13 arranged at a left end, and a tray transporting device
14 arranged in an area (area between the bobbin processing device 12 and the control
box 13) in which the winding units 11 are arranged.
Winding Unit
[0011] The winding unit 11 unwinds a yarn from a yarn supplying bobbin S (shown with a solid
circle) mounted on a tray T supplied via a later-explained supply path 31 and winds
the unwound yarn into a not-shown package. Moreover, the winding unit 11 discharges
to a later-explained collection path 34 a tray T on which has been mounted an empty
bobbin E (shown with a hollow circle) which is a yarn supplying bobbin S from which
all the yarn has been unwound.
Bobbin Processing Device
[0012] The bobbin processing device 12 transports (supplies) to the tray transporting device
14 the tray T on which the yarn supplying bobbin S has been mounted and collects the
tray T on which the empty bobbin E returned from the tray transporting device 14 has
been mounted. The bobbin processing device 12 performs pre-processing (for example,
yarn end finding) on the yarn supplying bobbin S that is going to be supplied to the
winding unit 11 to enable a wind processing in the winding unit 11. Moreover, the
bobbin processing device 12 performs post-processing (e.g., residual yarn removal)
on the empty bobbin E collected from the winding unit 11. The contents of the pre-processing
and the post-processing conducted in the bobbin processing device 12 is not limited
to the yarn end finding and the residual yarn removal. In the present embodiment,
it is assumed that the yarn supplying bobbin S is supplied to the bobbin processing
device 12 from a not-shown spinning frame; however, an operator may supply to the
bobbin processing device 12 the yarn supplying bobbin S spun in the spinning frame.
Control Box
[0013] The control box 13 includes an operation panel 16. The operation panel 16 is provided
on a front side of the control box 13. The operator can input a winding parameter
and the like by using the operation panel 16. Moreover, on the operation panel 16
are displayed an operating state, an abnormal state, and the like of the winding units
11.
Tray Transporting Device
[0014] The tray transporting device 14 transports the tray T between the bobbin processing
device 12 and the winding units 11. As shown in FIG. 1, the tray transporting device
14 includes the supply path 31, a return path 32, individual paths 33, and the collection
path 34. A conveyor device 39 (see FIG. 3) constituted by a belt conveyor and the
like is provided in each path and the transportation of the tray T in each path is
performed by the corresponding conveyor device 39. Arrows shown in FIG. 1 indicate
a transportation direction of the tray T (same hold true for other drawings).
[0015] The supply path 31 is located in the back side of the winding units 11 and extends
in the left-right direction from the winding unit 11 on the left to the winding unit
11 on the right. A right end (upstream end) of the supply path 31 is connected to
the bobbin processing device 12. As a result, the tray T is supplied directly from
the bobbin processing device 12 to the supply path 31. The tray T, which is supplied
to the supply path 31, is transported on the supply path 31 from the right side to
the left side. Moreover, the tray transporting device 14 includes a tray sensor 29
that can detect a surplus tray T. The surplus tray T is a tray that has been transported
to a downstream end (left end) of the supply path 31.
[0016] The return path 32 extends along the left-right direction in the back side of the
supply path 31. That is, the supply path 31 is located between the winding units 11
and the return path 32. Each ends of the return path 32 is connected to a corresponding
end of the supply path 31. The tray T is transported from the left side to the right
side on the return path 32. As a result, the surplus tray T that is transported to
the downstream end (left end) of the supply path 31 is transported via a connecting
member to an upstream end (left end) of the return path 32. That is, the surplus tray
T that is transported to the downstream end of the supply path 31 is returned to the
upstream end (right end) of the supply path 31 by being transported on the return
path 32.
[0017] A tray stopper 35 ("tray controlling device" according to the present invention)
is arranged in the middle of the return path 32. The tray controlling device is a
device that can send the tray T at a desired necessary pace (frequency). By deactivating
the control of the tray stopper 35 in a state in which the conveyor device 39 is being
driven, the tray T can be sent. It is preferable that the tray stopper 35 is arranged
in a downstream end part (right end part) of the return path 32. As shown in FIGS.
2A and 2B, the tray stopper 35 includes an arm 41 and two rollers 42 and 43. The arm
41 is connected to a not-shown motor and the like. The arm 41 is pivotable around
an axis 41a that extends vertically. Moreover, the arm 41 is divided into two parts
41b and 41c that extend in mutually different directions. The part 41b is located
in the downstream side (right side) of the return path 32 than the part 41c.
[0018] The roller 42 is attached to a tip end of the part 41b of the arm 41. The roller
42 is supported by the part 41b of the arm 41 so as to be rotatable around an axis
42a that extends vertically. The roller 43 is attached to a tip end of the part 41c
of the arm 41. The roller 43 is supported by the part 41c of the arm 41 so as to be
rotatable around an axis 43a that extends vertically.
[0019] When no tray T is to be sent, the tray stopper 35 is in a state shown in FIG. 2A.
In this state, the roller 42 can contact the tray T present in the return path 32,
and the roller 43 does not contact the tray T present in the return path 32. Because
the tray T that is being transported on the return path 32 contacts the roller 42,
further transportation of the tray T is stopped. While the tray stopper 35 is maintained
in the state shown in FIG. 2A, the transportation of the tray T that is transported
on the return path 32 is stopped by the tray stopper 35. That is, the trays T accumulate
on the return path 32.
[0020] When sending the tray T, a sending operation is performed. The sending operation
includes pivoting the arm 41 around the axis 41a in the clockwise direction when seen
from above so that the tray stopper 35 attains a state shown in FIG. 2B, and then
pivoting the arm 41 in the opposite direction so that the tray stopper 35 is returned
to the state shown in FIG. 2A. When the tray stopper 35 is in the state shown in FIG.
2B, the roller 42 does not contact the tray T present in the return path 32 but the
roller 43 contacts the tray T present in the return path 32. As a result, the tray
T that was stopped from being transported by the roller 42 is sent to the supply path
31. Moreover, the transportation of the next tray T is stopped by the roller 43. Then,
when the arm 41 is returned to the state shown in FIG. 2A by pivoting the arm 41 in
the opposite direction, the transportation of the tray T whose transportation was
previously stopped by the roller 43 is now stopped by the roller 42.
[0021] A bridge breaker 36 is arranged at a connecting part of the supply path 31 and the
downstream end of the return path 32. The bridge breaker 36 functions to prevent occurrence
of a so-called bridge. The bridge is a phenomenon that the tray T sent by the tray
stopper 35 and the tray T supplied from the bobbin processing device 12 to the supply
path 31 clog up the connecting part of the return path 32 and the supply path 31.
[0022] The plurality of the individual paths 33 is located toward a front side than the
supply path 31 and the individual paths 33 are arranged in the left-right direction.
Each of the individual paths 33 is provided corresponding to each of the winding units
11. Each of the individual paths 33 extends in a front-back direction while curving
on the way. A rear end of each of the individual paths 33 is connected to the supply
path 31 and a front end thereof is connected to the collection path 34. The connecting
part with the supply path 31 of the individual path 33 is inclined with respect to
the front-back direction so as to go toward left side more the same goes toward the
front side. Moreover, three trays T can be accommodated in each of the individual
paths 33. That is, two trays T can be accommodated between the supply path 31 and
the tray T positioned at a winding position of the individual path 33. As a result,
when the tray T transported on the supply path 31 from the right side to the left
side reaches the connecting part of the individual path 33 with the supply path 31,
and if the number of the trays T that have been accommodated in a given individual
path 33 is two or less, then this tray T is transported from the supply path 31 to
the individual path 33. On the other hand, if three trays T have already been accommodated
in a given individual path 33, then this tray T is transported on the supply path
31 toward the left side. That is, the trays T are supplied to the individual paths
33 sequentially from the individual path 33 located on the right side.
[0023] One winding unit 11 is arranged per individual path 33. The winding unit 11 unwinds
the yarn from the yarn supplying bobbin S mounted on the tray T located at the winding
position (in the present embodiment, position of the tray T present on the most front
side among the three trays T that have been accommodated in the individual path 33)
of the individual path 33 and performs winding of the yarn. When the unwinding of
the yarn from the yarn supplying bobbin S is finished, a not-shown tray discharging
section of the winding unit 11 discharges the tray T, on which the empty bobbin E
from which the yarn is unwound is mounted, from the winding position to the collection
path 34. Then, the new tray T is moved to the winding position so that the winding
unit 11 can unwind the yarn from the new yarn supplying bobbin S mounted on this new
tray T.
[0024] The collection path 34 extends in the left-right direction and is located toward
the front side than the individual paths 33. A right end (downstream end) of the collection
path 34 is connected to the bobbin processing device 12. The tray T discharged by
the winding unit 11 is transported from the individual path 33 to the collection path
34. In the collection path 34, the tray T is transported from the left side toward
the right side and the tray T is finally returned to the bobbin processing device
12. In this manner, the tray T is collected in the bobbin processing device 12.
Electrical Configuration of Yarn Winding Machine
[0025] An electrical configuration of the yarn winding machine 1 is explained next. As shown
in FIG. 3, the yarn winding machine 1 includes an MCU (Multi Control Unit) 51, a plurality
of winding control sections 52, a bobbin processing control section 53, a transportation
control section 54, a sending control section 55, and a communication board 56.
[0026] The MCU 51 is arranged in the control box 13. When a signal indicative of a setting
of the yarn winding machine 1 is received from the operation panel 16, the MCU 51
transmits a signal to each of the winding control sections 52, the bobbin processing
control section 53, the transportation control section 54, and the sending control
section 55 for performing various settings therein based on the received signal. Moreover,
the MCU 51 transmits a signal to the operation panel 16 to cause the operation panel
16 to display the operating state, the abnormal state, and the like of the winding
units 11.
[0027] One winding control section 52 is arranged in each of the winding units 11 and the
winding control section 52 controls an operation of this winding unit 11. The bobbin
processing control section 53 is arranged in the bobbin processing device 12 and the
bobbin processing control section 53 controls an operation of the bobbin processing
device 12. The transportation control section 54 is arranged in the conveyor device
39 and the transportation control section 54 controls an operation of the conveyor
device 39 (motor and the like that drives conveyors) . The sending control section
55 is arranged in the tray stopper 35 and the sending control section 55 controls
an operation of the tray stopper 35.
[0028] The MCU 51, the winding control sections 52, the bobbin processing control section
53, the transportation control section 54, the sending control section 55, the communication
board 56, and the tray sensor 29 are connected to each other and can perform communication
with each other. The communication board 56 is a device that controls this communication.
Note that, in the first embodiment, a combination of the MCU 51, the winding control
sections 52, the bobbin processing control section 53, the transportation control
section 54, the sending control section 55, the communication board 56 corresponds
to a "control device" according to the present invention.
Sending Control by Tray Stopper
[0029] A control of sending the tray T performed by the tray stopper 35 is explained next.
The sending control section 55 performs a process procedure in accordance with a flowchart
shown in FIG. 4 when the tray T is to be sent by the tray stopper 35. The process
procedure shown in FIG. 4 is started when the operation of the yarn winding machine
1 is started (that is, when the winding is started in the winding units 11) .
[0030] The process procedure shown in FIG. 4 is explained below in detail. When the operation
of the yarn winding machine 1 is started, the sending control section 55 starts a
maximum sending control (Step S101) . The maximum sending control is a control to
cause the tray stopper 35 to perform the sending operation at a maximum pace ("second
sending pace" according to the present invention). At the maximum speed, for example,
the sending operation is performed once per second. The sending control section 55
continues the maximum sending control while no tray T is detected by the tray sensor
29 (Step S102: NO). Whether the bobbin processing device 12 has stopped is determined
based on a signal received from the bobbin processing control section 53.
[0031] When a tray T is detected by the tray sensor 29 (Step S102: YES), the sending control
section 55 switches the control from the maximum sending control to a normal sending
control (S103). The normal sending control will be explained in detail later. The
sending control section 55 continues the normal sending control while the bobbin processing
device 12 (abbreviated to "BPD" in FIG. 4 for sake of convenience) does not stop abnormally
and the like (Step S104: NO).
[0032] If the bobbin processing device 12 had stopped abnormally and the like (Step S104:
YES), the sending control section 55 waits until the bobbin processing device 12 returns
to normal from the stopped state (Step S105: NO). Note that, the determination at
Step S105 as to whether the bobbin processing device 12 has returned to normal from
the stopped state is performed based on a signal received from the bobbin processing
control section 53.
[0033] Note that, the normal sending control is continued while the bobbin processing device
12 is in the stopped state. When the bobbin processing device 12 is in the stopped
state, each of the winding units 11 continues the winding until the winding of a predetermined
number of packages is completed. Then, when the winding of the predetermined number
of packages is completed in the winding units 11 and a certain time has elapsed since
a signal that indicates that the winding has been completed has been lastly outputted
from any of the winding units 11, by the method explained below, number K
N that is the number of times of performing the sending operation per cycle U calculated
in the normal sending control becomes equal to or less that 0 (zero), and the sending
operation is not performed.
[0034] When the bobbin processing device 12 returns to normal from the stopped state (Step
S105: YES), counting of the number of the trays T discharged thereafter from the winding
units 11 is started (Step S106). The counting of the trays T at Step S106 is performed
based on the signal sent from each of the winding units 11 and that indicates the
winding in the winding unit 11 has been completed.
[0035] When the count of the trays T exceeds a threshold value "a" (C>Ca) (Step S107: YES),
the sending control section 55 switches the control from the normal sending control
to the maximum sending control (Step S108). The sending control section 55 continues
the maximum sending control until a tray T is detected by the tray sensor 29 (Step
S109: NO). When a tray T is detected by the tray sensor 29 (Step S109: YES), the process
procedure is returned to Step S103.
[0036] If the count of the trays T has not exceeded the threshold value (Step S107: NO),
and if no tray T is detected by the tray sensor 29 (Step S110: NO), the process procedure
is returned to Step S107. When a tray T is detected by the tray sensor 29 (Step S110:
YES), the process procedure is returned to Step S104.
Normal Sending Processing
[0037] A normal sending processing is explained next. The normal sending processing is a
processing of setting the number of times the tray stopper 35 is to be caused to perform
the sending operation per predetermined cycle U and causing the tray stopper 35 to
perform the sending operation based on the set number. Note that, the pace at which
the tray stopper 35 is to be caused to perform the sending operation in the normal
sending processing corresponds to a "first sending pace" according to the present
invention. The term "pace" in the present specification means "frequency" and/or "number
of times per predetermined time".
[0038] The normal sending processing is a processing performed in accordance with a flowchart
shown in FIG. 5. More specifically, in the normal sending processing, first of all,
the sending control section 55 resets a variable N (N being a natural number) to 1
(Step S201) .
[0039] Then, the sending control section 55 sets the number K
N that is the number of times the sending operation is to be performed in the N-th
cycle U
N to (A
N-1-B
N-1+C
N-1) (Step S202). That is, the number K
N is set higher by C
N-1 than number (A
N-1-B
N-1). A
N-1 is the number of the trays T discharged from the winding units 11 in [N-1]-th cycle
U
N-1. B
N-1 is the number of the trays T supplied from the bobbin processing device 12 to the
supply path 31 in the cycle U
N-1. C
N-1 is the number of times the sending operation is canceled in the cycle U
N-1. Cancellation of the sending operation will be explained later. Note that, when N=1,
each of A0, B0, C0, which correspond to A
N-1, B
N-1, C
N-1, will be 0 (zero). Note that, C
N-1 is not essential; it is possible to calculate K
N from A
N-1 and B
N-1 without considering C
N-1.
[0040] If the number K
N is greater than 0 (Step S203: YES), a timing of performing the sending operation
in the cycle U
N is determined such that the sending operation is performed K
N times in the cycle U
N (Step S204) . When doing so, it is preferable to determine the timing of performing
the sending operation such that the sending operation is performed at regular intervals
as much as possible within the cycle U
N. When the sending timing comes (Step S205: YES), the sending control section 55 causes
the tray stopper 35 to perform the sending operation (Step S206). When all the sending
operations to be performed in one cycle (abbreviated to "SOC" in FIG. 5 for sake of
convenience) are completed by performing the sending operation at Step S206 (Step
S207: YES), the process procedure advances to Step S211. On the other hand, if all
the sending operations to be performed in one cycle are not completed (Step S207:
NO), the process procedure advances to Step S208. Moreover, if the sending timing
has not come yet (Step S205: NO), the process procedure advances to Step S208.
[0041] At Step S208, it is determined whether the tray T is supplied from the bobbin processing
device 12 to the supply path 31. If the tray T has not been supplied from the bobbin
processing device 12 to the supply path 31 (Step S208: NO), the process procedure
returns to Step S205. If the tray T has been supplied from the bobbin processing device
12 to the supply path 31, among the sending operations that are planned to be performed
next within the N-th cycle U
N, the last sending operation is canceled and not performed (Step S209). After canceling
the sending operation at Step S209, if the sending operation planned in the cycle
U
N is remaining (Step S210: NO), the process procedure returns to Step S205.
[0042] On the other hand, if all the sending operations planned in one cycle U
N are completed because of canceling the sending operation at Step S209 (Step S210:
YES), the process procedure advances to Step S211. Also, if K
N is 0 or less (Step S203: NO), the process procedure advances to Step S211. At Step
S211, the variable N is increased by 1 (that is, updated to [N+1]). After the sending
control section 55 updates the variable N at Step S211, the process procedure returns
to Step S202.
[0043] A concrete example of sending the tray T from the tray stopper 35 in each cycle U
when the normal sending control mentioned above is executed is explained below. FIG.
6 shows three Examples 1 to 3 of the timings of, when one cycle is of 10 seconds,
discharging the tray T from the winding units 11, supplying the tray T from the bobbin
processing device 12, and performing the sending operation by the tray stopper 35.
In FIG. 6, "tray discharging" means discharging the tray T from the winding units
11. Moreover, "tray supplying" means supplying the tray T from the bobbin processing
device 12. Moreover, "sending operation" means the sending operation performed by
the tray stopper 35.
[0044] In FIG. 6, each of 1, 2, ..., 9, 10 in each of the cycles represents a period of
0 to 1 second, 1 to 2 seconds, 2 to 3 seconds, 3 to 4 seconds, 4 to 5 seconds, 5 to
6 seconds, 6 to 7 seconds, 7 to 8 seconds, 8 to 9 seconds, and 9 to 10 seconds from
a starting point of a given cycle. Note that, the period of 0 to 1 second, for example,
may be called a period "1" in the following explanation. Moreover, in FIG. 6, the
timing at which the tray T is discharged from the winding unit 11, the timing at which
the tray T is supplied from the bobbin processing device 12, and the timing at which
the sending operation is performed are shown with a hatching pattern. Moreover, when
cross (X) is marked in the hatching pattern of the timing at which the sending operation
is performed, it means that this sending operation is canceled.
[0045] In the case of Example 1, three trays T are discharged from the winding units 11
in the cycle U
N-1 (A
N-1=3). Moreover, in the cycle U
N-1, one tray T is supplied from the bobbin processing device 12 (B
N-1=1). Moreover, in Example 1, because sending of the tray T from the tray stopper 35
in the cycle U
N-1 is not performed, canceling of the sending of the tray T from the tray stopper 35
is also not performed (C
N-1=0).
[0046] As a result, in the case of Example 1, the number K
N that is the number of times of performing the sending operation in the cycle U
N is set to 2 (=3-1+0). Moreover, in the cycle U
N, to cause these two sending operations to be performed at substantially regular intervals,
the periods "5" and "10" are determined as the timing of performing the sending operation.
Moreover, in the cycle U
N, the tray T is not supplied from the bobbin processing device 12 (B
N=0). Therefore, canceling of the sending of the tray T from the tray stopper 35 is
also not performed (C
N=0). Moreover, in the cycle U
N, two trays T are discharged from the winding unit 11 (A
N=2). Therefore, number K
N+1 that is the number of times of performing the sending operation in [N+1]-th cycle
U
N+1 is set to 2 (=2-0+0). Moreover, in the cycle U
N+1 also, the periods "5" and "10" are determined as the timing of performing the sending
operation.
[0047] In Example 2 also, A
N-1, B
N-1, C
N-1 are similar to those in Example 1, and the number K
N that is the number of times of performing the sending operation in the cycle U
N is set to 2, and the periods "5" and "10" are determined as the timing of performing
the sending operation. In Example 2, in the cycle U
N, the trays T are supplied from the bobbin processing device 12 during the periods
"3" and "8" (B
N=2). At the time point at which the tray T is supplied from the bobbin processing
device 12 during the period "3", thereafter, because the sending operations are planned
to be performed during the periods "5" and "10," among these sending operations, the
sending operation to be performed during the period "10", which is the last sending
operation, is canceled. Then, in the case of Example 2, when the sending operation
is performed during the period "5", all the sending operations in the cycle U
N are completed (that is, Step S207: YES is satisfied). Note that, in this case, at
the time point at which the tray T is supplied from the bobbin processing device 12
during the period "8", because all the sending operations in the cycle U
N have been completed (that is, the sending operation during the period "10" has been
already canceled), the sending operation is not canceled because of this.
[0048] In this manner, in Example 2, the sending operation is canceled one time in the cycle
U
N (C
N=1). Moreover, in the cycle U
N, two trays T are discharged from the winding units 11 (A
N=2). Therefore, the number K
N+1 that is the number of times of performing the sending operation in the cycle U
N+1 is set to 1 (=2-2+1).
[0049] In Example 3 also, A
N-1, B
N-1, C
N-1 are similar to those in Examples 1 and 2, and the number K
N that is the number of times of performing the sending operation in the cycle U
N is set to 2, and the periods "5" and "10" are determined as the timing of performing
the sending operation. In Example 3, in the cycle U
N, the trays T are supplied from the bobbin processing device 12 to the supply path
31 during the periods "1" and "3" (B
N=2). At the time point at which the tray T is supplied from the bobbin processing
device 12 to the supply path 31 during the period "1", thereafter, because the sending
operations are planned during the periods "5" and "10", among these sending operations,
the sending operation to be performed during the period "10", which is the last sending
operation, is canceled. Moreover, at the time point at which the tray T is supplied
from the bobbin processing device 12 to the supply path 31 during the period "3",
thereafter, because the sending operation is planned during the period "5", the sending
operation during the period "5" is canceled. Then, in the case of Example 3, at the
time point at which the tray T is supplied from the bobbin processing device 12 to
the supply path 31 during the period "3", all the sending operations in the cycle
U
N are completed (that is, Step S210: YES is satisfied).
[0050] In this manner, in Example 3, the sending operation is canceled twice in the cycle
U
N (C
N=2). Moreover, in the cycle U
N, two trays T are discharged from the winding units 11 (A
N=2). Therefore, the number K
N+1 that is the number of times of performing the sending operation in the cycle U
N+1 is set to 2 (=2-2+2).
Advantageous Effects
[0051] When the sufficient number of the trays T are supplied to every winding unit 11,
if the trays T are sent to the supply path 31 by causing the tray stopper 35 to perform
the sending operation more than required times, the trays T are repeatedly and needlessly
transported to the supply path 31 and the return path 32 without any tray T being
supplied to any of the winding units 11. As explained above, to enable the yarn end
finding of the yarn in the winding unit 11, the yarn supplying bobbins S are transported
in the trays T in the state in which the yarn end has been inserted in the hole formed
in the upper end of the core tube of the yarn supplying bobbin S. Therefore, when
the trays T on which the yarn supplying bobbins S have been mounted are needlessly
transported as mentioned above, the yarn end of the yarn wound on the yarn supplying
bobbin S drops due to vibration and the like of the tray T during transportation of
the tray T, so that it may not be possible to find the end of the yarn in the winding
unit 11. Moreover, the dropped yarn end may be disadvantageously caught in a member
that constitutes the supply path 31 and the return path 32.
[0052] To address this issue, in the first embodiment, the tray stopper 35 is caused to
perform the sending operation at the first sending pace that corresponds to a difference
between the pace at which the trays T are discharged from the winding units 11 to
the collection path 34 and the pace at which the trays T are supplied directly from
the bobbin processing device 12 to the supply path 31. Specifically, the number of
times of performing the sending operation is set for each predetermined cycle U, in
the cycle U
N-1, when the number of the trays T discharged from the winding units 11 is A
N-1, the number of the trays T supplied directly from the bobbin processing device 12
to the supply path 31 is B
N-1, and the number of times of cancellation of the sending operation is C
N-1, the number of times of performing the sending operation in the cycle U
N is set to (A
N-1-B
N-1+C
N-1). Accordingly, while supplying the trays T (yarn supplying bobbins S) of the number
necessary for the winding units 11, because the trays T that are in excess are left
in the return path 32, the trays T can be prevented from repeatedly and needlessly
being transported on the supply path 31 and the return path 32.
[0053] Moreover, in the cycle U
N, when the tray T has been supplied from the bobbin processing device 12 to the supply
path 31, if the sending operations are planned after the tray T was supplied, the
last sending operation among the planned sending operations is canceled. As a result,
in comparison to the case where the sending operation is not canceled, the number
of the trays T supplied to the supply path 31 in the cycle U
N can be set to an appropriate number. Moreover, in contrast, when C
N-1 number of the sending operations are canceled among the sending operations planned
in the cycle U
N-1, the number of times the sending operation should be performed in the cycle U
N is set to (A
N-1-B
N-1+C
N-1), that is, C
N-1 times higher than (A
N-1-B
N-1). As a result, even when the sending operation is canceled, shortage of the trays
does not occur in the cycle U
N.
[0054] Immediately after the start of the operation of the yarn winding machine 1 (that
is, start of winding by the winding units 11), because sufficient number of the trays
T are not being supplied to each of the winding units 11, the number of the trays
T present in the return path 32 is small. Therefore, even if the sending operation
is performed, the trays T may not be actually sent. Moreover, when the sufficient
number of the trays T is supplied to all the winding units 11, the tray T that is
transported to the downstream end of the supply path 31 without being supplied to
any of the winding units 11 is detected by the tray sensor 29.
[0055] Therefore, after the start of the operation of the yarn winding machine 1 and until
a tray T is detected by the tray sensor 29, the tray stopper 35 is caused to perform
the sending operation at the second sending pace that is faster than the first sending
pace set as explained above (by executing the maximum sending control). As a result,
immediately after the start of the operation of the yarn winding machine 1, the time
required to supply the sufficient number of the trays T to each of the winding units
11 can be shortened as much as possible. Then, after a tray T is detected by the tray
sensor 29, the tray stopper 35 is caused to perform the sending operation at the first
sending pace (by switching to the normal sending control). Accordingly, while supplying
the trays T of the number necessary for the winding units 11, the trays T can be prevented
from repeatedly and needlessly being transported on the supply path 31 and the return
path 32.
[0056] During the time from stopping the operation of the bobbin processing device 12 until
the bobbin processing device 12 returns to normal, the winding of the yarn is performed
in the winding units 11, and the trays T present in the supply path 31 are supplied
to each of the winding units 11. Therefore, immediately after the bobbin processing
device 12 returns to normal from the stopped state, because the sufficient number
of the trays T is not supplied to each of the winding units 11, it may happen that
the number of the trays T in the return path 32 is small. Therefore, the trays T may
not be actually sent even if the sending operation is performed. Moreover, when the
sufficient number of the trays T is supplied to all the winding units 11, the tray
T that is transported to the downstream end of the supply path 31 without being supplied
to any of the winding units 11 is detected by the tray sensor 29.
[0057] However, if the duration from stopping the operation of the bobbin processing device
12 until the bobbin processing device 12 returns to normal is short, because the number
of the trays T to be supplied from the supply path 31 to the winding units 11 during
this duration is small, a situation that the sufficient number of the trays T is not
supplied to each of the winding units 11 does not occur.
[0058] Therefore, when the bobbin processing device 12 returns to normal from the stopped
state, the tray stopper 35 is caused to perform the sending operation at the first
sending pace (by executing the normal sending control). Thereafter, the number of
the trays T discharged from the winding units 11 is counted. When the count of the
trays T exceeds a threshold value "a", from this time point, in a period while no
tray T is detected by the tray sensor 29 (or before a tray is detected), the tray
stopper 35 is caused to perform the sending operation at the second sending pace that
is faster than the first sending pace (by executing the maximum sending control).
As a result, after the bobbin processing device 12 returns to normal, the time required
to supply the sufficient number of the trays T to each of the winding units 11 can
be shortened as much as possible. Then, after a tray T is detected by the tray sensor
29 (or once a tray is detected), the tray stopper 35 is caused to perform the sending
operation at the first sending pace (by switching to the normal sending control).
Accordingly, while supplying the trays T of the number necessary for the winding units
11, the trays T can be prevented from repeatedly and needlessly being transported
on the supply path 31 and the return path 32.
[0059] On the other hand, after the bobbin processing device 12 returns to normal from the
stopped state, in a period while no tray T is detected by the tray sensor 29, if the
count of the trays T does not exceed the threshold value "a", the tray stopper 35
is caused to perform the sending operation at the first sending pace (by executing
the normal sending control). Accordingly, while supplying the trays T of the number
necessary for the winding units 11, the trays T can be prevented from repeatedly and
needlessly being transported on the supply path 31 and the return path 32.
[0060] Because the second sending pace is the maximum pace of the tray stopper 35, after
the start of the operation of the yarn winding machine 1 and/or after the bobbin processing
device 12 returns to normal, the time required to supply the sufficient number of
the trays T to each of the winding units 11 can be shortened.
[0061] To execute the normal sending control mentioned above, it is necessary for the sending
control section 55 to grasp the number of the trays T discharged from the winding
units 11 and the number of the trays T supplied from the bobbin processing device
12. In the first embodiment, because the sending control section 55 can communicate
with the bobbin processing control section 53 and the winding control section 52 of
each of the winding units 11, the sending control section 55 is able to grasp this
information.
Second Embodiment
[0062] A preferred second embodiment of the present invention is explained below. As shown
in FIG. 7, in a yarn winding machine 101 according to the second embodiment, opposite
to the yarn winding machine 1 according to the first embodiment, a bobbin processing
device 102 is arranged on the left side of a tray transporting device 104, and a control
box 103 is arranged on the right side of the tray transporting device 104. To cope
with this, in the tray transporting device 104, a left end of the return path 32 is
connected to the bobbin processing device 102. Also, in the second embodiment, the
tray T is supplied from the bobbin processing device 102 to an upstream end (portion
that is upstream than the tray stopper 35) of the return path 32.
[0063] Even in the second embodiment, the sending control section 55 causes the tray stopper
35 to perform the sending operation based on the control according to the flowchart
shown in FIG. 4. However, in the second embodiment, the process procedure in the normal
sending control is different from that in the first embodiment. The normal sending
control according to the second embodiment is performed based on a flowchart shown
in FIG. 8. More specifically, in the second embodiment, in the normal sending control,
first of all, the sending control section 55 resets a variable M to 0 (Step S301)
and waits until the tray T is discharged from either of the winding units 11 (Step
S302: NO). When the tray T is discharged from either of the winding units 11 (Step
S302: YES), the tray stopper 35 is caused to perform the sending operation (Step S303),
and the variable M is increased by 1 (that is, updated to [M+1]) (Step S304). Note
that, the determination at Step S302 is performed based on a signal received from
the winding unit 11. If the value of the variable M is smaller than a threshold value
Ma (Step S305: NO), the process procedure returns to Step S302. If the value of the
variable M is Ma or more (Step S305: YES), the tray stopper 35 is caused to perform
the sending operation (Step S306) one time, and the process procedure returns to Step
S301. As a result, in the second embodiment, each time Ma number of the sending operations
are performed, the sending operation is performed one more time.
[0064] In the first embodiment, the tray T supplied from the bobbin processing device 12
and the tray T sent by the tray stopper 35 are supplied directly to the supply path
31. In contrast, in the second embodiment, the tray T is supplied from the bobbin
processing device 12 to the portion that is upstream than the tray stopper 35 in the
return path 32, and the tray T sent by the tray stopper 35 is only supplied to the
supply path 31. Therefore, in this case, when the tray T is discharged from either
of the winding units 11, an interval between the trays T becomes larger if only the
tray stopper 35 is caused to perform the sending operation. Accordingly, there is
a possibility that the supply of the trays T to the winding units 11 is delayed.
[0065] To address this issue, in the second embodiment, each time Ma number of the sending
operations are performed, the sending operation is performed one more time. As a result,
the delay in the supply of the trays T to the winding units 11 can be prevented.
[0066] Note that, in the second embodiment, the sending operation is performed only one
time at Step S306 but the sending operation can be performed two or more times at
Step S306.
Third Embodiment
[0067] A preferred third embodiment of the present invention is explained below. As shown
in FIG. 9, in a yarn winding machine 201 according to the third embodiment, a bobbin
processing device 202 is arranged on the right side of a tray transporting device
204, and a control box 203 is arranged on the left side of the tray transporting device
204. Moreover, in the yarn winding machine 201, the bobbin processing device 202 can
supply the trays T from two tray supplying sections 202a and 202b. That is, the trays
T can be supplied from the bobbin processing device 202 to the winding units 11 from
two tray supply outlets. The tray T supplied from the tray supplying section 202a
and the tray T supplied from the tray supplying section 202b are the one that the
yarn supplying bobbin S mounted in each of them have been subjected to the pre-processing
by separate mechanism (pre-processing device) of the bobbin processing device 202.
Moreover, the bobbin processing device 202 supplies from the tray supplying sections
202a and 202b the trays T on which are mounted the yarn supplying bobbins S on which
the yarns of the same type have been wound.
[0068] The tray supplying section 202a is connected to a right end (upstream end) of the
supply path 31. As a result, the tray T supplied from the tray supplying section 202a
is supplied directly to the upstream end of the supply path 31. Moreover, in the third
embodiment, the tray transporting device 204 includes a connection path 215 that connects
the tray supplying section 202b to a portion in the return path 32 between the tray
stopper 35 and the bridge breaker 36. As a result, the tray T supplied from the tray
supplying section 202b is supplied via the connection path 215 to a portion in the
return path 32 that is downstream than the tray stopper 35.
[0069] Even in the third embodiment, like in the first embodiment, the tray stopper 35 is
caused to perform the sending operation based on the control according to the flowcharts
shown in FIGS. 4 and 5. However, in the case of the third embodiment, in the control
shown in FIG. 5, the total of the number of the trays T supplied from the two tray
supplying sections 202a and 202b of the bobbin processing device 202 in the cycle
U
N is taken as B
N.
Fourth Embodiment
[0070] A preferred fourth embodiment of the present invention is explained below. As shown
in FIG. 10, in a yarn winding machine 301 according to the fourth embodiment, a bobbin
processing device 302 is arranged on the left side of a tray transporting device 304,
and a control box 303 is arranged on the right side of the tray transporting device
304. Moreover, the bobbin processing device 302 can supply the trays T from two tray
supplying sections 302a and 302b. That is, the trays T can be supplied from the bobbin
processing device 302 to the winding units 11 from two tray supply outlets. The tray
T supplied from the tray supplying section 302a and the tray T supplied from the tray
supplying section 302b are the one that the yarn supplying bobbin S mounted in each
of them have been subjected to the pre-processing by separate mechanism (pre-processing
device) of the bobbin processing device 302. Moreover, the bobbin processing device
302 supplies from the tray supplying sections 302a and 302b the trays T on which are
mounted the yarn supplying bobbins S on which the yarns of the same type have been
wound.
[0071] The tray supplying section 302a is connected to an upstream end (left end) of the
return path 32. Moreover, the tray transporting device 304 includes a connection path
315 that connects the tray supplying section 302b to a portion in the return path
32 that is downstream than the tray stopper 35. In the fourth embodiment, the bridge
breaker 36 is arranged in a downstream end part of the supply path 31.
[0072] Even in the fourth embodiment, like in the second embodiment, the tray stopper 35
is caused to perform the sending operation based on the control according to the flowcharts
shown in FIGS. 4 and 8.
Fifth Embodiment
[0073] A preferred fifth embodiment of the present invention is explained below. As shown
in FIG. 11, in a yarn winding machine 401 according to the fifth embodiment, a bobbin
processing device 402 is arranged on the right side of a tray transporting device
404, and a control box 403 is arranged on the left side of the tray transporting device
404. Moreover, the bobbin processing device 402 can supply the trays T from two tray
supplying sections 402a and 402b. That is, the trays T can be supplied from the bobbin
processing device 402 to the winding units 11 from two tray supply outlets. The tray
T supplied from the tray supplying section 402a and the tray T supplied from the tray
supplying section 402b are the one that the yarn supplying bobbin S mounted in each
of them have been subjected to the pre-processing by separate mechanism (pre-processing
device) of the bobbin processing device 402. In the fifth embodiment, different types
of the yarns are wound on each of the yarn supplying bobbins S mounted on the tray
T in the tray supplying sections 402a and 402b.
[0074] The tray transporting device 404 includes two supply paths 411a and 411b, two return
paths 412a and 412b, and two collection paths 414a and 414b.
[0075] The supply path 411a extends in the left-right direction along a plurality of the
winding units 11 arranged on the right side among the winding units 11, and the supply
path 411a is connected to each of the individual paths 33 corresponding to these winding
units 11 arranged on the right side. An upstream end of the supply path 411a is connected
to the tray supplying section 402a of the bobbin processing device 402.
[0076] The supply path 411b is arranged on the left side of the supply path 411a. The supply
path 411b extends in the left-right direction along a plurality of the winding units
11 among the winding units 11 arranged on the left side of the winding units 11 that
correspond to the supply path 411a, and the supply path 411b is connected to each
of the individual paths 33 corresponding to these winding units 11 arranged on the
left side.
[0077] The tray T is transported from the right side to the left side on the supply paths
411a and 411b. Moreover, the tray transporting device 404 includes tray sensors 421a
and 421b that respectively detect the tray T that has been transported to a downstream
end of the respective supply paths 411a and 411b.
[0078] The return path 412a extends along the left-right direction in the back side of the
supply path 411a. Each ends of the return path 412a is connected to a corresponding
end of the supply path 411a. The tray T is transported from the left side to the right
side on the return path 412a. Moreover, a tray stopper 422a is arranged in a downstream
end part of the return path 412a. The tray stopper 422a is similar in configuration
and function to the tray stopper 35 (see FIG. 1). Moreover, a bridge breaker 423 is
arranged in a portion that is further downstream than the tray stopper 422a of the
return path 412a. The bridge breaker 423 is similar in configuration and function
to the bridge breaker 36 (see FIG. 1).
[0079] The return path 412b extends in the left-right direction and is positioned on the
back side of the supply path 411b but on the left side of the return path 412a. Each
ends of the return path 412b is connected to a corresponding end of the supply path
411b. The tray T is transported from the left side to the right side on the return
path 412b. Moreover, a tray stopper 422b is arranged at a central portion of the return
path 412b. The tray stopper 422b is similar in configuration and function to the tray
stopper 35 (see FIG. 1) . Moreover, the tray transporting device 404 includes a connection
path 415 that connects the tray supplying section 402b of the bobbin processing device
402 to a portion in the return path 412b that is downstream than the tray stopper
422b.
[0080] The collection path 414a extends in the left-right direction and is positioned on
the front side of the individual paths 33 to which the supply path 411a is connected,
and the collection path 414a is connected to these individual paths 33. A right end
of the collection path 414a is connected to the bobbin processing device 402. In the
collection path 414a, the tray T is transported from the left side to the right side.
[0081] The collection path 414b extends in the left-right direction and is positioned on
the front side of the individual paths 33 to which the supply path 411b is connected,
and the collection path 414b is connected to these individual paths 33. In the collection
path 414b, the tray T is transported from the left side to the right side. A position
in the front-back direction of a substantially half portion of the collection path
414b on the upstream side that includes the connecting part with the individual paths
33, is almost the same as the collection path 414a. On the other hand, a substantially
half portion of the collection path 414b on the downstream side is positioned on the
front side than the collection path 414a, and this part runs parallel to the collection
path 414a in the front-back direction. A downstream end of the collection path 414b
is connected to the bobbin processing device 402.
[0082] In the fifth embodiment, like in the first embodiment, the tray stoppers 422a and
422b are caused to perform the sending operations based on the control according to
the flowcharts shown in FIGS. 4 and 5.
[0083] However, in the fifth embodiment, in the control shown in FIG. 5, the number of the
trays T discharged to the collection path 414a in the cycle U
N is taken as A
N. Moreover, the number of the trays T supplied from the tray supplying section 402a
in the cycle U
N is taken as B
N. Moreover, the number of times the sending operation is canceled among the sending
operations that the tray stopper 422a is caused to perform in the cycle U
N is taken as C
N.
[0084] Moreover, in the control to cause the tray stopper 422b to perform the sending operation,
the number of the trays T that are discharged to the collection path 414b in the cycle
U
N is taken as A
N. Moreover, the number of the trays T supplied from the tray supplying section 402b
in the cycle U
N is taken as B
N. Moreover, the number of times the sending operation is canceled among the sending
operations that the tray stopper 422b is caused to perform in the cycle U
N is taken as C
N.
Sixth Embodiment
[0085] A preferred sixth embodiment of the present invention is explained below. As shown
in FIG. 12, in a yarn winding machine 501 according to the sixth embodiment, a bobbin
processing device 502 is arranged on the left side of a tray transporting device 504,
and a control box 503 is arranged on the right side of the tray transporting device
504. Moreover, the bobbin processing device 502 can supply the trays T from two tray
supplying sections 502a and 502b. That is, the trays T can be supplied from the bobbin
processing device 502 to the winding units 11 from two tray supply outlets. The tray
T supplied from the tray supplying section 502a and the tray T supplied from the tray
supplying section 502b are the one that the yarn supplying bobbin S mounted in each
of them have been subjected to the pre-processing by separate mechanism (pre-processing
device) of the bobbin processing device 502. In the sixth embodiment, different types
of the yarns are wound on each of the yarn supplying bobbins S mounted on the tray
T in the tray supplying sections 502a and 502b.
[0086] The tray transporting device 504 includes two supply paths 511a and 511b, two return
paths 512a and 512b, and two collection paths 514a and 514b.
[0087] The supply path 511a extends in the left-right direction along a plurality of the
winding units 11 arranged on the right side among the winding units 11, and the supply
path 511a is connected to each of the individual paths 33 corresponding to these winding
units 11 arranged on the right side. The supply path 511b is arranged on the left
side of the supply path 511a. The supply path 511b extends in the left-right direction
along a plurality of the winding units 11 among the winding units 11 arranged on the
left side of the winding units 11 that correspond to the supply path 511a, and the
supply path 511b is connected to each of the individual paths 33 corresponding to
these winding units 11 arranged on the left side. The tray T is transported from the
right side to the left side on the supply paths 511a and 511b. Moreover, the tray
transporting device 504 includes tray sensors 521a and 521b that respectively detect
the tray T that has been transported to a downstream end of the respective supply
paths 511a and 511b.
[0088] The return path 512a extends along the left-right direction in the back side of
the supply path 511a. Each ends of the return path 512a is connected to a corresponding
end of the supply path 511a. The tray T is transported from the left side to the right
side on the return path 512a. Moreover, a tray stopper 522a is arranged at a central
portion of the return path 512a. The tray stopper 522a is similar in configuration
and function to the tray stopper 35 (see FIG. 1). Moreover, a bridge breaker 523 is
arranged in a portion that is further downstream than the tray stopper 522a of the
return path 512a. The bridge breaker 523 is similar in configuration and function
to the bridge breaker 36 (see FIG. 1). Moreover, the tray transporting device 504
includes a connection path 515 that connects the tray supplying section 502a to a
portion in the return path 512a between the tray stopper 522a and the bridge breaker
523.
[0089] The return path 512b extends in the left-right direction and is positioned on the
back side of the supply path 511b but on the left side of the return path 512a. Each
ends of the return path 512b is connected to a corresponding end of the supply path
511b. The tray T is transported from the left side to the right side on the return
path 512b. Moreover, an upstream end of the return path 512b is connected to the tray
supplying section 502b.
[0090] A substantially half portion of the collection path 514a on the upstream side (right
side) extends in the left-right direction and is positioned on the front side of the
individual paths 33 to which the supply path 511a is connected, and the collection
path 514a is connected to these individual paths 33. In the collection path 514a,
the tray T is transported from the right side to the left side. A substantially half
portion of the collection path 514a on the downstream side (left side) is positioned
on the front side than the substantially half portion of the collection path 514a
on the upstream side. A downstream end of the collection path 514a is connected to
the bobbin processing device 502.
[0091] The collection path 514b extends in the left-right direction and is positioned on
the front side of the individual paths 33 to which the supply path 511b is connected,
and the collection path 514b is connected to these individual paths 33. In the collection
path 514b, the tray T is transported from the right side to the left side. A downstream
end of the collection path 514b is connected to the bobbin processing device 502.
[0092] In the sixth embodiment, like in the first embodiment, the tray stopper 522a is caused
to perform the sending operation based on the control according to the flowcharts
shown in FIGS. 4 and 5. Moreover, like in the second embodiment, a tray stopper 522b
is caused to perform the sending operation based on the control according to the flowcharts
shown in FIGS. 4 and 8.
[0093] However, in the sixth embodiment, in the control shown in FIG. 5, the number of the
trays T discharged to the collection path 514a in the cycle U
N is taken as A
N. Moreover, the number of the trays T supplied from the tray supplying section 502b
in the cycle U
N is taken as B
N. Moreover, the number of times the sending operation is canceled among the sending
operations that the tray stopper 522a is caused to perform in the cycle U
N is taken as C
N.
[0094] The first to sixth embodiments according to the present invention are explained above;
however, the present invention is not limited to the above first to sixth embodiments
and various modifications thereof can be made within the scope defined in the claims.
[0095] Moreover, in the first embodiment, in a given cycle U, when the tray T is supplied
from the bobbin processing device, if the sending operation is planned after the tray
T is supplied, the last sending operation among the planned sending operations is
canceled; however, the configuration is not limited to this. Some sending operation
other than the last sending operation among the planned sending operations may be
canceled. Same holds true with respect to the sending operation performed by the tray
stopper according to the third, fifth, and sixth embodiments.
[0096] Moreover, in a given cycle U, when the tray T is supplied from the bobbin processing
device, the sending operation needs not be canceled even if the sending operation
is planned after the tray T is supplied. Note that, in this case, the number K
N that is the number of times the tray stopper is caused to perform the sending operation
in the cycle U
N is set to (A
N-1-B
N-1).
[0097] Moreover, in the first embodiment, the number of times the tray stopper 35 is caused
to perform the sending operation in each cycle U is set; however, the configuration
is not limited to this. By using a different method than causing to perform the sending
operation by setting the number of times of performing the sending operation in each
cycle U, the tray stopper 35 can be caused to perform the sending operation at a pace
that corresponds to a difference between the number of the trays T discharged from
the winding units 11 and the number of the trays T supplied directly from the bobbin
processing device 12 to the supply path or to a portion in the return path 32 that
is downstream than the tray stopper 35. Same holds true for the sending operation
performed by the tray stopper 35 according to the third embodiment, the tray stopper
422a according to the fifth embodiment, and the tray stopper 522a according to the
sixth embodiment.
[0098] In the second embodiment, the tray stopper 35 is caused to perform the sending operation
when the tray T is discharged from either of the winding units 11; however, the configuration
is not limited to this. By using a different method, when the tray T has been discharged,
than causing the tray stopper 35 to perform the sending operation, the tray stopper
35 can be caused to perform the sending operation at a pace that corresponds to a
difference between the number of the trays T discharged from the winding units 11
and the number of the trays T supplied directly from the bobbin processing device
to the supply path or to a portion in the return path that is upstream than the tray
stopper. Same holds true for the sending operation performed by the tray stopper 35
according to the fourth embodiment and the tray stopper 522b according to the sixth
embodiment.
[0099] Moreover, in the first to sixth embodiments, after the yarn winding machine starts
operating, in a period while no tray T is detected by the tray sensor arranged at
the downstream end part of the supply path, the tray stopper is caused to perform
the sending operation at a maximum pace by executing a maximum sending control; however,
the configuration is not limited to this. For example, instead of executing the maximum
sending processing, the tray stopper can be caused to perform the sending operation
at a fast pace ("second sending pace" according to the present invention) that is
slower than the maximum pace but faster than the pace at which the normal sending
processing is performed. Alternatively, after the yarn winding machine starts operating,
even in a period while no tray T is detected by the tray sensor arranged at the downstream
end part of the supply path, the tray stopper can be caused to perform the sending
operation by executing the normal sending processing. That is, in this case, the Steps
S101 and S102 are absent from the flowchart of FIG. 4, and the process procedure can
be advanced to Step S103 when the operation of the yarn winding machine is started.
[0100] In the first embodiment, when the bobbin processing device 12 returns to normal from
the stopped state, the tray stopper is caused to perform the sending operation by
executing the normal sending control, and thereafter, the number of the trays T discharged
from the winding units 11 is counted. Then, if the count of the trays T exceeds a
threshold value, from this time point, in a period while no tray T is detected by
the tray sensor 29, the tray stopper is caused to perform the sending operation by
executing the maximum sending control. However, the configuration is not limited to
this.
[0101] For example, irrespective of the number of the trays T discharged from the winding
unit 11 after the bobbin processing device 12 returns to normal from the stopped state,
the tray stopper 35 can be caused to perform the sending operation by executing the
maximum sending control in a period from when the bobbin processing device 12 returns
to normal from the stopped state and while no tray T is detected by the tray sensor
29.
[0102] Instead of executing the maximum sending processing, the tray stopper can be caused
to perform the sending operation at a fast pace ("second sending pace" according to
the present invention) that is slower than the maximum pace but faster than the pace
at which the normal sending processing is performed. Alternatively, irrespective of
the number of the tray T discharged from the winding unit 11 after the bobbin processing
device returns to normal from the stopped state, the tray stopper can be caused to
perform the sending operation by executing the normal sending processing in a period
from when the bobbin processing device returns to normal from the stopped state and
while no tray T is detected by the tray sensor.
[0103] The tray stopper 35 according to the second embodiment, the tray stopper 35 according
to the fourth embodiment, and the tray stopper 522b according to the sixth embodiment
are caused to further perform the sending operation each time the sending operation
is performed Ma times; however, the configuration is not limited to this. The tray
stopper can be caused to perform the sending operation simply when the tray T is discharged
from either of the winding units.
[0104] Moreover, in the first to sixth embodiments, the MCU 51, the winding control sections
52, the bobbin processing control section 53, the transportation control section 54,
the sending control section 55, the communication board 56, and the tray sensor are
connected to each other and can perform communication with each other; however, the
configuration is not limited to this. Among these components, it is sufficient that
at least the sending control section 55, the winding control sections 52, the bobbin
processing control section 53, and the tray sensor can perform communication with
each other. Alternatively, for example, the MCU 51 can perform communication with
the winding control sections 52, the bobbin processing control section 53, the transportation
control section 54, the sending control section 55, and the tray sensor. In this case,
the MCU 51 can receive a signal from each of the winding control sections 52, the
bobbin processing control section 53, and the tray sensor, and send a signal to the
sending control section 55 based on the received signal. With this configuration,
the sending control section 55 is able to perform the above control.
[0105] The configuration of the tray controlling device is not limited to that of the tray
stopper 35. The tray controlling device can be a device that can send the tray T by
driving the conveyor device 39, which is in a stopped state, at a necessary timing.
Alternatively, the tray controlling device can be a device that pushes the tray T
present on the conveyor device 39, which is in a stopped state, at a necessary timing.
[0106] A yarn winding machine according to one aspect of the present invention includes
a plurality of winding units; a bobbin processing device; a tray transporting device;
and a control device. Each of the winding units unwinds a yarn from a yarn supplying
bobbin and winds the unwound yarn into a package. The bobbin processing device performs
pre-processing on the yarn supplying bobbin that is mounted on a tray and collects
the tray on which an empty bobbin from which the yarn has been unwound in the winding
unit is mounted. The tray transporting device transports the tray between the winding
units and the bobbin processing device. The tray transporting device includes a supply
path; a collection path; a return path; a conveyor device; and a tray controlling
device. The supply path is a path on which the tray on which the yarn supplying bobbin
has been mounted is transported to the winding units. The collection path is a path
on which the tray that has been discharged from the winding units is transported to
the bobbin processing device. The return path is a path on which the tray that has
been transported to a downstream end of the supply path is transported so as to be
returned to an upstream end of the supply path. The conveyor device transports the
tray along the supply path, the collection path, and the return path. The tray controlling
device is arranged on the return path and sends the tray present on the return path
to the upstream end of the supply path. The bobbin processing device supplies the
tray to any one of the supply path and the return path. The control device causes
the tray controlling device to perform a sending operation of sending the tray at
a first sending pace that corresponds to a difference between a pace at which the
trays are discharged from the winding units to the collection path and a pace at which
the trays are supplied from the bobbin processing device directly to the supply path
or to a portion in the return path that is downstream than the tray controlling device.
[0107] In the above yarn winding machine, the tray controlling device is arranged on the
return path, and the tray controlling device is caused to send the tray at the first
sending pace that corresponds to the difference between the pace at which the trays
are discharged from the winding units to the collection path (e.g., number of the
trays discharged per predetermined time) and the pace at which the trays are supplied
from the bobbin processing device directly to the supply path or to the portion in
the return path that is downstream than the tray controlling device (e.g., number
of the trays supplied per predetermined time. Accordingly, while supplying the trays
(yarn supplying bobbins) of the number necessary for the winding units, because the
trays that are in excess are left in the return path, the trays can be prevented from
repeatedly and needlessly being transported on the supply path and the return path.
[0108] In the above yarn winding machine, the tray transporting device includes a tray sensor
arranged at a downstream end part of the supply path and that detects the tray. The
control device causes the tray controlling device to perform the sending operation
at a second sending pace that is faster than the first sending pace in a period from
when winding starts in the winding units and while no tray is detected by the tray
sensor, and causes the tray controlling device to perform the sending operation at
the first sending pace after a tray is detected by the tray sensor.
[0109] Immediately after the start of the winding of the winding units, because sufficient
number of the trays are not being supplied to each of the winding units, the number
of the trays present in the return path is small. Therefore, even if the sending operation
is performed, the trays may not be actually sent. Moreover, when the sufficient number
of the trays is supplied to all the winding units, the tray that is transported to
the downstream end of the supply path without being supplied to any of the winding
units is detected by the tray sensor.
[0110] Therefore, in the above yarn winding machine, after the start of the winding of the
winding units and until a tray is detected by the tray sensor, the tray controlling
device is caused to perform the sending operation at the second sending pace that
is faster than the first sending pace. As a result, after the start of the winding
of the winding units, the time required to supply the sufficient number of the trays
to each of the winding units can be shortened as much as possible. Then, after a tray
is detected by the tray sensor, the tray controlling device is caused to perform the
sending operation at the first sending pace. Accordingly, while supplying the trays
of the number necessary for the winding units, the trays can be prevented from repeatedly
and needlessly being transported on the supply path and the return path.
[0111] In the above yarn winding machine, the tray transporting device includes a tray sensor
arranged at a downstream end part of the supply path and that detects the tray. The
control device causes the tray controlling device to perform the sending operation
at a second sending pace that is faster than the first sending pace in at least a
part of a period from when the bobbin processing device returns to normal from a stopped
state and while no tray is detected by the tray sensor, and causes the tray controlling
device to perform the sending operation at the first sending pace after a tray is
detected by the tray sensor.
[0112] During the time from stopping the operation of the bobbin processing device until
the bobbin processing device returns to normal, the winding of the yarn is performed
in the winding units, and the trays present in the supply path are supplied to each
of the winding units. Therefore, immediately after the bobbin processing device returns
to normal from the stopped state, it may happen that the number of the trays in the
return path is small. Moreover, in this case, the trays may not be actually sent even
if the sending operation is performed. Moreover, after the bobbin processing device
returns to normal, when the sufficient number of the trays is supplied to all the
winding units, the tray that is transported to the downstream end of the supply path
without being supplied to any of the winding units is detected by the tray sensor.
[0113] Therefore, in the above yarn winding machine, the tray controlling device is caused
to perform the sending operation at the second sending pace that is faster than the
first sending pace in at least a part of the period from when the bobbin processing
device returns to normal from the stopped state and while no tray is detected by the
tray sensor. As a result, after the bobbin processing device returns to normal, the
time required to supply the sufficient number of the trays to each of the winding
units can be shortened as much as possible. Then, after a tray is detected by the
tray sensor, the tray controlling device is caused to perform the sending operation
at the first sending pace. Accordingly, while supplying the trays of the number necessary
for the winding units, the trays can be prevented from repeatedly and needlessly being
transported on the supply path and the return path.
[0114] In the above yarn winding machine, the control device causes the tray controlling
device to perform the sending operation at the first sending pace when the bobbin
processing device returns to normal from the stopped state, and counts number of the
trays discharged from the winding units after the bobbin processing device returns
to normal from the stopped state. When the count of the trays exceeds a threshold
value, from this time point, the control device causes the tray controlling device
to perform the sending operation at the second sending pace in a period while no tray
is detected by the tray sensor.
[0115] If the duration from stopping the operation of the bobbin processing device until
the bobbin processing device returns to normal is short, because the number of the
trays on each of which the yarn supplying bobbin from which the yarn had been unwound
in the winding unit is mounted to be discharged to the collection path (number of
the trays to be supplied to the winding units) during this duration is small, a situation
that the sufficient number of the trays is not supplied to each of the winding units
does not occur.
[0116] Therefore, in the above yarn winding machine, when the bobbin processing device returns
to normal from the stopped state, the tray controlling device is caused to perform
the sending operation at the first sending pace, and the number of the trays discharged
from the winding units is counted. When the count of the trays exceeds the threshold
value, from this time point, in the period while no tray is detected by the tray sensor,
the tray controlling device is caused to perform the sending operation at the second
sending pace. As a result, after the bobbin processing device returns to normal, if
the sufficient number of the trays is not supplied to each of the winding units, the
time required to supply the sufficient number of the trays to each of the winding
units can be shortened as much as possible.
[0117] On the other hand, if the count of the trays does not exceed the threshold value,
the tray controlling device continues to perform the sending operation at the first
sending pace. Accordingly, it is possible to prevent more than required number of
the trays from being sent by the tray controlling device.
[0118] In the above yarn winding machine, the second sending pace is a maximum pace at which
the tray controlling device can perform the sending operation.
[0119] In the above yarn winding machine, in a situation where no tray is likely to be sent
even if the tray controlling device performs the sending operation, the tray controlling
device is caused to perform the sending operation at the maximum pace. As a result,
the time required to supply the sufficient number of the trays to each of the winding
units can be shortened as much as possible.
[0120] In the above yarn winding machine, the bobbin processing device supplies the tray
to a portion in the return path that is upstream than the tray controlling device.
The control device causes the tray controlling device to perform the sending operation
at least one more time each time the sending operation is performed a predetermined
number of times.
[0121] In the case where the tray is supplied from the bobbin processing device to the portion
in the return path that is upstream than the tray controlling device, only the tray
sent by the tray controlling device is supplied to the supply path. As a result, in
comparison to the case where the tray is supplied from the bobbin processing device
to the supply path or to the portion in the return path that is downstream than the
tray controlling device, an interval between the trays becomes larger. Accordingly,
there is a possibility that the supply of the trays to the winding units is delayed
even if the tray controlling device is caused to perform the sending operation.
[0122] Therefore, in the above yarn winding machine, when only the tray sent by the tray
controlling device is supplied to the supply path, in addition to performing the sending
operation at the first sending pace, the tray controlling device is caused to perform
the sending operation at least one more time each time the sending operation is performed
a predetermined number of times. Accordingly, the delay in the supply of the trays
to the winding units can be suppressed.
[0123] In the above yarn winding machine, the control device sets per predetermined cycle
number of times to cause the tray controlling device to perform the sending operation.
Assuming that N is a natural number, when number of the trays discharged from the
winding units in [N-1]-th cycle is A
N-1 and number of the trays supplied in [N-1]-th cycle from the bobbin processing device
directly to the supply path or to the portion in the return path that is upstream
than the tray controlling device is B
N-1, the control device sets the number of times to cause the tray controlling device
to perform the sending operation in N-th cycle to (A
N-1-B
N-1).
[0124] In the above yarn winding machine, because the number of times to cause the tray
controlling device to perform the sending operation in N-th cycle is set to (A
N-1-B
N-1), the tray controlling device can send the tray at the first sending pace.
[0125] In the above yarn winding machine, the control device cancels, in each cycle, when
the tray is supplied from the bobbin processing device directly to the supply path
or to the portion in the return path that is downstream than the tray controlling
device, if the sending operation is planned after the tray is supplied, any of the
planned sending operations. The control device sets, when C
N-1 number of the sending operations among the sending operations planned in [N-1]-th
cycle are canceled, the number of times to cause the tray controlling device to perform
the sending operation in N-th cycle higher by C
N-1.
[0126] In the above yarn winding machine, in each cycle, when the tray is supplied from
the bobbin processing device directly to the supply path or to the portion in the
return path that is downstream than the tray controlling device, if the sending operation
is planned after the tray is supplied, any of the planned sending operations is canceled.
As a result, the number of the trays supplied to the supply path in each cycle can
be set to an appropriate number. Moreover, when C
N-1 number of the sending operations among the sending operations planned in [N-1]-th
cycle are canceled, the number of times to cause the tray controlling device to perform
the sending operation in N-th cycle is set higher by C
N-1. As a result, even when the sending operation is canceled to cope with the supply
of the trays from the bobbin processing device, shortage of the trays does not occur.
[0127] In the above yarn winding machine, the control device includes a plurality of winding
control sections; a bobbin processing control section; and a sending control section.
Each of the winding control sections is arranged in a corresponding one of the winding
units and controls the corresponding winding unit. The bobbin processing control section
controls the bobbin processing device. The sending control section controls the tray
controlling device. The sending control section is communicably connected to the winding
control sections and communicably connected to the bobbin processing control section.
[0128] To cause the tray controlling device to send the tray at a pace explained above,
it is necessary for the sending control section to grasp information about the number
of the trays supplied from the bobbin processing device and information about the
number of the trays discharged from the winding units. In the above yarn winding machine,
because the sending control section is communicably connected to the winding control
sections and communicably connected to the bobbin processing control section, the
sending control section can perform control while grasping the above information.
[0129] According to the present invention, while supplying necessary trays to the winding
units, because the trays that are in excess are left in the return path, the trays
can be prevented from repeatedly and needlessly being transported on the supply path
and the return path.
[0130] In the above explanation, the meaning of "a plurality of" also includes "a predetermined
number of".
[0131] Although the invention has been explained with respect to specific embodiments for
a complete and clear disclosure, the appended claims are not to be thus limited but
are to be construed as embodying all modifications and alternative constructions that
may occur to one skilled in the art that fairly fall within the scope of the claims.