The present invention generally relates to creels used for supporting a plurality of packages or spools of stranded materials and automated loading of such spools on the creel. More particularly, the present invention relates to an automated creel loading system for use in the textile industry, wherein the stranded materials are yarns or other textile products. With even greater particularity, the invention relates to an automated handling apparatus and method for transferring a yarn package from a pallet or other material delivery platform to any one of a plurality of package support holders located on the creel. The invention further contemplates an improved package support holder for the creel.
The use of creels for supporting a plurality of yarn packages is well known in the textile industry and has application in other stranded materials based industries. However, despite their widespread use, the task of loading a creel remains an extremely labor intensive operation involving both gross and fine motor skills. The nature of the loading tasks presents various risks to repetitive motion injuries such as carpal tunnel syndrome, spinal injuries, and other musculo-skeletal maladies. This is particularly the case in the manufacture of woven carpets, where the strength, durability, and weight of the yarns to manufacture such carpets typically requires yarn spools, known as packages, that have considerable weight in order to provide sufficient strand lengths to effectively feed modern high-speed processing systems.
Modern high-speed processing systems require a continuous, uninterrupted supply of yarns, fed from a plurality of yarn packages supported throughout the creel. The yarn package supports are arrayed on a plurality of support posts extending from the free standing frame of the creel, which is positioned to feed the manufacturing process. Eyelets or other guide means are provided throughout the creel through which each of a plurality of yarn strands are fed to the processing system. Usually a pair of package supports are configured in alignment with a single eyelet and the respective yarn strands from the paired packages are tied or otherwise attached in series to alternately feed the process. Due to the varying weights and strengths of a particular yarn package selected for a particular package support on the creel, as well as variations in the strand lengths of like yarn packages, the yarn will be depleted from the packages at irregular intervals. Consequently, laborers tasked to load and maintain the supply of yarns must constantly monitor the yarn packages and replace them at frequent intervals as the yarns are dispensed to feed the manufacturing process.
Replacement of a yarn package in a creel typically requires a worker to rotate a depleted package support out of the creel from its feed position to a loading position; remove and dispose of a spent cone from the package holder; lift the replacement yarn package from a delivery platform, such as a pallet; transport the package to the indicated package support; manipulate the package to mount it on the package support; rotate the replenished package support into the creel; and tie or otherwise secure the lead end of the replenished yarn package to the tail end of the paired feeding yarn package. A typical package will weigh on the order of 8 to 14 pounds.
In a given shift, a textile worker tasked to load and maintain the creel in a conventional process will lift, transport, and manipulate as much as six thousand pounds of yarn packages. Because the package supports are arrayed at varying heights and distances from the delivery platform, the typical laborer is subjected to significant risk of musculo-skeletal injuries presented at each step of the yarn package replacement process.
For example, in creels equipped with yarn package supports such as that disclosed in U.S. Pat. No. 4,880,184, rotation of the package support requires a two handed operation. First, the laborer must pull the locking handle with one hand in order to unlock the package support before it may be rotated from its use position. The laborer must then grasp the cone holder with the other hand to rotate the spent package cone to the loading position.
During lifting, transport and manipulation of a new cone, laborers will have a tendency to grasp the yarn package at the end of the package and either extend the fingers into the cylindrical cone and secure the outer diameter of the package with the thumb or vice versa, focusing the stresses in the hands, wrists, and forearms. In addition, the subsequent lifting, transport and manipulation of yarn package when grasped in this manner is particularly stressful on the musculo-skeletal tissues of the hand, wrist, and arm. Due to the dispersion of the package supports within the creel, frequent bending, lifting, and reaching is required to load the package, leading to shoulder, back and other musculo-skeletal stresses.
Objects of the present invention are to provide various means for relieving musculo-skeletal stresses on the laborers tasked to load a creel. The invention alleviates many musculo-skeletal stresses by providing a package manipulator operatively attached to an overhead vertical hoist assembly in order to relieve the stresses of grasping, manipulating, transporting, and loading a package of stranded material, such as yarn, used to supply a manufacturing process.
The hoist assembly comprises a hoist frame supporting a longitudinal and lateral track system that permits a vertical hoist within the boundaries of a work station defined by the hoist frame and track system. A package manipulator assembly is suspended from the vertical hoist and performs the tasks of grasping, manipulating and transporting a package within the work station. Grips are provided on the manipulator for the laborer to ergonomically grasp and exercise gross and fine motor control over the movements of the suspended manipulator. Controls are provided on the manipulator assembly for activation of the vertical hoist, grasping a package, and rotating the package from a delivered position to a loading position. Preferably the controls are ergonomically positioned to permit the laborer to activate the controls while grasping the manipulator grip so that the laborer can quickly and efficiently complete loading tasks.
To facilitate loading, the present invention further contemplates an improved rotator package support assembly for loading packages to supply the manufacturing process. The rotator package support assembly of the present invention permits single-handed rotation of the package support arm and comprises a support arm extending outwardly from a collar, which is attached to a creel in pivotal relation to a rotator bearing. Rotator bearing comprises a rotator guide channel, that receives a guide pin extending inwardly from the collar. Guide channel has a locking portion, or first detent, that maintains the support arm in alignment within a material delivery point, such as an eyelet in a textile creel. An intermediate portion of the guide channel guides rotation of the support arm from the use position, defined by the first detent, to a loading position, defined by a second detent, or loading stop.
In addition to the advantages of relieving musculo-skeletal stresses on the package loader, the automatic creel loading system of the present invention provides efficiencies for the manufacturing process, particularly for the textile industry.
Referring more particularly to the various drawings
As shown in reference to
To further reduce the stresses encountered by package loading laborers, the package manipulator 20 is provided and is adapted to perform the task of grasping and rotating a package 80 from a vertical orientation, as defined by the central axis of the package spool, or cone 82. As is best seen in reference to
Attachment points 22 are selected to permit balancing of the manipulator 20 to varying weights of material carried on package 80. A control handle 25 is provided at a second end of control arm 24 and provides a suitable gripping point for the operator to grasp and maneuver the manipulator 20, and is more preferable disposed at an ergonomic angled with respect the manipulator 20 so as to avoid the imposition of undue musculo-skeletal stresses. A guide handle 26 extends outwardly from a lower end of pivot arm 23 to provide the operator a second point for grasping and maneuvering the manipulator 20 and package 80. Preferably guide handle 26 is disposed at an ergonomic angle with respect to the manipulator frame 21, so as to avoid musculo-skeletal stresses. A second guide handle 26 may be provided at an opposite side of the frame 21, to accommodate the dexterity of a particular laborer. A second guide handle 26 may also be advantageous in providing a given laborer the ability to alternate his or her control of the manipulator 20 between limbs, so as to avoid introducing a new repetitive impact hazard.
As previously discussed, a primary source of musculo-skeletal stress injuries for package loaders involves the laborer's grasping and manipulation of the packages 80, while completing the requisite package loading tasks. A significant object of the present invention, therefore involves elimination of this risk. In this regard, manipulator 20 is intended to substitute the laborer's need to manually grasp and manipulate the package 80. In order to grasp a spool or package 80 of materials, manipulator 20 includes a gripping assembly 30 which comprises a plurality of projections, or fingers 33, disposed about central axis A. Fingers 33 are selectively extensible about axis A between a closed, release position, and an open gripping position. In the open gripping position the outer surface 34 of fingers 33 engage an inner surface of cylindrical core, or cone 82 of the package 80. Preferably, fingers 33 have a curved outer surface 34 having a radius of curvature R substantially the same as an inner radius R′ of a cylindrical core 82 of the package 80, to be grasped and carried by the manipulator 20.
Because the packages 80 are intended to be placed and supported on a support arm 60, the inner surface 35 of fingers 33 will define a void along axis A, which is capable of receiving support arm 60. As will be appreciated by those in the textile industry, support arm 60, may also include a cone holder 66, that will extend outwardly from support arm as shown in
In the typical textile manufacturing process, replenishment packages 80 are stacked and delivered to the work station with their cylindrical cores aligned vertically. Because the support arms 60 are horizontally disposed, the replenishment packages 80 must be rotated from their delivered vertical disposition to the substantially horizontal alignment necessary to load the package 80 into the creel. Accordingly, the manipulator's gripping assembly 21 is pivotally disposed in manipulator frame 30 at a pivot point 27, and operable between a package retrieval position and a package loading position by a pivot actuator 28. Activation of pivot actuator 28 rotates gripping assembly 30 about pivot point 27 such that fingers 33 are substantially horizontally disposed. In the package retrieval position, gripping assembly 30 is oriented such that fingers 33 project downwardly. As may be seen in reference to
Pivot actuator 28 is operatively attached between manipulator frame 21 and a fulcrum acting through the pivot point 27 on gripping assembly 30, such as the pivot lever 32 shown in the drawings. A pivot control 29, permits the laborer to control rotation of pivot actuator 28. Preferably, pivot control 29 is operable by the laborer while the laborer grips either control handle 25 or guide handle 26 which permits the laborer to maintain control of the manipulator 20, while maneuvering the carried package 80 for loading on creel a creel package support 60.
To facilitate loading of packages 80 on creel 40, the present invention further contemplates the provision of an improved package support 50 that permits one-handed rotation of support arm 60 and package 80 carried thereon. As may be seen in reference to
The rotator package support assembly 50 of the present invention comprises a mounting post, or bolt 51 for attaching support assembly 50 to a support stub 43; a rotator bearing 52; a support arm 60; and a collar 61. As is best seen in reference to
Collar 61 defines an axial collar bore 62, a support arm 60 extends radially outwardly from a collar aperture 64, and a rotator guide pin 63 extends from an inner surface 65 of collar 61 into collar bore 61. Collar bore 62 is dimensioned such that it pivotally receives bearing 53 therein. In the exemplary embodiment depicted, support arm 60 is threadingly received through aperture 64 such that a first end of support arm 60 also serves as the rotator guide pin 63. Support arm 60 may retained in aperture 64 with a lock nut 67 or other securing means. As will be appreciated by those of skill in the art, support arm 60 may also include a cone holder 66 suited to a particular yarn package 80. Cone holder 66 may be attached to collar 61 or a cone holder retainer 68 may be provided on support arm 60, in which case cone holder retainer may be substituted for lock nut 67. Alternatively, support arm 60 may be press fit or welded to collar 61.
For ease of assembly, at least one stop 56, 57, preferably loading stop portion 57 of guide channel 54, extends through the upper end of bearing 52. By this arrangement, assembly of rotator package support assembly 50 is readily accomplished by placing a retainer 58, such as a washer, over bolt 51 and then inserting bolt 51 through collar 61, which is preferably pre-assembled with the first end of support arm 60 extending through collar 61 to serve as guide pin 63, as described in the preceding paragraph. Bolt 51 may then be inserted through bearing bore 53 and bearing 52 rotated such that guide pin 63 aligns with the opening of loading stop portion 57 extending through the upper end of bearing 52. The assembled rotator package support 50 may then attached to stub 43 by inserting post or bolt 51 through a mounting hole 46 defined in stub 43, and then secured to stub 43 by a fastener, such as a nut 68 and lock washer 69, or any other suitable means. Before tightening the assembly, support arm 60 should be rotated on bearing 52 until guide pin 63 is received in guide channel first stop portion 56. Support arm 60 and bearing 52 should then be aligned with its associated creel eyelet 44. Once aligned, nut 68 is tightened such that bearing 52 is secured in its proper orientation between retainer 58 and stub 43.
Inasmuch as the alignment of support arms 60 with its associated creel eyelet 44 can be predetermined based on the geometry of guide channel 54 and the disposition of stub 53, a preferred embodiment of the invention contemplates that bearing 52 further comprises an alignment slot 59, or bore 59, defined in the lower end face of bearing 52. Stub 43 is also modified to include a cooperating alignment pin 44 defined on the surface of the stub 43 subjacent the bearing 52. By this arrangement, the rotator package support assembly 50 can be automatically aligned with eyelet by the engagement of alignment pin 44 within alignment slot or bore 59, and the assembly may then be securely tightened to stub 43 without need of further alignment.
In preferred embodiments such as those shown in reference to
In this preferred embodiment, I have also found that it is desirable for locking portion 56 to be defined with a slope greater than or equal to that of the spiral portion 55 and having a vertical depth sufficient to receive a portion of guide pin 63 in a detent relation, as best seen in reference to
An added advantage we have discovered in connection with providing a hoist frame 11 to the creel loading work station of the present invention is that we were able to stabilize the creel 40. Normally, creel 40 is a free standing framework that is secured to the floor of the work station. Due to the height and loading of the creel, the framework may become unstable such that it will sway from side to side. Hoist frame 11 is defined to provide access to the full length and height of the creel 40 with manipulator 20. As may be seen in the right hand portion of
While the system thus far described has discussed the various aspects of the invention provided to relieve musculo-skeletal stresses at a package loading station having a single creel 40, the advantages provided by these the hoist assembly 10 and package manipulator 20, also facilitate expansion of the package loading work station to service multiple creels with the same equipment. As will be appreciated additional creels may be effectively serviced from any of the four sides of the work station as defined by the hoist frame assembly 11, since the manipulator 20 is readily translated to any point within the enclosure. Similarly, the efficiency of the package loading work station, as described herein, may be further improved by providing an improved package delivery platform, such that packages 80 are provided at the work station elevated from the floor so as to avoid the need for the package loaders to bend over in order to grasp a package 80 with manipulator 20. Alternatively, delivery platform may include as a conveyor so elevated.
While the improvements described herein will provide substantial relief for the potential for musculo-skeletal injuries, they also offer significant manufacturing advantages. For example, with the system herein described, the weight of the yarn packages 80 may be substantially increased from their current 8 to 14 pounds. With the system contemplated, yarn package 80 weights of approximately 50 pounds will be readily maintainable. The increased weights will provide yarn lengths of approximately 2.5 times that of conventional yarn packages. In as much as the knots joining yarn packages can become a significant source of process failures, the elimination of this source of error and disruption presents a significant improvement to the manufacturing process.
From the above description of the various aspects of the invention, those skilled in the art will perceive improvements, changes and modifications within the skill of the art from those herein described. Application in a wide variety of manufacturing process as well as various changes and modifications from the described embodiments may be made without departing from the spirit and scope of the invention, as defined by the appended claims.
This application claims the benefit of prior U.S. Provisional application Ser. No. 60/885,743, filed Jan. 19, 2007.
Number | Name | Date | Kind |
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339684 | Patrick | Apr 1886 | A |
2349639 | Theiler | May 1944 | A |
4829611 | Fireman et al. | May 1989 | A |
4880184 | Crow | Nov 1989 | A |
6345783 | Worner | Feb 2002 | B1 |
7434774 | Floersch et al. | Oct 2008 | B1 |
Number | Date | Country | |
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20080173742 A1 | Jul 2008 | US |
Number | Date | Country | |
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60885743 | Jan 2007 | US |