Apparatus for inserting connection yarn into three-dimensional fabric

Information

  • Patent Grant
  • 6267149
  • Patent Number
    6,267,149
  • Date Filed
    Thursday, March 23, 2000
    24 years ago
  • Date Issued
    Tuesday, July 31, 2001
    23 years ago
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)
Number Name Date Kind
4095619 Kallmeyer Jun 1978
4183993 Benstead et al. Jan 1980
5327621 Yasui et al. Jul 1994
5720320 Evans Feb 1998
5772821 Yasui et al. Jun 1998
5833802 Yasui et al. Nov 1998
Foreign Referenced Citations (3)
Number Date Country
8-218249 Aug 1996 JP
10-325043 Dec 1998 JP
0029659 May 2000 WO