Information
-
Patent Grant
-
6267149
-
Patent Number
6,267,149
-
Date Filed
Thursday, March 23, 200024 years ago
-
Date Issued
Tuesday, July 31, 200123 years ago
-
Inventors
-
Original Assignees
-
Examiners
- Calvert; John J.
- Muromoto, Jr.; Robert H.
Agents
-
CPC
-
US Classifications
Field of Search
-
International Classifications
-
Abstract
A connection yarn inserting apparatus for manufacturing three-dimensional fabric. The apparatus inserts connection yarns into a lamination of fiber layers in a direction transverse to each fiber layer. The apparatus has insertion needles for inserting connection yarns into the lamination. The insertion needles are moved between a standby position, where the needles are separated from the lamination, and an operational position, where the needles penetrate the lamination. The lamination is clamped by a pair of opposed pressing members. The pressing members are operated by air cylinders. A stopper can be moved into and away from the moving range of the piston rod of each of the air cylinders. The stopper is actuated by an actuator. When the stoppers in the moving range of the associated piston rod, the stopper limits the stroke of the piston rod. This reduces the time necessary to move the associated piston rod and increases productivity.
Description
BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for inserting connection yarns into a three-dimensional fabric, and more particularly to an apparatus for simultaneously inserting a plurality of connection yarns into a fiber lamination. Specifically, the apparatus is used to manufacture a fiber lamination that is folded in at least two directions and has connection yarns that extend perpendicularly to each layer of the lamination.
Japanese Unexamined Patent Publication No. 8-218249 discloses a method for manufacturing a three-dimensional fabric. In this method, pins are provided with a predetermined pitch between one another on a frame to surround an area where connection yarns are inserted into a fiber lamination. Fiber layers are formed by folding back fibers at each pin to form a lamination. A row of insertion needles insert connection yarns, which are perpendicular to the lamination, into the lamination.
Connection yarns are typically inserted into a lamination in the following manner. A frame holding the lamination is first secured to a support table. The support table is moved by a predetermined pitch such that the lamination passes the movement range of connection yarn insertion needles. When insertion of the connection yarns in a predetermined area of the lamination is completed, the frame, together with the lamination, is removed from the support table. Then, another table to which a lamination is attached is fixed to the support table. Connection yarns are then inserted into the new lamination.
When inserting connection yarns into a lamination, a row of first needles, to each of which a connection yarn is engaged, are inserted into the lamination. After the needles penetrate the lamination and the needle eyes are located at the opposite side of the lamination from the standby position of the insertion needles, the needles are slightly retracted. This forms a yarn loop at the distal end of each insertion needle at the opposite side of the lamination. A second needle to which a lock yarn is engaged is reciprocated such that the lock yarn is inserted into each loop. The first needles are pulled back in this state, which tightens the lamination and prevents the connection yarns from being loosened. The second needle has a latch at its distal end and is reciprocated by a driving device. The driving device is generally an air cylinder or a lead screw mechanism, which is actuated by a servomotor.
Three-dimensional fabrics are typically used to form a frame member of a composite. The strength of such composite largely depends on the properties of the three-dimensional fabric. To increase the strength of the composite, the density of the fiber (lines) in the fabric must be increased and the lines must be orderly. Accordingly, laminations must be tightly bundled by connection yarns and the tightening force of the connection yarns must be equalized.
Japanese Unexamined Patent Publication No. 10-325043 discloses a connection yarn supplying apparatus having a tension adjusting means and a brake means. The tension adjusting means includes two stationary rollers and a movable roller. The stationary rollers are located at predetermined positions and are perpendicular to the inserting direction of the connection yarns. The movable roller is supported by a pivotable support arm and is parallel to the stationary rollers. The support arm is actuated by an air cylinder. the connection yarn is bent and held between the stationary rollers and the movable roller. To control the tension of a connection yarn, the brake means is first activated. The air cylinder then applies a force in a predetermined direction to the support arm to tension the connection yarn. The tension of the connection yarn is controlled by adjusting the pressure of air in the air cylinder.
A three-dimensional fabric may be manufactured by inserting connection yarns into a lamination that is supported only by a frame. However, the process of inserting and removing needles is likely to loosen the fibers of the lamination, which degrades the characteristics of the material when a composite is formed from the lamination. The apparatus of the publication No. 8-218249 has an apparatus for overcoming this drawback. That is, the apparatus of the publication has first and second pressing members to sandwich a lamination in the vicinity of the inserting area of the row of first needles. Connection yarns are inserted into the lamination while the pressing members are holding the laminate. The first and second pressing members are moved between an operation position and a standby position. When at the operational position, the pressing members hold the lamination. When at the standby position, the pressing members do not engage the laminate.
A three-dimensional fabric with high density is obtained by setting the pitch of the connecting yarns to three millimeters. Therefore, if the length of a lamination is sixty centimeters and the pitch of the connection yarns is three millimeters, there will be two hundred insertion cycles. The above described apparatuses include air cylinders and lead screw mechanisms. A lead screw mechanism is actuated by a servomotor. The first needles, the position of which must be relatively accurately determined, and the second needle, which is moved by a relatively great distance, are actuated by lead screw mechanism. The tension adjusting means and first and second pressing members, which requires a pressure control, are actuated by air cylinders.
However, if an air cylinder is used for moving a member, it is difficult to increase the moving speed while maintaining the applied pressure. While inserting connection yarns into a lamination, the pressing members must be separated from the lamination when the lamination is moved by a predetermined pitch. When moving the lamination by the predetermine pitch, the separation distance between the lamination and the pressing members may be a minimum distance. However, since the lamination is secured to the frame by the support pins, if the pressing members are retracted by the minimum distance when setting the frame on a predetermined position of the yarn inserting apparatus, the pins interfere with the pressing members. Therefore, the standby position of the pressing members is separated from the lamination such that the pressing members do not interfere with the support pins. As a result, the moving distance of the pressing members is increased, which extends the time required for inserting connection yarns. Accordingly, productivity is lowered.
The movable roller of the tension adjusting means for connection yarns is supported by the support arm. The support arm is actuated by an air cylinder. The support arm therefore cannot be moved quickly, which also lowers productivity.
The apparatuses of the publications can process only be one frame of lamination at a time. Therefore, the insertion of connection yarns must be prepared every time a new frame is set in the apparatus. Specifically, the end of each connection yarn, which is inserted in the corresponding first needle, must be fixed to the frame, which increases the time required for manufacturing three-dimensional fabric. Productivity is lowered accordingly.
The second needle for a lock yarn is actuated by the lead screw mechanism, which is actuated by a servomotor. The moving speed of the lock yarn needle is therefore not as fast as desired. Thus, there is a demand for a lock yarn needle that moves faster to improve productivity.
SUMMARY OF THE INVENTION
Accordingly, it is an objective of the present invention to provide a connection yarn inserting apparatus that shortens the time required for inserting connection yarns when manufacturing three-dimensional fabrics to improve productivity.
To achieve the foregoing and other objectives and in accordance with the purpose of the present invention, a connection yarn inserting apparatus for manufacturing three-dimensional fabric is provided. The apparatus inserts a connection yarn into a lamination, which is formed by laminating a plurality of fiber layers and has fibers extending in at least two different directions, in a direction transverse to the fiber layers. The apparatus includes a frame for holding the lamination, a needle for inserting the connection yarn into the lamination held by the frame, a first pressing member located at the same side of the lamination as the standby position of the insertion needle, a first air cylinder for moving the first pressing member between an operational position, a second pressing member located at the opposite side of the lamination relative to the first pressing member, a second air cylinder for moving the second pressing member between an operational position, a stopper that is engageable with a piston rod of at least one of the first and second air cylinders, and an actuator for actuating the stopper. The insertion needle moves in an advancement direction and a retraction direction between a standby position, where the insertion needle is separated from the lamination, and an operation position, where the insertion needle penetrates the lamination. The first pressing member is moved in the moving direction of the insertion needle to and from the vicinity of an insertion location of the insertion needle. The first pressing member engages the lamination in the vicinity of an insertion location of the insertion needle and presses the lamination in the advancing direction of the insertion needle, and a standby position, where the first pressing member is separated from the lamination. The second pressing member is moved in the moving direction of the insertion needle to and from the vicinity of the insertion location of the insertion needle. The second pressing member engages the lamination and presses the lamination in the retraction direction of the insertion needle, and a standby position, at which the second pressing member is separated from the lamination. When the stopper is engaged with the piston rod, the stopper limits the movement of the piston rod in the retraction direction to directly vary the stroke of the piston rod and the corresponding pressing member.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention that are believed to be novel are set forth with particularity in the appended claims. The invention, together with objects and advantages thereof, may best be understood by reference to the following description of the presently preferred embodiments together with the accompanying drawings in which:
FIG.
1
(
a
) is a diagrammatic side view illustrating a connection yarn inserting apparatus according to a first embodiment;
FIG.
1
(
b
) is an enlarged partial cross-sectional view showing a coupling portion of a carrier table;
FIG.
2
(
a
) is a diagrammatic plan view showing the apparatus of FIG.
1
(
a
);
FIG.
2
(
b
) is an enlarged partial view showing a wheel of the table of FIG.
2
(
a
);
FIG.
3
(
a
) is an enlarged partial view of FIG.
1
(
a
);
FIG.
3
(
b
) is an enlarged partial view showing the brake means of FIG.
3
(
a
);
FIG. 4
is a diagrammatic front view illustrating the apparatus of FIG.
1
(
a
);
FIG. 5
is an enlarged partial plan view showing the apparatus of FIG.
1
(
a
);
FIG. 6
is a diagrammatic front view showing an actuation mechanism for connection yarn insertion needles of the apparatus shown in FIG.
1
(
a
);
FIG. 7
is an enlarged partial cross-sectional view showing a supporting structure of the carrier table;
FIG. 8
is an enlarged partial view showing a lamination pressing member of FIG.
3
(
a
);
FIG. 9
is a diagrammatic front view illustrating an actuation mechanism for perforation needles;
FIG. 10
is a diagrammatic front view illustrating a tension applying mechanism for connection yarns;
FIG. 11
is a diagrammatic front view illustrating a lamination pressing mechanism;
FIG. 12
is a diagrammatic front view illustrating a lamination pressing mechanism and a lock yarn inserting mechanism;
FIG.
13
(
a
) is a plan view showing the lock yarn inserting mechanism of
FIG. 12
;
FIG.
13
(
b
) is a plan view showing a supporting state of the rod fixing member;
FIG.
13
(
c
) is an enlarged partial view of
FIG. 12
;
FIGS.
14
(
a
),
14
(
b
),
14
(
c
) are side views for showing the operation of a press plate;
FIG. 15
is a diagrammatic view showing the insertion of a lock yarn;
FIGS.
16
(
a
),
16
(
b
),
16
(
c
) are side views showing the operation of the press block;
FIGS.
17
(
a
) and
17
(
b
) are plan views for showing the operation of the carrier tables;
FIGS.
18
(
a
),
18
(
b
) are diagrammatic views for showing the operation of the lock yarn insertion needle according to a second embodiment;
FIG.
18
(
c
) is diagrammatic view for showing the operation of the lock yarn insertion needle according to first embodiment; and
FIG. 19
is a front view showing a lamination pressing mechanism and a lock yarn inserting mechanism according to the second embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first embodiment according to the present invention will now be described with reference to
FIGS. 1
to
17
(
b
).
As shown in FIGS.
1
(
a
) and
2
(
a
), a connection yarn inserting apparatus
1
includes a lamination conveying mechanism
2
, a first feeding mechanism
3
(see FIG.
1
(
a
)) for connection yarns, a connection yarn tension applying mechanism
4
, a first actuation mechanism
5
for inserting perforation needles, a second actuation mechanism
6
for inserting connection yarn needles, a lamination pressing mechanism
7
, a lock yarn inserting mechanism
8
and a second feeding mechanism
9
for feeding lock yarn (only shown in FIG.
2
).
Carrier tables
10
, the number of which is three in this embodiment, are located on the conveying mechanism
2
. Each carrier table
10
supports a lamination F. The structure of the connection yarn feeding mechanism
3
is similar to that of Japanese Unexamined Patent Publication No. 10-325043. That is, the feeding mechanism
3
transmits the rotation of motors to bobbins, about each of which a connection yarn z is wound, through a sliding transmission means. Accordingly, each bobbin feeds a yarn. Further, the feeding mechanism
3
applies a predetermined tension to each connection yarn z.
As shown in FIGS.
2
(
a
),
5
and
6
, the lamination conveying mechanism
2
includes support rails
12
a
,
12
b
, which extend in the longitudinal direction of a body frame
11
. The rails
12
a
,
12
b
are fixed to the body frame
11
through support brackets
13
. Each carrier table
10
includes a table body
14
, which is a substantially rectangular frame. Wheels
14
a
, the number of which is six in this embodiment, are attached to the sides of the table body
14
. Each carrier table
10
is supported on the rails
12
a
,
12
b
through the wheels
14
a
. The rails
12
a
,
12
b
function as a carrier table guide mechanism for moving the tables
10
in the direction of the row of the tables
10
. The rails
12
a
,
12
b
have pointed cross-section as shown in FIG.
7
. Each wheel
14
a
has a V-shaped groove to engage the rails
12
a
,
12
b.
A frame
15
is attached to the table body
14
by removable fasteners such as bolts. The frame
15
includes support pins
15
a
to support the lamination F. Each table body
14
includes rear and front couplers
16
a
,
16
b
. Each coupler
16
a
,
16
b
is connected to a mating coupler
16
b
,
16
a
to connect a pair of adjacent carrier tables
10
. As shown in FIGS.
1
(
b
),
3
(
a
) and
5
, each rear coupler
16
a
is located at the rear end of the corresponding table body
14
, and each front coupler
16
b
is located at the front end of the corresponding table body
14
. The couplers
16
a
,
16
b
are formed such that the front coupler
16
b
is located over the corresponding rear coupler
16
a
. Each coupler
16
a
,
16
b
has a hole
17
, which is aligned with the hole of the mating coupler
16
b
,
16
a
. A coupler pin
18
is fitted in the aligned holes
17
to couple an adjacent pair of carrier tables
10
. FIG.
1
(
b
) is an enlarged cross-sectional view showing a pair of the couplers
16
a
,
16
b.
As shown in
FIGS. 5
,
6
and
7
, the body frame
11
includes a guide rail
19
to correspond to the left support rail
12
a
. The guide rail
19
extends parallel to the support rail
12
a
. A screw shaft
20
of a lead screw mechanism extends parallel to the guide rail
19
. A driven pulley
21
is fixed to an end of the screw shaft
20
(see
FIG. 5
) to rotate integrally with the shaft
20
. A servomotor
23
is attached to the body frame
11
by a bracket
22
as illustrated in FIGS.
1
(
a
) and
4
. The servomotor
23
is located below the driven pulley
21
. A drive pulley
24
is fixed to the drive shaft of the servomotor
23
to rotate integrally with the drive shaft. The drive pulley
24
is coupled to the driven pulley
21
by a belt
25
. Therefore, the screw shaft
20
is rotated by the servomotor
23
through the drive pulley
24
, the belt
25
and the driven pulley
21
.
A lead screw nut
26
of the lead screw mechanism has a guide member
27
at the side facing the guide rail
19
. The guide member
27
engages and slides on the guide rail
19
. An actuator, which is air cylinder
28
in this embodiment, is located below the guide member
27
. A piston rod
28
a
of the air cylinder
28
functions as a coupler. The piston rod
28
a
engages a hole
14
b
formed in the front wall of the table body
14
. The hole
14
b
functions as an engagement member. The piston rod
28
a
is moved between an engagement position and a standby position by the air cylinder
28
. The piston
28
a
engages the hole
14
b
when at the engagement position and is separated from the hole
14
b
when at the standby position.
The screw shaft
20
is longer than the table body
14
. The lead screw nut
26
is moved between a position facing the second actuation mechanism
6
and a position upstream the second actuation mechanism
6
. Also, the lead screw nut
26
is moved downstream the second actuation mechanism
6
by a distance greater than the length of the table body
14
. When the lead screw nut
26
is moved downstream, the piston rod
28
a
engages the engagement hole
14
b.
When the servomotor
23
rotates in the forward direction, the screw shaft
20
is rotated to move the lead screw nut
26
to the left as viewed in FIG.
5
. In other words, the screw shaft
20
is rotated to move the lead screw nut
26
in the moving direction of the carrier tables
10
. When the servomotor
23
is rotated in the reverse direction, the screw shaft
20
is rotated such that the lead screw nut
26
is moved to the right as viewed in FIG.
5
. In other words, the screw shaft
20
is rotated such that the lead screw nut
26
approaches the connection yarn feeding mechanism
3
. The screw shaft
20
, the lead screw nut
26
, the air cylinder
28
, the driven pulley
21
, the drive pulley
24
, the belt
25
and the servomotor
23
form a conveying device of the laminations F to move the carrier tables
10
by a predetermined pitch. The conveying device causes the laminations F to consecutively pass the insertion position of the connection yarns z.
As shown in Figs.
1
(
a
) and
2
(
a
), the first actuation mechanism
5
for perforation needles and the second actuation mechanism
6
for connection yarn needles are located at the approximate center of the body frame
11
adjacent to each other. The second actuation mechanism
6
is located downstream (to the left as viewed in FIG.
1
(
a
)) the second actuation mechanism
5
in the moving direction of the carrier tables
10
. The actuation mechanisms
5
,
6
are located on a movable support frame
29
, which moves relative to the body frame
11
in the longitudinal direction of the body frame
11
.
As shown in
FIGS. 4 and 6
, a pair of rails
30
are fixed on the body frame
11
. The movable frame
29
is supported on the rails
30
through linear guide blocks
31
to move relative to the body frame
11
. As shown in FIGS.
3
(
a
) and
5
, a pair of air cylinders
33
are fixed to the body frame
11
by brackets
32
. The air cylinders
33
are located in the vicinity of the movable support frame
29
and downstream of the frame
29
. As shown in
FIG. 8
, the movable support frame
29
is coupled to a piston rod
33
a
of each air cylinder
33
and reciprocated by a distance that is equal to the pitch of the perforation needle and the connection yarn insertion needles.
FIG. 6
is a diagrammatic front view showing the actuation mechanism
6
for inserting the connection yarn needles. The actuation mechanism
5
for the perforation needles and the tension applying mechanism
4
are not shown in FIG.
6
.
The second actuation mechanism
6
includes the movable support frame
29
as illustrated in
FIG. 6. A
pair of rails
34
are supported by the frame
29
to extend vertically. A screw shaft
35
of a lead screw mechanism is located between the rails
34
. The screw shaft
35
is parallel to the rails
34
. Each rail
34
has a linear guide block
36
. The guide blocks
36
are coupled to each other by a coupler plate
37
. The coupler plate
37
has a lead screw nut
38
, into which the screw shaft
35
is threaded. As shown in
FIG. 8
, a needle support
39
is to the coupler plate
37
at the opposite side from the lead screw nut
38
. Connection yarn insertion needles
40
(hereinafter referred to insertion needles) are fixed to the needle support
39
and are arranged in a row with a predetermined pitch (for example, one to nine millimeters).
A servomotor
42
is fixed to the upper portion of the sidewall of the movable support frame
29
by a support bracket
41
. The servomotor
42
rotates the screw shaft
35
in the forward and reverse directions through a belt transmission mechanism
43
. Accordingly, the needle support
39
is moved integrally with the lead screw nut
38
between a standby position and an operational position. At the standby position, the needles
40
do not engage the lamination F, which is supported by the frame
15
. At the operational position (see FIG.
6
), the needles
40
are inserted into the lamination F such that the needle eyes (not shown) are located at the opposite side of the lamination F. The servomotor
42
rotates the screw shaft
35
such that the insertion needles
40
are moved at an optimum rate when being inserted into the lamination F, when being removed from the lamination F, and when being moved without contacting the lamination F. Specifically, the insertion needles
40
are moved slowly when the needles
40
are contacting the lamination F and quickly when the needles
40
are not contacting the lamination F.
As shown in
FIGS. 5 and 9
, the movable support frame
29
includes a pair of vertical lead screw mechanisms
44
. The lead screw mechanisms
44
extend vertically and form a part of an elevating mechanism of the first actuation mechanism
5
. Each lead screw mechanism
44
includes a shaft
45
. A lead screw groove and a spline are formed on each shaft
45
. A support bearing is directly fitted to each of a pair of nuts
46
a
,
46
b
, which engage the shafts
45
, respectively. Rotating the nuts
46
a
,
46
b
causes the shafts
45
to move axially. The lead screw mechanisms
44
are commercially available (a product of THK Kabushiki Kaisha).
The lead screw nuts
46
a
,
46
b
of the lead screw mechanisms
44
are rotatably supported in the upper portion of the movable support frame
29
. Pulleys
47
,
48
a
are fixed to the nut
46
a
, which is located near the support bracket
41
. The pulleys
47
,
48
a
rotate integrally with the nut
46
a
. A pulley
48
b
is fixed to and rotates integrally with the other nut
46
b
. The pulley
48
a
is coupled to the pulley
48
b
by a belt
49
. A servomotor
50
is fixed to the support bracket
41
adjacent to the servomotor
42
. A drive pulley
51
is fixed to the drive shaft
50
a
of the servomotor
50
. The drive pulley
51
is coupled to the pulley
47
by a belt
52
. When the servomotor
50
is activated, the shafts
45
are either lifted or lowered in a synchronized manner.
As shown in
FIG. 9
, a coupler plate
53
is located between the lower ends of the shafts
45
. A needle support
54
is secured to the coupler plate
53
. Perforation needles
55
are fixed to the needle support
54
and are arranged in a row with a predetermined pitch. The pitch of the perforation needles
55
corresponds to the pitch of the insertion needles
40
. As the shafts
45
are lifted and lowered, the coupler plate
53
is lifted and lowered, which lifts and lowers the perforation needles
55
. A guide roller
29
a
is supported by the movable frame
29
above the perforation needles
55
. The guide roller
29
a
leads connection yarns z to the insertion needles
40
such that the yarns z extend vertically.
FIG. 9
is a diagrammatic front view of the first actuation mechanism
5
and does not show the tension applying mechanism
4
, which is located behind the actuator
5
, and the pressing mechanism
7
, which is located below the actuator
5
.
The servomotor
50
rotates the shafts
45
such that the perforation needles
55
are moved at an optimum rate when being inserted into the lamination F, when being removed from the lamination F, and when being moved without contacting the lamination F. Specifically, the shafts
45
are rotated slowly when the needles
55
are contacting the lamination F and quickly when the needles
55
are not contacting the lamination F.
As shown in FIGS.
1
(
a
) and
3
(
a
), the tension applying mechanism
4
is located upstream of the second actuation mechanism
6
. The tension applying mechanism
4
includes a tension applying device
56
and a brake device
57
. The tension applying device
56
is located in the path of the connection yarns z. The brake device
57
is closer to the feeding mechanism
3
than the tension applying device
56
.
As shown in FIGS.
3
(
a
) and
10
, a support frame
58
is located on the body frame
11
. The support frame
58
is perpendicular to the body frame
11
and is located closer to the feeding mechanism
3
than the movable support frame
29
. The support frame
58
includes a pair of support walls
58
a
, which are spaced from each other by a distance greater than the width of each lamination F. Guide rollers
59
a
to
59
e
are supported by the support walls
58
a
at the same height as the guide roller
29
a
. The guide rollers
59
a
to
59
e
are parallel to one another. The guide rollers
59
a
and
59
b
are located in the vicinity of the feeding mechanism
3
. A guide roller
59
f
is located between and below the guide rollers
59
a
,
59
b.
As shown in
FIG. 10
, a support
58
b
extends from each support wall
58
a
at a position close to the feeding mechanism
3
. A support plate
60
is supported between the supports
58
b
. A pair of air cylinders
61
are pivotably supported by the support plate
60
through brackets. As shown in
FIGS. 3 and 10
, a support shaft
63
(see
FIG. 3
) is located below each air cylinder
61
. Each support shaft
63
is supported by a bracket (not shown). The proximal end of a lever
62
is pivotally supported by each support shaft
63
. The distal end of the lever
62
is pivotally coupled to the piston rod
61
a
of each air cylinder
61
. A support member
64
is pivotally supported by each lever
62
through a shaft
65
.
Brake bars
66
are fixed to the support members
64
to face the guide rollers
59
a
,
59
b
. A V-shaped groove is formed in each brake bar
66
. An elastic member, such as a piece of rubber, is adhered to the V-shaped groove. The air cylinders
61
, the levers
62
, the support members
64
and the brake bars
66
form the brake device
57
. The brake device
57
operates when the tension applying device
56
applies tension to the yarns z. Specifically, the brake device
57
operates with the guide rollers
59
a
,
59
b
to hold the yarns z.
As shown in
FIG. 10
, a support plate
67
extends horizontally and is located in the lower portion of the support frame
58
. The support plate
67
is at a position corresponding to the guide rollers
59
c
,
59
d
and is perpendicular to the guide rail
19
. A pair of moving mechanisms, which are lead screw mechanisms, are located between the upper portion of the support frame
58
and the support plate
67
. Screw shafts
68
a
,
68
b
of the lead screw mechanisms extend vertically. Toothed pulleys
69
a
,
69
b
are fixed to the lower end of the shafts
68
a
,
68
b
, respectively. The pulleys
69
a
,
69
b
rotate integrally with the corresponding shafts
68
a
,
68
b
. The pulleys
69
a
,
69
b
are coupled to each other by a belt
70
such that the pulleys
69
a
,
69
b
rotate in a synchronized manner. A servomotor
72
is fixed to the upper portion of the support frame
58
by a bracket
71
. A drive pulley
73
a
is fixed to the drive shaft of the servomotor
72
. The drive pulley
73
a
is coupled to a driven pulley
73
b
, which is fixed to the screw shaft
68
a
by a belt
74
.
A lead screw nut
75
is threaded to each of the screw shafts
68
a
,
68
b
. A support board
76
is supported between the lead screw nuts. The axis of a piston
77
a
of the air cylinder
77
lies in a vertical plane that perpendicularly bisects the guide rollers
59
c
,
59
d
. In this embodiment, the axis of the piston
77
a
is perpendicular to a plane that includes the axes of the guide rollers
59
c
,
59
d
. A support bracket
78
is fixed to the distal end of the piston rod
77
a
. A movable roller
79
is supported by the bracket
78
to extend parallel to the guide rollers
59
c
,
59
d
. That is, the movable roller
79
is reciprocated by two mechanisms, namely, by the lead screw mechanism actuated by the servomotor
72
and by the air cylinder
77
to change the length of the yarns z between the guide rollers
59
c
,
59
d
. The guide rollers
59
c
,
59
d
, the lead screw mechanism, the servomotor
72
, the air cylinder
77
and the movable roller
79
form the tension applying device
56
.
The pressing mechanism
7
for pressing the lamination F includes a first pressing mechanism
80
and a second pressing mechanism
81
. The pressing mechanism
80
presses the lamination F from the side of insertion of the insertion needles
40
, and the second pressing mechanism
81
presses the lamination F from the other side. The first pressing mechanism
80
includes a first air cylinder
82
, which is fixed to a support plate
83
fixed to the support frame
58
. The first air cylinder
82
is located below the first actuation mechanism
5
. The air cylinder
82
has a piston rod
82
a
, which extends downward. A first pressing member, which is a press plate
85
in this embodiment, is fixed to the distal end of the piston rod
82
a
. The press plate
85
includes a support section
85
a
and a comb section
85
b
. The support section
85
a
has an L-shaped cross-section, and the comb section
85
b
is formed integrally with the support section
85
a
. The comb section
85
b
has teeth (not shown). Grooves are formed on the sides of each tooth to guide the insertion needle
40
and the perforation needle
55
. The press plate
85
is pressed against the lamination F with the insertion needles
40
or the perforation needles
55
held by the comb section
85
b
. As shown in
FIG. 11
, the press plate
85
is slightly shorter (in the left-to-right direction of
FIG. 11
) than the corresponding inner dimension of the frame
15
such that the plate
85
is pressed against the lamination F without engaging the frame
15
.
The press plate
85
is moved between an operational position and a standby position. When at the operational position, the press plate
85
is moved by the air cylinder
82
to engage the lamination F thereby pressing the lamination F in the advancing direction of the insertion needles
40
. When at the standby position, the press plate
85
does not engage the lamination F.
An actuator, which is an air cylinder
87
in this embodiment, is located adjacent to the air cylinder
82
as shown in FIG.
8
. The air cylinder
87
is supported horizontally and has a piston rod
87
a
. A stopper
88
is fixed to the piston rod
87
a
. The stopper
88
is located in the moving range of the piston rod
82
a
of the first air cylinder
82
to limit the retracting movement of the piston rod
82
a
. The air cylinder
87
moves the stopper
88
into and out of the moving range of the piston rod
82
a
. The stroke of the press plate
85
is adjusted among several discrete positions. In this embodiment, the press plate
85
is moved between two positions. Specifically, the press plate
85
is located at one of the positions when the stopper
88
is in the moving range of the piston rod
82
a
. The press plate
85
is located at the other position when the stopper
88
is out of the moving range of the piston rod
82
a.
As shown in
FIGS. 11 and 12
, a pair of support brackets
89
a
,
89
b
are fixed to the sides of the body frame
11
below the support brackets
13
. The support bracket
89
a
supports a screw shaft
90
a
of a lead screw mechanism and a guide rod
91
a
. The support bracket
89
b
supports a screw shaft
90
b
of a lead screw mechanism and a guide rod
91
b
. The screw shafts
90
a
,
90
b
and the guide rods
91
a
,
91
b
extend vertically. Pulleys
92
a
,
92
b
are fixed to the lower ends of the screw shafts
90
a
,
90
b
, respectively. The pulleys
92
a
,
92
b
rotate integrally with the screw shafts
90
a
,
90
b
, respectively. The pulleys
92
a
,
92
b
are coupled to each other by a belt
92
c
. An adjuster wheel
93
is fixed to the screw shaft
90
a
to rotate integrally with the shaft
90
a
. Rotating the wheel
93
causes the shafts
90
a
,
90
b
to rotate in a synchronized manner.
FIGS. 11 and 12
are combined cross-sectional views in each of which left part and right part represent cross-sections at different levels to show the part for lifting and lowering the support frame
96
. Also, the pressing mechanism
80
is not shown in FIG.
12
.
Lead screw nuts
94
a
,
94
b
are threaded to the screw shafts
90
a
,
90
b
, respectively. Blocks
95
are slidably supported by the guide rods
91
a
,
91
b
. The support frame
96
is supported by the nuts
94
a
,
94
b
and the blocks
95
. The support frame
96
is lifted and lowered below the inserting position of the connection yarns. Second air cylinders
97
,
98
are secured to the support frame
96
and are spaced from one another in the moving direction of the carrier tables
10
as shown in FIG.
8
. The air cylinders
97
,
98
have piston rods
97
a
,
98
a
respectively. The piston rods
97
a
,
98
a
project upward. Second pressing members, which are press blocks
99
a
,
99
b
in this embodiment, are fixed to the distal end of the piston rods
97
a
,
98
b
, respectively.
The press blocks
99
a
,
99
b
each have an L-shaped cross-section and have the same length (in the left-to-right direction of
FIG. 11
) as the press plate
85
. A pair of guide rods
100
are fixed to each of the press blocks
99
a
,
99
b
. The guide rods
100
extend through the support frame
96
. The press blocks
99
a
,
99
b
face the comb section
85
b
of the press plate
85
. The press blocks
99
a
,
99
b
are located close to each other such that there is a space in which the insertion needles
40
and the perforation needles
55
enter. The press blocks
99
a
,
99
b
are moved between an operational position and a standby position by the air cylinders
97
,
98
. At the operational position, the press blocks
99
a
,
99
b
engage the lamination F to press the lamination F in the retracting direction of the insertion needles
40
. At the standby position, the press blocks
99
a
,
99
b
are separated from the lamination F.
As shown in
FIG. 8
, a support bracket
101
is attached to the support frame
96
to extend toward the feeding mechanism
3
. An actuator, which is an air cylinder
102
, is horizontally supported on the bracket
101
. The air cylinder
102
has a piston rod
102
a
. A stopper
103
is fixed to the piston rod
102
a
. The stopper
103
is moved into the moving range of the piston rods
97
a
,
98
a
of the second air cylinders
97
,
98
and engage the press blocks
99
a
,
99
b
to limit the retracting movement of the piston rods
97
a
,
98
a
. A step is formed on the upper side of the stopper
103
. The step forms first and second engagement portions
103
a
,
103
b
. The first engagement portion
103
a
is lower than the second engagement portion
103
b
. The first engagement portion
103
a
engages with the first press block
99
a
, which is located further from the connection yarn feeding mechanism
3
than the second press block
99
b
. The second engagement portion
103
b
engages the second press block
99
b.
The stopper
103
is moved in and away from the moving range of the piston rods
97
a
,
98
a
by the air cylinder
102
. The press blocks
99
a
,
99
b
have discretely differing strokes. In this embodiment, the piston rods
97
a
98
a
are moved between two positions, that is, between a position at which the stopper
103
is in the moving range of the piston rods
97
a
,
98
a
and a position at which the stopper
103
is outside the moving range.
As shown in FIGS.
2
(
a
) and
4
, the lock yarn inserting mechanism
8
protrudes laterally from the body frame
11
. As shown in
FIG. 12
, a support frame
104
of the inserting mechanism
8
is supported by the support frame
96
of the press blocks
99
a
,
99
b
. As shown in
FIGS. 12
,
13
, the support frame
104
extends horizontally at a position that is slightly lower than the carrier table
10
and has a pair of pulleys
105
a
,
105
b
. The axes of the pulleys
105
a
,
105
b
are perpendicular to the row of the insertion needles
40
shown in FIG.
6
. An endless belt
106
is engaged with the pulleys
105
a
,
105
b
. Part of the path of the belt
106
is parallel to the row of the insertion needles
40
.
The first pulley
105
a
is located away from the body frame
11
, and the second pulley
105
b
is located near the body frame
11
. The second pulley
105
b
is fixed to a rotary shaft
107
(see
FIG. 12
) to rotate integrally with the shaft
107
. Another pulley
108
is fixed to the other end of the shaft
107
to rotate integrally with the shaft
107
. A servomotor
109
is supported by the support frame
104
below the pulley
105
b
. A drive pulley
110
is fixed to the drive shaft of the servomotor
109
. The drive pulley
110
is coupled to the pulley
108
by a belt
111
. As the servomotor
109
rotates in forward and reverse directions, the belt
106
move accordingly.
The belt
106
is parallel to the row of the insertion needles
40
. The upper portion of the belt
106
is at the same level as the insertion path of the lock yarn P. A fixing member
112
is fixed to the outer surface of the belt
106
. The fixing member
112
fixes a rod
114
to the belt
106
. As shown in FIG.
13
(
a
), a support member, which is the proximal end of the rod
114
, is fixed to the fixing member
112
. A lock yarn insertion needle
113
is fixed to the distal end of the rod
114
. The rod
114
is made of a carbon fiber reinforced resin.
As shown in
FIGS. 12
,
13
(
b
), a guide rail
115
is fixed to the support frame
104
. The guide rail
115
extends horizontally between the upper and lower horizontal portions of the belt
106
. A guide
116
is fixed to the fixing member
112
. The guide
116
slides along the guide rail
115
to prevent the fixing member
112
from being displaced in the lateral direction of the belt
106
. A rod guide
117
is fixed to the support frame
104
by a bracket
118
. The rod guide
117
is located in the vicinity of the row of the insertion needles
40
when the needles
40
are located at the operational position. A guide groove is formed in the upper surface of the rod guide
117
to prevent lateral displacement of the rod
114
. A cover
119
is located above the horizontal portion of the belt
106
to prevent the rod
114
from moving upward.
The servomotors
23
,
42
,
50
,
72
,
109
are electrically connected to and controlled by signals from a controller
120
, which is shown only in FIG.
1
. Each of the air cylinders
28
,
33
,
82
,
87
,
97
,
98
,
102
is connected to an electromagnetic valve. Each valve supplies compressed air to and draws air from the corresponding air cylinder and is electrically connected to the controller
120
. The air cylinders
28
,
33
,
82
,
87
,
97
,
98
,
102
are controlled by signals from the controller
120
and are actuated in a predetermined order.
The operation of the above described connection yarn inserting apparatus
1
will now be described. Before starting the insertion of the connection yarns z, the operational members of the apparatus
1
are located at the standby position or the initial position. For example, as shown in FIGS.
14
(
c
) and
16
(
c
), the stoppers
88
,
103
are at the standby positions, at which they do not engage the press blocks
99
a
,
99
b
. The press plate
85
and the press blocks
99
a
,
99
b
are located at the standby positions, at which the press plate
85
and the press blocks
99
a
,
99
b
do not engage the carrier table
10
.
The preparation of the connection yarn insertion is done as follows. Fiber layers are laminated by a conventional method to form a lamination F, which has fibers arranged in at least two directions, or axes. The lamination F is fixed on the frame
15
. The frame
15
is then secured to one of the carrier tables
10
. The table
10
is placed on the support rails
12
a
,
12
b
at a position upstream from the position of the second actuation mechanism
6
for inserting connection yarn needles. Next, the carrier table
10
is manually moved to a position where the hole
14
b
(
FIG. 7
) faces the piston rod
28
a
of the air cylinder
28
. The air cylinder
28
is fixed to the lead screw nut
26
, which is at the standby position. In this state, the air cylinder
28
is actuated to cause the piston rod
28
a
to engage the hole
14
b
, which permits the carrier table
10
to move integrally with the lead screw nut
26
on the guide rail
19
.
Thereafter, the servomotor
23
, which is shown in FIG.
1
(
a
), rotates the screw shaft
20
in the forward direction. This moves the carrier table
10
with the lead screw
26
to a position where the lamination F faces the perforation needles
55
. The air cylinders
82
,
97
,
98
are then actuated to move the press plate
85
and the press blocks
99
a
,
99
b
to the operational positions as shown in FIGS.
14
(
a
) and
16
(
a
). The air cylinder
87
,
102
are actuated in this state to move the stoppers
88
,
103
to a position shown in FIGS.
14
(
a
) and
16
(
a
) for engaging the press blocks
99
a
,
99
b.
The air cylinders
82
,
97
,
98
are actuated to move the press plate
85
and the press blocks
99
a
,
99
b
to the standby positions shown in FIGS.
14
(
b
) and
16
(
b
), where the press blocks
99
a
,
99
b
engage the stoppers
88
,
103
. The stoppers
88
,
103
are retained at the operational position until the insertion of the connection yarns z to the lamination F is completed. The strokes of the press plate
85
and the press blocks
99
a
,
99
b
are shorter when the stoppers
88
,
103
are at the operational positions than when the stoppers
88
,
103
are at the standby positions.
The connection yarns z are fed from the first feeding mechanism
3
. The yarns z are engaged with the guide rollers
59
a
,
59
f
,
59
b
,
59
c
, movable roller
79
, the guide rollers
59
d
,
59
e
,
29
a
and inserted into the eyes (not shown) of the insertion needles
40
. The end of each yarn z is fixed to the frame
15
. The preparation of the connection yarns z is thus completed.
Prior to the operation of the insertion needles
40
, connection yarns z, each of which has a predetermined length, are bent and reserved between the movable roller
79
and the guide rollers
59
c
,
59
d
. This applies a weak tension to the yarns z such that the yarns z do not become loose. The tension is set weak enough not to disturb the handling of the yarns z. When reserving the connection yarns z, the brake bars
66
are first located at a non-braking position and the movable roller
79
is at the same height as the guide rollers
59
c
,
59
d
. Then, the servomotor
72
rotates in the forward direction to lower the movable roller
79
through the lead screw mechanism.
When the movable roller
79
is lowered to a position for reserving the predetermined length of the connection yarns z, the air cylinder
61
is actuated to move the brake bars
66
to the braking position. The yarns Z are held by the brake bars
66
and the guide rollers
59
a
,
59
b
. Accordingly, the yarns z of the predetermined length are reserved between the movable roller
79
and the guide rollers
59
c
,
59
d.
The insertion of the connection yarns z is started in this state. The air cylinders
82
,
97
,
98
are actuated to move the press plate
85
and the press blocks
99
a
,
99
b
to the operational positions. The press plate
85
and the press blocks
99
a
,
99
b
compresses the lamination F at a position corresponding to the row of the perforation needles
55
. The servomotor
50
rotates in the forward direction to actuate the lead screw mechanism, which moves the perforation needles
55
toward the lamination F. Accordingly, the needles
55
are moved to the operational position and penetrate the lamination F. Thereafter, the servomotor
50
rotates in the reverse direction to move the needles
55
to the standby position.
The perforation needles
55
are moved quickly when separated from the lamination F and are moved slowly when engaging the lamination F. The perforation needles
55
are guided by the comb section
85
b
and penetrate the lamination F at a right angle. Since the fibers forming the lamination F are compressed by the press plate
85
and the press blocks
99
a
,
99
b
, holes formed remain on the lamination F after the perforation needles
55
are removed. Also, since the lamination F is pressed by the press blocks
99
a
,
99
b
at the side where the distal end of the perforation needles
55
protrude, the arrangement of the fibers of the lamination F remain in place during the advancement of the perforation needles
55
.
The air cylinder
33
is actuated to move the movable frame
29
near the first feeding mechanism
3
such that the insertion needles
40
face the holes formed by the perforation needles
55
.
The air cylinder
97
is actuated to move the press block
99
a
to the standby position. Thereafter, the servomotor
42
shown in
FIG. 4
rotates in the forward direction to move the insertion needles
40
toward the lamination F through the corresponding lead screw mechanism. The insertion needles
40
are moved to the operational position. That is, the insertion needles
40
penetrate the lamination F until the eye of each needle
40
is located below the lamination F. After the needles
40
are moved to the end of the movement range, the servomotor
42
rotates in the reverse direction to retract the insertion needles
40
by a predetermined amount. As a result, a loop is formed in each yarn z, which runs from the lamination F to the eye of the associated needle
40
. The loops receive the lock yarn needle
113
. The needles
40
are moved quickly when separated from the lamination F and are moved slowly when engaging the lamination F.
When the servomotor
42
is advancing the insertion needles
40
, the servomotor
72
rotates in the reverse direction at a rate corresponding the speed of the insertion needles
40
. That is, the servomotor
72
lifts the movable roller
79
to advance the sections of the yarns z reserved between the movable roller
79
and the guide rollers
59
c
,
59
d.
When the insertion needles
40
are inserted into the lamination F, the press block
99
a
is moved to the standby position. This decreases the pressing force against the lamination F. However, since the insertion needles
40
are inserted into the holes formed by the perforation needles
55
, the resistance against the insertion needles
40
during insertion is small. This allows the fibers of the lamination F to remain in position.
The servomotor
109
shown in
FIG. 12
rotates in the forward direction to advance the lock yarn needle
113
together with the fixing member
112
. The distal end of the needle
113
consecutively passes through the loops of the yarns z held by the insertion needles
40
. The needle
113
stops when it reaches the edge of the lamination F. The lock yarn P is then hooked to a hook
113
a
at the distal end of the needle
113
. The latch (not shown) of the needle
113
is then closed. The needle
113
is moved back through the loops of the yarns z such that the needle
113
does not hook the loops. As a result, two lines of the lock yarn P extend through the loops of the connection yarns z.
Thereafter, the servomotor
42
rotates in the reverse direction to remove the insertion needles
40
from the lamination F to the standby position. The needles
40
are moved slowly when engaging the lamination F and are moved quickly when separated from the lamination F. The air cylinder
97
then moves the press block
99
a
to the operational position once more. In this state, the tension applying mechanism
4
pulls back the connection yarns z inserted into the lamination F and tightens them with the lock yarn P. The lock yarn P prevents the connection yarns z from being removed from the lamination F.
After the insertion needles
40
are removed from the lamination F, the fiber layers of the lamination F are tightly held together with the connection yarns z. Specifically, the servomotor
72
rotates in the forward direction to lower the movable roller
79
to a predetermined position. Then, air that is compressed to a predetermined pressure is sent to the air cylinder
77
. The air cylinder
77
tightens the fiber layers accordingly. In other words, the fiber layers are tightly held together by the force of the compressed air supplied to the air cylinder
77
.
The air cylinder
33
then returns the movable support frame
29
together with the perforation needles
55
and the insertion needles
40
to the initial position. The air cylinders
82
,
97
,
98
are actuated to move the press plate
85
and the press blocks
99
a
,
99
b
to the standby positions. This completes a single inserting cycle of the connection yarns z.
The motor
23
then rotates in the forward direction to advance the carrier table
10
together with the lead screw nut
26
by a distance equal to the inserting pitch of the yarns z. The perforation needles
55
are opposed to the lamination F at the next connection yarn inserting position. The steps of the connection yarns inserting cycle, which include the reservation of the yarns z, are repeated. During the final insertion of the connection yarns z into a lamination F, the air cylinders
87
,
102
are actuated to move the stoppers
88
,
103
to the standby position after the lamination F is tightened with the yarns z and before the air cylinders
82
,
97
,
98
are actuated. Thereafter, the air cylinders
82
,
97
,
98
are actuated to move the press plate
85
and the press blocks
99
a
,
99
b
to the standby position shown in FIGS.
14
(
c
) and
16
(
c
), where the press plate
85
and the press blocks
99
a
,
99
b
do not engage the stoppers
88
,
103
.
Before insertion of the connection yarn z to the lamination F on a carrier table
10
is completed, a subsequent carrier table
10
, on which an unfinished lamination F is placed, is connected to the rear of the preceding table
10
. Therefore, when the insertion of the connection yarns z in the lamination F on the preceding carrier table
10
is completed, as illustrated by cross-hatching in FIG.
17
(
a
), the next table
10
having another lamination F is coupled to the preceding carrier table
10
.
In this state, the air cylinder
28
is actuated to separate the piston rod
28
a
from the hole
14
b
. Then, the servomotor
23
rotates in the reverse direction to move the lead screw nut
26
to a position where the hole
14
b
of the following table
10
faces the piston rod
28
a
. The air cylinder
28
is actuated to cause the piston rod
28
a
to engage the hole
14
b
, which permits the table
10
to move integrally with the lead screw nut
26
. The servomotor
23
then rotates in the forward direction to advance the following table
10
. Accordingly, the table
10
advances while pushing the preceding table
10
to a position shown in FIG.
17
(
b
), or to a position facing the connection yarn insertion position shown by broken line in FIGS.
17
(
a
) and
17
(
b
). The connection yarn insertion is repeated on the new lamination F in the above described manner.
The connection yarns z, which extend from the first feeding mechanism
3
to the insertion needles
40
via the guide rollers
59
a
to
59
f
, are still connected to the finished lamination F. The connection yarns z are then positioned at the initial insertion position for the next lamination F on the following table
10
. Therefore, the connection yarn insertion to the lamination F on the following table
10
is started without the preparation. Then, the insertion cycle of the connection yarn z is repeated. When the coupler
16
a
of the finished table
10
is moved downstream the second actuation mechanism
6
as shown in FIG.
2
(
a
), the connection yarns z connecting the finished lamination F to the unfinished lamination F are cut. When the tables
10
are disconnected, the table
10
of the finished lamination F is removed from the connection yarn inserting apparatus
1
.
The first embodiment of the
FIGS. 1
to
7
(
b
) has the following advantages.
The first and second pressing members (the press plate
85
and the press blocks
99
a
,
99
b
) are actuated by the air cylinders
82
,
97
,
98
. The strokes of the first and second pressing members are controlled by the actuators (the air cylinders
87
,
102
). Therefore, when the perforation needles
55
and the insertion needles
40
are inserted into the lamination F and when the needles
55
,
40
are removed from the lamination F, the yarn arrangement of the lamination F is not disturbed. Also, the fiber layers of the lamination F are easily tightened by the connection yarns z.
When the connection yarn insertion for the lamination F on a carrier table
10
is completed, a next carrier table
10
, which carries an unfinished lamination F, is moved to the connection yarn insertion position. At this time, the first and second pressing members are moved to the positions shown in FIGS.
14
(
c
) and
16
(
c
). While the insertion of the connection yarns z is performed, the pressing members are moved between the position shown in FIGS.
14
(
a
) and
16
(
a
) and the positions shown in FIGS.
14
(
b
) and
16
(
b
). Therefore, the distance between the lamination F and the pressing members when the stoppers
88
,
103
do not engage the pressing members as shown in FIGS.
14
(
c
) and
16
(
c
) can be relatively large while the stroke of the pressing members between the state of FIGS.
14
(
a
) and
16
(
a
) and the state of FIGS.
14
(b) and
16
(b) relatively small. This reduces the operational time required for inserting connection yarns into laminations F. The productivity of the three-dimensional fabric stitching process is improved, accordingly.
The pressing members are actuated by the air cylinders
82
,
97
,
98
. Compared to an apparatus where the pressing members are actuated by motors and lead screw mechanisms, using the air cylinders
82
,
97
,
98
simplifies the structure. Also, the force pressing the lamination F can be easily adjusted by controlling the pressure of air supplied to the air cylinders
82
,
97
,
98
. Unlike lead screw mechanisms, air cylinders act as cushions, which prevent the lamination F from receiving an excessive force.
The actuators for actuating the stoppers
88
,
103
are the air cylinders
87
,
102
. Compared to a lead screw
10
mechanisms, the air cylinders
87
,
102
simplify the structure.
The second pressing mechanism
81
, together with the support frame
96
, is arranged perpendicular to the lamination F at the inserting position of the connection yarns z. Thus, the position of the second pressing members (the press blocks
99
a
,
99
b
) can be adjusted in accordance with the thickness of the three-dimensional fabric, or the thickness of the lamination F. In other words, the distance between the standby position and the lamination F can be optimized in accordance with the thickness of the lamination F.
The support frame
96
is supported, lifted, and lowered by the lead screw nuts
94
a
,
94
b
of the corresponding lead screw mechanisms. The screw shaft
90
a
of the lead screw mechanism is rotated by the manually operated wheel
93
. The structure of the elevation mechanism of the support frame
96
is therefore simple.
The movable roller
79
forms part of the device for tensioning the connection yarns z. The roller
79
is located between the fixed rollers (the guide rollers
59
c
,
59
d
). The movable roller
79
is moved by the air cylinder
77
and the lead screw mechanism actuated by the servomotor
72
to change the length of the yarn z between the guide rollers
59
c
,
59
d
. That is, the movable roller
79
is moved by two different actuating systems. When reserving the connection yarns z and when the insertion needles
40
are moved by a great amount for inserting the yarns z into the lamination F, the movable roller
79
is quickly moved to a desired position by the servomotor
72
.
If the movable roller
79
is actuated solely by the lead screw mechanism driven by the servomotor
72
, the tension of the connection yarns z could not be controlled various ranges corresponding to the inserting conditions. However, in this embodiment, the tension of the yarns z is controlled by adjusting the pressure of compressed air supplied to the air cylinder
77
. As a result, the tension of the yarn z is optimized depending on the condition of current three-dimensional fabric, which reduces the time required for inserting the connection yarns. Accordingly, productivity is improved.
The apparatus of the embodiment shown in
FIGS. 1
to
7
(
b
) includes the conveying mechanism
2
. The conveying mechanism
2
moves the carrier tables
10
by the predetermined pitch. Specifically, the conveying mechanism
2
causes a table
10
having an unfinished lamination F to follow a table
10
having a finished lamination F such that the tables
10
consecutively pass the connection yarn inserting position. Therefore, unlike prior art apparatuses, the apparatus of
FIGS. 1
to
7
(
b
) consecutively performs connection yarn insertion on multiple laminations without repeating the troublesome preparation. Specifically, the operator only needs to remove a carrier table
10
having a finished lamination F and feed a carrier table
10
having an unfinished lamination F. As a result, the time required for inserting connection yarns is reduced in the total manufacturing time of three-dimensional fabric, which improves productivity.
The adjacent carrier tables
10
are coupled to each other by the couplers
16
a
,
16
b
and are moved integrally. The actuator (the air cylinder
28
) includes the coupling member (the piston rod
28
a
), which engages the engagement portion (hole
14
b
) of the carrier table
10
. The air cylinder
28
is reciprocated by the lead screw nut
26
of the corresponding lead screw mechanism within a range. The range is greater than the corresponding range of the carrier table
10
. The mechanism for moving the carrier table
10
by the predetermined pitch is therefore simple. Also, the pitch can be accurately adjusted.
The carrier tables
10
are held horizontally and are moved to a position below the first actuation mechanism
5
for the perforation needles
55
and the second actuation mechanism
6
for the insertion needles
40
. The lamination conveying mechanism
2
moves the laminations F through the insertion position of the connection yarns z by using the carrier table
10
. The lamination conveying mechanism
2
therefore has a simple structure.
The lock yarn needle
113
inserts the lock yarn P through the loops of the connection yarns z, which are arranged along the row of the insertion needles
40
. The endless belt
106
is engaged with the pulleys
105
a
,
105
b
and actuated by a motor (the servomotor
109
). The lock yarn needle
113
is fixed to the belt
106
by the support member and is linearly moved as the belt
106
is reciprocated. Compared to a case where the lock yarn needle
113
is moved by a lead screw mechanism actuated by a servomotor, the needle
113
moves more. Thus, the time for moving the lock yarn needle
113
in the insertion of connection yarns is reduced, which improves productivity.
The perforation needles
55
are reciprocated by the lead screw mechanism actuated by the servomotor
50
. The perforation needles
55
are moved quickly when the needles
55
are not contacting, or are not engaging, the lamination F. The needles
55
are moved slowly when contacting, or engaging, the lamination F. This reduces the manufacturing time while maintaining the quality of the finished three-dimensional fabric. Accordingly, productivity is improved.
The insertion needles
40
are reciprocated by the lead screw mechanism actuated by the servomotor
42
. The needles
40
are moved quickly when the needles
40
are not contacting, or are not engaging, the lamination F. The needles
40
are moved slowly when contacting, or engaging, the lamination F. In other words, the speed of the needles
40
is varied in each stroke. This reduces the manufacturing time while maintaining the quality of the finished three-dimensional fabric. Accordingly, the productivity is improved.
The support frame
104
of the lock yarn inserting mechanism
8
is fixed to the support frame
96
located on the second pressing mechanism
81
. The support frames
96
,
104
are lifted and lowered integrally. When the position of the second pressing mechanism
81
is adjusted in accordance with the thickness of the lamination F, the position of the lock yarn inserting mechanism
8
, or the position of the lock yarn needle
113
relative to the lamination F, is automatically optimized.
A second embodiment of the present invention will now be described with reference to FIGS.
18
(
a
) to
19
. Unlike the embodiment of
FIGS. 1
to
17
(
b
), the support frame
96
, which forms a part of the second pressing mechanism
81
, is not manually operated but is automatically lifted or lowered. Other structures are the same as the apparatus of
FIGS. 1
to
17
(
b
). As shown in
FIG. 19
, a servomotor
122
is located above the screw shaft
90
a
. Specifically, a bracket
121
is fixed to the support bracket
89
a
and the servomotor
122
is mounted on the bracket
121
. The shaft
90
a
is coupled to the drive shaft of the servomotor
122
by a coupler to rotate integrally with the drive shaft. The servomotor
122
is electrically connected to the controller
120
and is actuated by commands from the controller
120
.
The controller
120
adjusts the vertical position of the support frame
96
in accordance with the thickness of the lamination F prior to insertion of the connection yarn z. Specifically, the controller
120
controls the servomotor
122
based on the thickness of the lamination F, which is entered through an input device (not shown). The relationship between the thickness of the lamination F and the proper position of the support frame
96
is stored in a database stored in a memory. The controller
120
computes the proper position of the support frame
96
in accordance with the inputted lamination thickness referring to the database and controls the servomotor
122
, accordingly.
During insertion of the connection yarns z, the controller
120
controls the servomotor
122
to lift or lower the support frame
96
to lift or lower the lock yarn inserting mechanism
8
. In one insertion cycle of the connection yarns z, the insertion needles
40
are moved to the operational positions such that a loop of the connection yarn z is formed at the distal end of each insertion needle
40
. Until the two lines of the lock yarn P are inserted in the loops as illustrated in FIG.
18
(
a
), the lock yarn inserting mechanism
8
is retained at the initial position. The needles
40
are then retracted and the yarn z is retracted accordingly. At this time, the support frame
96
is lifted to lift the lock yarn needle
113
to a position of FIG.
18
(
b
), where the lock yarn needle
113
is at the same level as the bottom side of the lamination F.
When the support frame
96
is lifted, the pressure of the compressed air supplied to the air cylinders
97
,
98
is lowered to prevent the press blocks
99
a
,
99
b
from applying excessive force to the lamination F. When the support frame
96
is lifted to a predetermined height, a predetermined air pressure is applied to the air cylinders
97
,
98
again. After tightening of the lamination F with the connection yarns z is completed, the servomotor
122
is actuated to lower the support frame
96
, which moves the lock yarn insertion needle
113
to the initial position.
In addition to the advantages of the apparatus of
FIGS. 1
to
17
(
b
), the apparatus of FIGS.
18
(
a
) to
19
has the following advantages.
To prepare for the insertion of the connection yarns z, the thickness of the lamination F is entered through the input device. Accordingly, the height of the support frame
96
is automatically adjusted by the servomotor
122
to a position corresponding to the thickness of the lamination F. Therefore, compared to a case where the height of the support frame
96
is controlled by manually operating the wheel
93
, the preparation of the connection yarn insertion is easier for the operator.
When the connection yarns z, together with the insertion needles
40
, are retracted, the lock yarn insertion needle
113
is lifted by the support frame
96
to a position that corresponds the lower side of the lamination F. In the first embodiment of
FIGS. 1
to
17
(
b
), the vertical position of the lock yarn insertion needle
113
is fixed. Therefore, when the connection yarns z are retracted, the needle
113
applies a force loosening the connection yarns z through the lock yarn P as shown in FIG.
18
(
c
). Unlike the first embodiment of
FIGS. 1
to
17
(
b
) and
18
(
c
), the needle
113
of the second embodiment is lifted as shown in FIG.
18
(
b
) when the connection yarns z are retracted. The needle
113
of the second embodiment therefore does not apply a force that loosens the connection yarns z. As a result, the tightening force at the edge of the finished three-dimensional fabric is firm.
It should be apparent to those skilled in the art that the present invention may be embodied in many other specific forms without departing from the spirit or scope of the invention. Particularly, it should be understood that the invention may be embodied in the following forms.
If at least one of the conveying mechanism
2
, the tension applying mechanism
4
, the pressing mechanism
7
and the lock yarn inserting mechanism
8
is embodied in a connection yarn inserting apparatus, the time required for inserting connection yarns is reduced and the productivity is improved accordingly. In other words, even if all but one of the mechanisms have the prior art structure, the productivity will improve. Further, if all the mechanisms of the apparatus have the structures of the illustrated embodiments or structures having the same effects, the productivity is further improved.
In the illustrated embodiments, the stroke of the first pressing member (the press plate
85
) and the second pressing member (the press blocks
99
a
,
99
b
) of the pressing mechanism
7
are discretely changed. However, the stroke of only one of the first and second pressing members may be discretely adjustable. In this case, the operation speed is slower compared to the case where the stroke of both pressing members are adjustable. However, the operation speed is faster than prior art apparatuses.
If the thickness of the lamination F varies discretely in its longitudinal direction, for example, if the lamination F has two thicknesses, the stopper
103
may have two engagement surfaces, each of which corresponds to one of the thicknesses of the lamination F. In this case, an actuator that has two stroke positions is used. As a result, the press blocks
99
a
,
99
b
have two standby positions at which the press blocks
99
a
,
99
b
engage the stopper
103
. The press blocks
99
a
,
99
b
therefore have three different strokes. The same effect will be achieved by actuating two stoppers
103
that have different thicknesses by two actuators.
Instead of air cylinders for actuating the stoppers
88
,
103
, the stoppers
88
,
103
may be actuated by solenoids.
In the illustrated embodiments, the table
10
is held horizontal. However, the tables
10
may be vertical or inclined.
The engagement hole
14
b
, which functions as the engagement portion of the table
10
, may be formed as a through hole or other shape. The air cylinder
28
, or the actuator, may be replaced by a solenoid. The piston rod
28
a
or the plunger of the solenoid, which serve as couplers, may indirectly engage the hole
14
b
. Specifically, a coupler that has a shape corresponding to the shape of the hole
14
b
may be attached to the piston rod
28
a
or the plunger.
A linear pulse motor may be used for moving the carrier tables
10
. In this case, the stator is located on the guide rail
19
and the armature is fixed to the actuator (air cylinder
28
). Using a linear pulse motor simplifies the structure of the apparatus compared to the servomotor
23
and the lead screw mechanism.
The mechanism for moving the carrier tables
10
includes the coupling members and the actuator, which move linearly. However, the mechanism may include an endless belt or a chain, which move circularly.
The actuator for the lock yarn insertion needle
113
may be a linear motor.
In the embodiment of FIGS.
18
(a),
18
(
b
) and
19
, the lock yarn insertion needle
113
may be lifted while maintaining the pressure air supplied to the air cylinders
97
,
98
.
The lock yarn insertion needle
113
and its actuator may be lifted and lowered independently from the second pressing mechanism
81
. When the insertion needles
40
are being retracted, the needle
113
and its actuator may be moved to a predetermined position without moving the second pressing mechanism
81
. In this case, the second pressing mechanism
81
need not be lifted or lowered in every cycle of the insertion of the connection yarns z, which reduces the energy consumption.
The movable roller
79
of the tension applying mechanism
4
is moved by the lead screw mechanism, which is actuated by a motor, in the illustrated embodiments. Instead, the movable roller
79
may be moved by a rack and pinion mechanism or by a linear motor. The motor for moving the lead screw mechanism or the rack and pinion mechanism may be a motor other than a servomotor.
The support member
64
supporting the brake bars
66
is actuated by the air cylinder
61
through the lever
62
in the illustrated embodiments. Instead, the support member
64
may be secured to the piston rod
61
a
of the air cylinder
61
.
A yarn guide may be provided in the path of the connection yarns z to prevent the yarns z from becoming tangled.
In the illustrated embodiments, the lamination F is formed with threads. However, the lamination F may be formed with a combination of threads and cloth.
Depending on the thickness and the fiber type of the lamination F, perforation by the perforation needles
55
may be omitted. In this case, the insertion needles
40
are directly inserted into the lamination F.
Therefore, the present examples and embodiments are to be considered as illustrative and not restrictive and the invention is not to be limited to the details given herein, but may be modified within the scope of the appended claims.
Claims
- 1. A connection yarn inserting apparatus for manufacturing three-dimensional fabric, wherein the apparatus inserts a connection yarn into a lamination, which is formed by laminating a plurality of fiber layers and has fibers extending in at least two different directions, in a direction transverse to the fiber layers, the apparatus comprising:a frame for holding the lamination; a needle for inserting the connection yarn into the lamination held by the frame, wherein the needle moves in an advancement direction and a retraction direction, the insertion needle being moved between a standby position, where the insertion needle is separated from the lamination, and an operation position, where the insertion needle penetrates the lamination; a first pressing member located at the same side of the lamination as the standby position of the insertion needle, wherein the first pressing member is moved in the moving direction of the insertion needle to and from the vicinity of an insertion location of the insertion needle; a first air cylinder for moving the first pressing member between an operational position, where the first pressing member engages the lamination in the vicinity of an insertion location of the insertion needle and presses the lamination in the advancing direction of the insertion needle, and a standby position, where the first pressing member is separated from the lamination; a second pressing member located at the opposite side of the lamination relative to the first pressing member, wherein the second pressing member is moved in the moving direction of the insertion needle to and from the vicinity of the insertion location of the insertion needle; a second air cylinder for moving the second pressing member between an operational position, where the second pressing member engages the lamination and presses the lamination in the retraction direction of the insertion needle, and a standby position, at which the second pressing member is separated from the lamination; a stopper that is engageable with a piston rod of at least one of the first and second air cylinders, wherein, when the stopper is engaged with the piston rod, the stopper limits the movement of the piston rod in the retraction direction to directly vary the stroke of the piston rod and the corresponding pressing member; and an actuator for actuating the stopper.
- 2. The connection yarn inserting apparatus according to claim 1, wherein the strokes of the first and second pressing members are discretely variable.
- 3. The connection yarn inserting apparatus according to claim 1, wherein the second pressing member and the second air cylinder are supported by a support frame, and wherein the support frame is supported to be movable in a direction perpendicular to the lamination.
- 4. The connection yarn inserting apparatus according to claim 3, wherein the support frame is supported by a lead screw nut of a lead screw mechanism to be lifted and lowered, and wherein the screw shaft of the lead screw mechanism is coupled to a manually operated handle.
- 5. The connection yarn inserting apparatus according to claim 4, wherein, when the insertion needle is at the operation position, an eye of the insertion needle is located at the opposite side of the lamination from the standby position and the insertion needle forms a loop of the connection yarn, wherein the loop is connected to the insertion needle; andwherein the apparatus further includes a lock yarn needle for inserting a lock yarn into the loop and an actuation mechanism for actuating the lock yarn needle.
- 6. A connection yarn inserting apparatus for manufacturing three-dimensional fabric, wherein the apparatus inserts a connection yarn into a lamination, which is formed by laminating a plurality of fiber layers and has fibers extending in at least two different directions, along a direction crossing the fiber layers, the apparatus comprising:a first feeding mechanism for feeding the connection yarn; a needle for inserting the connection yarn into the lamination; a tension applying mechanism located in the path of the connection yarn, which extends from the first feeding mechanism to the insertion needle, wherein the tension applying mechanism applies tension to the connection yarn; and a brake device located closer to the first feeding mechanism than the tension applying mechanism, wherein, when the tension applying mechanism applies tension to the connection yarn, the brake device is actuated to hold the connection yarn; wherein the tension applying mechanism includes: two fixed rollers, the axes of which are perpendicular to the connection yarn; a movable roller, wherein the movable roller is moved in a direction perpendicular to a plane that includes the axes of the fixed rollers; and an actuation mechanism including an air cylinder and a moving device, which has a motor as a drive source, wherein the actuation mechanism reciprocates the movable roller to change the length of the connection yarn between the two fixed rollers.
- 7. A connection yarn inserting apparatus for manufacturing three-dimensional fabric, wherein the apparatus inserts a connection yarn into one of a plurality of laminations, each of which is formed by laminating a plurality of fiber layers and has fibers extending in at least two different directions, in a direction transverse to the fiber layers, the apparatus comprising:frames for holding the laminations, wherein one of the frames holds an unprocessed lamination, and one of the frames holds a processed lamination; at least two carrier tables for supporting the frames, respectively; a guiding mechanism for guiding the carrier tables, wherein the guiding mechanism simultaneously guides the carrier tables to move in a conveying direction; and a conveying device for moving the carrier tables by a predetermined pitch such that the laminations consecutively pass a position at which the connection yarn is inserted.
- 8. The connection yarn inserting apparatus according to claim 7, wherein each carrier table has a coupler for joining the carrier tables to one another.
- 9. The connection yarn inserting apparatus according to claim 7, wherein the conveying device includes:an engagement portion provided in the carrier table; a coupling member that engages the engagement portion of the carrier table; and an actuator for moving the coupling member between an engagement position, at which the coupling member engages the engagement portion, and a standby position, at which the coupling member is separated from the engagement portion; wherein the coupling member moves in the conveying direction within a predetermined range that is greater than the corresponding length of each carrier table.
- 10. The connection yarn inserting apparatus according to claim 7, wherein the guiding mechanism guides the carrier table such that each carrier table is horizontal.
- 11. The connection yarn inserting apparatus according to claim 9, further comprising a lead screw mechanism extending in the conveying direction, wherein the lead screw mechanism is actuated by a servomotor, and wherein the actuator is fixed to a lead screw nut of the lead screw mechanism.
- 12. The connection yarn inserting mechanism according to claim 9, wherein the engagement portion is a hole formed in the carrier table, and wherein the actuator is either an air cylinder or a solenoid.
- 13. A connection yarn inserting apparatus for manufacturing three-dimensional fabric, wherein the apparatus inserts connection yarns into a lamination, which is formed by laminating a plurality of fiber layers and has fibers extending in at least two different directions, in a direction transverse to the fiber layers, the apparatus comprising:a frame for holding the lamination; a row of needles for simultaneously inserting the connection yarns into the lamination held by the frame, each needle having an eye, wherein, when the insertion needles are at an operation position, the eye of each insertion needle has been passed through the lamination and the each insertion needle forms a loop of the associated connection yarn, wherein the loop is connected to the associated insertion needle; a lock yarn needle movable along the row of the insertion needles, wherein the lock yarn needle includes a hooking member for hooking a lock yarn and is moved between an operational position, at which the lock yarn needle is received by the loops of the connection yarns to insert the lock yarn into the loops, and a standby position, at which the lock yarn needle is outside the loops; a plurality of pulleys; an endless belt engaging the pulleys; a motor for actuating the pulleys to move the belt along a running path; wherein a segment of the belt is parallel to the row of the insertion needles, wherein the segment is longer than the distance that the hooking member of the lock yarn needle moves to insert the lock yarn to the loops; and a support member fixed to the belt for supporting the lock yarn needle, wherein the support member moves the lock yarn needle between the operational position and the standby position as the belt runs.
- 14. A connection yarn inserting apparatus for manufacturing three-dimensional fabric, wherein the apparatus inserts connection yarns into a lamination, which is formed by laminating a plurality of fiber layers and has fibers arranged in at least two different directions, in a direction transverse to the fiber layers, the apparatus comprising:a frame for holding the lamination; a row of insertion needles for simultaneously inserting the connection yarns into the lamination held by the frame; a support body movable in a direction perpendicular to the lamination held by the frame; a row of perforation needles supported by the support body, wherein the perforation needles are arranged at a pitch corresponding to the insertion needles; and an actuation mechanism for moving the perforation needles between a standby position, where the perforation needles are separated from the lamination, and an operational position, where the perforation needles penetrate the lamination; wherein the speed of the actuation mechanism is controlled such that the perforation needles are moved relatively quickly when the perforation needles are separated from the lamination and are moved relatively slowly when the perforation needles engage the lamination.
- 15. A connection yarn inserting apparatus for manufacturing three-dimensional fabric, wherein the apparatus inserts connection yarns into a lamination, which is formed by laminating a plurality of fiber layers and has fibers extending in at least two different directions, in a direction transverse to the fiber layers, the apparatus comprising:a frame for holding the lamination; a row of needles for simultaneously inserting the connection yarns into the lamination held by the frame, each needle having an eye, wherein, when the insertion needles are at an operation position, the eye of each insertion needle has been passed through the lamination and the each insertion needle forms a loop of the associated connection yarn, wherein the loop is connected to the associated insertion needle; a lock yarn needle for inserting a lock yarn through the loops of the connection yarns; an actuation mechanism for actuating the lock yarn needle; a support frame for supporting the lock yarn and the actuation mechanism, wherein the support frame is moved in the moving direction of the lock yarn; and a driving device, wherein, when the insertion needles are being retracted, the driving device moves the support frame until the lock yarn needle is on a side of the lamination that is opposite to the side from which the insertion needles are inserted into the lamination.
Priority Claims (1)
Number |
Date |
Country |
Kind |
11-083827 |
Mar 1999 |
JP |
|
US Referenced Citations (6)
Foreign Referenced Citations (3)
Number |
Date |
Country |
8-218249 |
Aug 1996 |
JP |
10-325043 |
Dec 1998 |
JP |
0029659 |
May 2000 |
WO |