Patent Application
20230331511
The present application claims priority to Australian provisional application numbers AU 2020903209, AU 2020903210 and AU 2020903212, the entire disclosures of each are incorporated herein by reference.
The present disclosure relates to systems, methods and apparatus for use in the manufacture of woven or tufted products, including textiles such as carpets and rugs.
Carpet making machines are used to manufacture rugs and carpets. Broadly, there are two types of carpet making machine, namely weaving machines and tufting machines.
Weaving involves the interweaving of perpendicular sets of weft and warp yarns. In the production of a woven carpet, several uniformly spaced parallel strands of yarn extend along a length of the carpet. These strands are referred to as warp strands. As the warp yarns are indexed forward by looms of the weaving machine, strands of yarns are fed perpendicularly through the set of warp yarns across the width of the carpet, being trapped therebetween to form the carpet. These strands are known as weft strands. Each of the strands of yarn making up the warp and the weft are fed by a different supply of yarn, often in the form of a yarn cone, bobbin or spool.
Tufting involves the stitching of yarns through a net-like backing. In the production of a tufted carpet using a large tufting machine, several needles extend linearly across a width of the backing. As the backing is indexed forward through the tufting machine, the needles loop yarn through the backing. Each needle is fed by a different supply of yarn.
Conversely, small tufting machines utilise a single needle being mounted to a moving needle assemble that translates across the width of the carpet. Accordingly, such machines require only a single supply of yarn. Such smaller tufting machines are particularly suitable for the manufacturer of smaller products and samples.
The gauge of a woven or tufted product is a measure of the number of strands or needles per unit inch of width. Typical carpets and rugs are manufactured in 1/10 gauge, which equates to ten yarns per inch. Accordingly, a carpet or rug of a typical width can comprise one thousand or more yarns across its width, each being fed from a different supply of yarn.
Conventionally, carpet making machines comprise multiple needles and/or “operation points”, and are provided with yarn via large, stationary creels. A creel is a rack or frame that provides a plurality of locations for accommodating spools of yarn, or “yarn packages”. Each location within the creel supplies a different operation point of the carpet making machine.
Early carpet making machines used to produce level cut or loop carpet piles would use yarn from each package equally such that the packages would run out of yarn at approximately the same time. More modern carpet making machines, however, can produce patterned carpets or rugs which have variable height loops or cut pile, resulting in different consumption of yarn at different operation points. In addition, full width patterning capabilities of more modern carpet manufacturing machines mean that yarn consumption at each operation point, and hence for each yarn package, may be different. Furthermore, some recent machines can also show one of a number of colours at a position within a pattern to produce a variety of carpet or rug patterns, further increasing the variation of yarn usage between different packages.
Yarn from each location within a creel is typically drawn towards a “header” device, which in turn feeds the individual supplies of yarn to the operation point of the carpet making machine. Typical creels can accommodate hundreds or even thousands of packages of yarn. Conventionally, each yarn package within the creel is wound with a uniform length of yarn, approximated to the amount of yarn required. This can result in yarn waste at the end of the job, with excess yarn remaining on the package at the completion of a job being drawn through the carpet making machine and disposed of before the next job commences.
Typically, new yarn packages are supplied to the locations within the creel manually by a worker who manually restrains a free end or “yarn tail” of the yarn, and delivers this to the creel, where it is threaded through an eye or conduit to the header, where it is typically joined or “spliced” to the previous length of yarn fed therethrough. Given the large number of locations within the creel requiring loading and unloading, the threading of the yarn tails and feed towards the header, and manual unloading of the empty cores can be a laborious and time-consuming endeavour. Alternatively, the creel arrangement may provide for two yarn positions for each operation point of the carpet making machine, in which case the new yarn may be connected to the existing yarn within the creel. Furthermore, when several yarn packages are being loaded and spliced together at the header at the same time, there is a risk of entanglement of neighbouring yarns.
Complete replacement or replenishment of these packages can represent many man hours of work, around 20 hours for this example. Accordingly, whilst conventional large, manually-fed creels were well suited to early carpet making machines, more modern machines, often consuming differing amounts of yarn at different operation points, are less suited, with the variability of yarn usage leading to an increase in the amount of yarn being wasted. Alternatively, partially used yarn packages may be removed from the creel and placed into storage until yarn of that colour and amount is required, which increases the amount of storage required.
Against this backdrop, alternative systems have been recently developed which attempt to provide improvements to creels and in the supply of yarn thereto.
One such system relies on the use of smaller, mobile creels that can be filled with yarn away from the carpet making machine. A first mobile creel is used to supply the carpet making machine while a second mobile creel is loaded with yarn packages, and when the use of yarn on the first creel is completed it can be swapped with the second creel. This system reduces down-time associated with the emptying and refilling of a conventional, stationary creel. However, such a system still requires manual refilling of the yarn packages into the locations within each mobile creel, and if the consumption of yarn at each position is unequal, the yarn packages with a substantial amount of yarn remaining must still be removed and stored.
Another alternative system involves the use of winding machines configured to wind a precise length of yarn onto an empty core with a high degree of accuracy. Labels are then placed onto the yarn packages to identify specific positions within the creel where each package is to be uniquely placed. A batch of the uniquely wound packages is then delivered to the creel, with each package will placed manually into the designated position denoted on the label on that package. One example of such a system is the Gilbos ‘UniWinder’ machine and associated software.
Accordingly, it would be desirable to provide an improved method of supplying yarn to a production machine that addresses some of the drawbacks of conventional creel-based systems. It would also be advantageous to provide systems and apparatus for undertaking such a method.
The present invention was conceived with these shortcomings in mind.
An aspect of the present invention provides a system for handling yarn packages and empty cores, comprising: a creel comprising an array of creel positions each configured to receive a yarn package, wherein removal of a yarn from the yarn package results in the yarn package becoming an empty core; a winder located adjacent to the creel, the winder being configured to receive an empty core, and wherein the winder is configured to wind a predetermined length of yarn onto the empty core to create a yarn package; and a gripper assembly configured to be moveable between the creel and the winder, the gripper assembly comprising a gripping jaw adapted to grip a yarn package or empty core, wherein the gripping jaw of the gripper assembly is adapted to grip an empty core in a creel position and remove the empty core from the creel and deliver the empty core to the winder.
The removal of the yarn from the yarn package may be through a process of using the yarn in the formation of a rug or carpet. For example, the yarn may be removed from the yarn package by being fed from the creel position to a header plate. The yarn may be fed through a conduit in the centre of the creel position to the header plate. When the required amount of yarn has been used, there may be a small residual amount of yarn remaining on the package which is removed to result in the empty core.
According to embodiments, the creel comprises an array of tubes which each encircle a respective creel position.
According to embodiments, the creel comprises a first side and a second side. The first side may comprise a first array of creel positions. The second side may comprise a second array of creel positions. Optionally, at least one winder is located adjacent to the first side of the creel and at least one winder is located adjacent to the second side of the creel. Optionally, at least one winder is located adjacent to the first side in an initial orientation and the creel is configured to be rotated such that the first side can be serviced by the winder in the initial orientation and the creel may be rotated such that the second side may be serviced by the winder in a rotated configuration.
According to embodiments, the creel is a mobile creel. The mobile creel may be filled with yarn packages at one location and moved to another location, such as a location adjacent to a tufting machine, where desired.
According to embodiments, the winder comprises a plurality of winding areas. Each winding area may be adapted to wind a predetermined length of yarn onto a respective empty core. The winder may wind a predetermined length of yarn onto a plurality of empty cores simultaneously. The winder may comprise a plurality of heads which can each wind yarn onto an empty core. Optionally, the winder comprises a plurality of magazines adapted to receive empty cores. Each head of the winder or winding area may comprise a respective magazine. The magazine may be configured to receive at least one empty core at a time. Optionally, the magazine may be configured to receive a plurality of empty cores simultaneously. The winder may comprise a storage buffer adapted to receive a single empty core. Where the winder has a plurality of winding areas, the winder may comprise a plurality of storage buffers each adapted to receive a single empty core.
According to embodiments, the winder comprises at least one port through which the winder receives an empty core.
According to embodiments, the gripper assembly is moveable horizontally and vertically between the creel and winder such that gripper assembly may remove an empty core from any creel position in the array or deliver a yarn package to any creel position in the array.
According to embodiments, the system further comprises a gantry onto which the gripper assembly is connected. The gripper assembly may be moveable horizontally and vertically between the creel and the winder on the gantry.
According to embodiments, the gripper assembly is rotatable between a first orientation where the gripping jaw is aligned towards the creel and a second orientation where the gripping jaw is aligned towards winder.
According to embodiments, the gripping jaw is moveable along a longitudinal direction of the gripper assembly towards and away from a creel position when in the first orientation or towards and away from the winder when in the second orientation. The gripper assembly and gripping jaw may be moveable and actuated by air pressure and/or may comprise a pneumatic control system.
According to embodiments, each creel position comprises a package holder into which the core of the yarn package is placed. The package holder is preferably positioned and sized such that it will not interfere with the gripping jaw of the gripper assembly when the gripper assembly delivers a yarn package to said creel position or when the gripper assembly removes an empty core from said creel position.
According to embodiments, the gripping jaw is adapted to grip an inner surface of the yarn package or empty core. Optionally, the gripping jaw comprises a plurality of fingers. The fingers may have a low radial profile in a closed position and the fingers have an increased radial profile in an open position. The fingers may be adapted to engage the inner surface of a yarn package or empty core when in the open position and may release the yarn package or empty core when transitioning from the open position to the closed position.
According to embodiments, the system further comprises a sensing means. The sensing means may comprise a feature recognition camera or sensor. The system may comprise a controller. The feature recognition camera or sensor may be adapted to recognise and locate each creel position and to send signals to the controller. Thus, the controller may control the gripper assembly into alignment with a respective creel position when delivering a yarn package or removing an empty core. The feature recognition camera or sensor and controller may also control the gripper assembly to align with a magazine or a port of the winder when delivering an empty core to the winder. The feature recognition camera or sensor and controller may control the gripper assembly to align the gripper to a wound package on the winder. The sensing means may utilise a LiDAR ((light detection and ranging) for accurate positioning of the jaw. The sensor may utilise LiDAR.
Another aspect of the present invention provides a method for handling yarn packages and empty cores, comprising: providing a creel having an array of creel positions, where each creel position is adapted to receive a yarn package; providing a winder configured to receive an empty core, wherein the winder is configured to wind a predetermined length of yarn onto an empty core to create a yarn package, wherein the winder is positioned adjacent to the creel; providing a gripper assembly which is configured to be moveable between the creel and the winder, the gripper assembly having a gripping jaw adapted to grip a yarn package or an empty core; locating an empty core at a creel position; maneuvering the gripper assembly to said creel position and gripping said empty core with the gripping jaw of the gripper assembly; moving the gripper assembly between the creel and the winder; delivering the empty core to the winder; maneuvering the gripper assembly such that the gripping jaw collects a yarn package from the winder; and delivering the yarn package to the creel position by maneuvering the gripper assembly.
According to embodiments, the method further comprises providing a gantry onto which the gripper assembly is connected and adapted to move horizontally and vertically between the creel and the winder. Preferably, the gripper assembly is rotatable on the gantry between a first orientation where the gripping jaws face the creel and a second orientation where the gripping jaws face the winder.
According to embodiments, prior to gripping said empty core, the gripper assembly moves on the gantry to the creel position corresponding to the empty core. To grip said empty core the gripping jaw in a closed position may move in a longitudinal direction of the gripper assembly towards the empty core, the gripper jaw may actuate to an open position and engage the inner surface of the empty core. The empty core may be removed from its respective creel position, once gripped by the gripping jaw, by moving the gripping jaw in a direction opposite to said longitudinal direction, in other words away from the respective creel position. Similarly, to grip said yarn package the gripping jaw in a closed position may move in a longitudinal direction of the gripper assembly towards the yarn package, the gripper jaw may actuate to an open position and engage the inner surface of the yarn package.
It is understood that any of the individual features provided above or described below or shown in the accompanying Figures may themselves be the subject of independent or dependent claims. The features as described herein may be utilised in any combination as would provide a beneficial outcome and no single embodiment is considered on its own to be limiting to the scope of the invention.
Another aspect of the present invention provides a yarn control device for controlling a yarn tail of a yarn, comprising: a moveable body configured to capture the yarn and guide the yarn to an operative region of the body; an inlet for introducing a first fluid into the body; a first fluid outlet located in proximity to the operative region of the body, and oriented to expel the first fluid in a first fluid flow; and a first moveable member within the body that moves between an operative configuration to clamp the yarn and an inoperative configuration to release the yarn; wherein in the operative configuration the yarn is clamped in the operative region of the body such that the first fluid flow captures the yarn tail and orients the yarn tail coaxially with the first fluid flow, whereby movement of the movable body adjusts the direction of the first fluid flow and yarn tail entrained therein to control orientation of the yarn tail.
A further aspect, the invention is directed to a yarn control system for delivering a yarn tail of a yarn to a receiver, comprising: a moveable body configured to capture the yarn and guide the yarn to an operative region of the body; an inlet for introducing a first fluid into the body; a first fluid outlet located in proximity to the operative region of the body, and oriented to expel the first fluid in a first fluid flow; and a moveable member within the body that moves between an operative configuration and an inoperative configuration; and a nozzle having a second fluid outlet that expels a second fluid in a second fluid flow towards the receiver; wherein in the operative configuration the yarn is clamped in the operative region of the body such that the first fluid flow captures the yarn tail and orients the yarn tail coaxially with the first fluid flow, and in moving the movable body the first fluid flow is reoriented to intersect the second fluid flow, such that the second fluid flow expels the entrained yarn tail from the first fluid flow thereby delivering the yarn tail to the receiver.
A winder is configured to receive an empty core wherein the winder is configured to wind a predetermined length of yarn onto the empty core to create a yarn package.
A gripper assembly is configured to be moveable between the creel and the winder, the gripper assembly comprising a gripping jaw adapted to grip the package or empty core, the gripper assembly configured to: (i) remove an empty core from a designated creel position and deliver the empty core to the winder; and (ii) remove a yarn package from the winder and deliver the package to a designated creel position.
The yarn is removed from the yarn package by being fed from the designated creel position to a header plate or header. The yarn is fed to the receiver in the form of a conduit or tube in the centre of the designated creel position and fed therethrough to the header.
According to embodiments, each designated creel position comprises a housing or package holder into which the yarn spool is located and supported. The housing is preferably positioned and sized such that it will not interfere with the loading members of the gripper assembly when the gripper assembly delivers the yarn package to the designated creel position or when the gripper assembly removes an empty core from the designated creel position.
The housing may be a loading tube. The creel may comprise an array of loading tubes each of which encircle a designated creel position and receive and support the yarn package or empty core at the designated creel position. The housing may further comprise a locating boss or bracket for supporting and retaining the yarn package thereon. The housing may house the conduit or tube. The conduit may be centrally located in the housing to support the yarn spool and to allow the yarn to be fed from the loading face of the creel to an opposing face thereof.
According to embodiments, the gripper assembly is moveable horizontally and vertically between the creel and winder such that gripper assembly may remove an empty core from any creel position in the array or deliver a yarn package to any creel position in the array.
According to embodiments, the system further comprises a gantry onto which the gripper assembly is mounted. The gripper assembly may be moveable horizontally and vertically between the creel and the winder on the gantry. The gripper assembly may have telescoping movement to allow the gripper assembly to extend and retract. The gripper assembly may be configured to operate in three degrees of freedom. The gripper assembly may be mounted to allow rotation thereof. The rotation may be in a horizontal plane. The rotation may be in a vertical plane.
According to embodiments, the gripper assembly is rotatable between a first orientation where the gripping jaw is aligned towards the creel and a second orientation where the gripping jaw is aligned towards the winder.
According to embodiments, the gripper assembly may be moveable along a longitudinal direction of the gripper assembly towards and away from a designated creel position, when in a first orientation, or towards and away from the winder, when in a second orientation. The gripper assembly may be moveable and actuated by air pressure and/or may comprise a pneumatic control system or may be electronically actuated.
In Another aspect of the present invention, there is provided a method for loading yarn packages into a creel, comprising: winding a length of yarn onto an empty core in a winder to create a yarn package; capturing the yarn package with a gripper assembly configured to move between the creel and the winder, the gripper assembly adapted to grip the yarn package and comprising a yarn control device, wherein the yarn control device captures and retains a yarn tail of the yarn package; moving the gripper assembly adjacent to the creel and delivering the yarn package to an empty creel position; and activating the yarn control device to urge the yarn tail toward the receiver.
Yet another aspect of the present invention provides a method for loading yarn packages into a creel and threading the yarn tail through the creel, comprising: winding a length of yarn onto an empty core in a winder to create a yarn package; capturing the yarn package with a gripper assembly configured to move between the creel and the winder, the gripper assembly adapted to grip the yarn package and comprising a yarn control system, wherein the yarn control system captures and retains a yarn tail of the yarn package; moving the gripper assembly adjacent to the creel and delivering the yarn package to a designated creel position; and activating the yarn control system to direct the yarn tail toward the receiver of the designated creel position and threading the yarn tail through the receiver of the designated creel position.
In some embodiments, the receiver may be a conduit of the creel. The conduit may be a central tube. A plurality of central tubes may be dispersed across the creel, each central tube defining a designated creel position. The central tube of each creel position may be bounded by a housing or loading tube for protecting the yarn package therein. The yarn package may be coaxially located on the central tube, to facilitate feeding of the yarn from the spool through the central tube to a working face of the creel. The conduit may direct the yarn tail through the yarn package to a working face of the creel. The yarn package is loaded from a loading face of the creel. The loading face may oppose the working face of the creel. In some embodiments the loading face or the creel is also the working face.
In some embodiments, the receiver may be an eye or eyelet for receiving the yarn tail. In some embodiments, the receiver may be a header or header box, for storing a plurality of yarn tails of a loaded creel.
In a further aspect still, the invention provides a method of controlling a feed of yarn from a yarn package to an outlet, comprising: determining a length of a yarn feed path extending between a package holder to which the yarn package is attached during production of a yarn product and the outlet; winding a first span of yarn onto an empty core with a winding machine to form a wound core; winding a second span of yarn onto the wound core to form the yarn package, the second span having a length equal to or slightly greater than the length of the yarn feed path; and selectively feeding a tail end of the yarn package along the yarn feed path to the outlet, such that only the second span of yarn is dispensed from the yarn package. By determining the length of the yarn feed path prior to winding of the yarn package, the amount of excess yarn remaining on the yarn package at the completion of the production of the product is reduced.
The winding of the first span of yarn may be an angled winding, the first span of yarn traversing along the empty core from a first end of the empty core to a second end of the empty core. The angled winding may be a helical winding, the first span of yarn repeatedly traversing between the first and second ends of the empty core. The winding of the second span of yarn may be a straight winding, the second span of yarn concentrating within a portion of the wound core. The straight winding may be concentrated within a substantially central portion of the wound core. By concentrating the winding of the second span within the central portion, the process of dispensing only the second span from the yarn package is simplified.
The package holder may be one of a plurality of package holders, each of the plurality of package holders having a different yarn feed path, the method further comprising the step of defining a designated package holder to which the yarn package is to be attached, prior to determining the length of the yarn feed path. The plurality of package holders may be provided within a creel. The method may further comprise the step of transporting the yarn package from the winding machine to the designated package holder. The transporting of the yarn package may involve the use of an automated gripper, the automated gripper picking up the yarn package from the winding machine and attaching the yarn package to the designated package holder. By attaching the yarn brake to the automated gripper, a single yarn brake can be moved between several yarn packages attached to different package holders to dispense yarn therefrom.
In some embodiments, the feeding of yarn from the yarn package may comprise applying a tension force to the tail end of the yarn package and feeding the tail end along the yarn feed path to the outlet. The feeding of yarn may comprise applying a frictional force to the first span of yarn with a yarn brake, to thereby inhibit dispensing of the first span of yarn from the yarn package. The yarn brake may be attached to a or the automated gripper, the automated gripper transporting the yarn package from the winding machine to the package holder. The yarn brake provides a simple mechanism for restricting the feeding of yarn from the yarn package.
The method may further comprise the step of defining the total length of yarn required to produce the product and calculating the first span of yarn such that the first and second spans of yarn together provide the total length of yarn. By calculating the first and second yarn lengths prior to winding, the amount of yarn on each yarn package is limited to the amount of yarn required to be consumed at each operation point of the production machine. Accordingly, yarn wastage associated with excess yarn being left over on the yarn package at the completion of a job is further reduced.
In yet another aspect, the invention provides a yarn brake for controlling a feed of yarn from a yarn package to an outlet, the yarn package being attached to a package holder and comprising a core around which first and second spans of yarn are wound, the yarn brake including a frictional element moveable between a disengaged position, in which the frictional element does not contact the yarn package, and an engaged position, in which the frictional element engages with the first span of yarn, such that with the yarn brake in the engaged position, application of a tension force to a tail end of the yarn package results in only the second span of yarn being dispensed from the yarn package, the second span of yarn having a predetermined length calculated to feed the tail end along a yarn feed path extending from the package holder to the outlet. As the length of the second span of yarn is of a predetermined length related to the yarn feed path, the amount of excess yarn wound onto the yarn package can be reduced. Furthermore, by feeding out only the measured second span of yarn, yarn protruding beyond the outlet is reduced, thereby reducing the risk of entanglement with neighbouring yarns or other objects.
The frictional element may be engageable with the core when the first and second spans of yarn have been dispensed from the yarn package. As such, the yarn brake is configured to interact with yarn packages having varied external diameters, resulting from different amounts of yarn being wound thereon. The frictional element may engage with the first span of yarn towards an opposite end of the yarn package with respect to an end of the yarn package from where the yarn is being dispensed. The frictional element may be pivotably moveable between the disengaged position and the engaged position. The frictional element may be removably insertable into a slot of a housing of the package holder.
In some embodiments, the package holder is one of a plurality of package holders provided within a creel, the yarn brake being moveable between each of the package holders. The yarn brake may be incorporated within or attachable to an automated gripper, the automated gripper being adapted to load the yarn package into the creel. By attaching the yarn brake to the automated gripper, the yarn brake is easily implemented into existing automated yarn handling systems.
In a still further aspect, the invention provides a system for controlling a feed of yarn from a yarn package to an outlet, comprising: a winding machine configured to wind a first span of yarn and a second span of yarn onto an empty core to form a yarn package; a package holder configured to hold the yarn package during production of a yarn product; and a yarn brake configured to selectively engage with the yarn package; wherein the second span of yarn has a predetermined length calculated to feed a tail end of the yarn package along a yarn feed path extending from the package holder to the outlet, such that when the yarn brake engages with the first span of yarn, application of a tension force to the tail end results in only the second span of yarn being dispensed from the yarn package.
The system may further comprise an automated gripper to transport the yarn package between the winding machine and the package holder. The yarn brake may be incorporated within or attached to the automated gripper.
In some embodiments, the package holder may be one of a plurality of package holders provided within a creel. The creel may be a mobile creel. The outlet may be one of a plurality of outlets provided within a header, each outlet being associated with a corresponding package holder. By providing a plurality of package holders within a creel, the length of the yarn feed path from each package holder to a corresponding outlet of the header can be simply determined.
It is understood that any of the individual features provided above or described below or shown in the accompanying figures may themselves be the subject of independent or dependent claims. The features as described herein may be utilised in any combination as would provide a beneficial outcome and no single embodiment is considered in its own to be limiting to the scope of the invention.
Embodiments of the present disclosure will now be described, by way of non-limiting example, with reference to the accompanying drawings, in which:
In this description, the term “yarn” is understood to be a continuous strand composed of either natural or man-made fibres or filaments and used in weaving, tufting, sewing and knitting. The term is intended to be synonymous with the term, thread, fibre, string, filament, twine, strand, ply, cord, line, wool or cotton and the like.
In this description, the term “yarn package” is understood to mean a core that is would with a known, predetermined amount of yarn that is used to supply a machine for producing yarn-based products including textiles, for example soft floor coverings such as carpet and rugs. The term is intended to be synonymous with the terms: spool, bobbin, cone and the like.
In this description, axis and movements in the X, Y and Z directions are to be understood generally as horizontal, longitudinal and vertical movements respectively. For clarity, some of the accompanying Figures include an indicator to mark the respective orientations.
Yarn Handling System
The following section and accompanying Figures are used to describe an automated yarn handling system for loading and unloading yarn packages into a creel. Various aspects of the handling system will then be explored in more detail, in later sections.
The Creel
The creel 10 shown in the Figures is a mobile creel comprising a creel frame 11 and wheels 12. The frame 11 holds the elements of the creel 10 together. The creel 10 is a double-sided creel, having two sides, a first side 13 and a second side 14, each side comprising an array of creel positions. Each side 13,14 of the creel 10 has an outwardly facing loading face 13a,14a, respectively, and an inwardly facing non-loading face 13b,14b, respectively. The loading and non-loading faces are indicated in
It is understood, however, that the creel 10 could, alternatively, be a single sided creel, as shown in
Each creel position comprises a package holder 20, for receiving and supporting a yarn package 30. The package holders 20 are arranged in a hexagonal array. Each package holder 20 comprises a mounting bracket 21 sized and shaped to receive a core 31 of the yarn package 30, and a housing 22.
Best shown in
Other methods of protecting the yarn packages 30 from entanglement with yarn of other yarn packages 30 in other package holders 20 and from debris are also contemplated within the overall scope of the present disclosure.
With reference to
Returning now to
The yarn conduit 24 includes a rigid conduit 24a that extends from a central opening 25 through which the yarn is drawn to a terminal aperture 23 disposed within a non-loading face of the creel 10. The opening 25 protrudes outwardly from the open end of the housing 22, such that the yarn conduit 24 extends therefrom, when viewed in a side profile. In the illustrated embodiment, the yarn conduit 24 passes through the central plinth 21a of the mounting bracket 21. The rigid conduit 24a can be a plastic material or a metal such as steel or aluminium. The rigid conduit 24a preferably has an internal diameter of between 2 mm and 6 mm, and preferably about 4.8 mm
The rigid conduit 24a guides the yarn tail 33 through the housing 22 to exit the housing 22 at an aperture 26, where the yarn tail 33 enters the flexible conduit 24b which guides the yarn tail 23 to the outlet 60. The flexible conduit 24b is a tube or a hose and can be made from plastic and other resilient materials synthetic or otherwise. The flexible conduit 24b can be transparent to allow the yarn tail 33 to be visible as it exits the rigid conduit 24a. This can provide a visual inspection point to assess the yarn tail's 33 progress along the flexible conduit 24b.
In other embodiments, it is contemplated that bespoke conduits 24 can be individually dimensioned as rigid conduits that run through the housing 22 and up to the outlet 60 thereby replacing flexible conduits 24b; however, for ease of manufacture the combination of rigid 24a and flexible 24b portions is preferred.
The Header
Best shown in
The header 61 comprises a header plate 62 within which each of the plurality of outlets 60 are disposed. The header plate 62 is enclosed by a header cover 63. The header cover 63 is moveable between an open position to a closed position. The header cover 63 is made of a perforated or screen-type material, allowing air to flow though the header cover 63, while the yarn tails 33 remain contained therein.
In the closed position, the header cover 63 is configured to capture and restrain the yarn tails 33 during, for example, transportation of the creel 10. With the header cover 63 in the closed position, the yarn tails 33 are constrained therein preventing them from interfering with the operation of loading further packages 30 into the creel 10.
In the open position, the header cover 63 provides access to the yarn tails 33 for connecting to the production machine via, for example, splicing of the tails 33 to the machine for use. The open configuration of the header cover 63 is also shown in broken line in
The Winder
Returning now to
In the embodiment shown in
The length of yarn wound on a particular yarn package 30 is calculated based on the amount of yarn required at the respective package holder 20 where the yarn package 30 will be placed. Accordingly, some yarn packages 30 may comprise more yarn than other yarn packages 30.
A winder supply store 43 is located adjacent to the winder 40. The winder supply store 43 has at least one yarn supply 44 that provides yarn to each winding head 41, when desired. Preferably, the yarn supply store 43 comprises a plurality of yarn supplies 44 in the form of large packages of yarn. Each yarn supply 44 may provide yarn in a desired colour. Each winding head 41 may be supplied by a distinct yarn supply 44 relative to the other winding heads 41.
In order to service the package holders 20 on each side of the creel 10 simultaneously, at least one winder 40 and gantry frame 50 may be located respectively adjacent to each of the first and second sides 13, 14 of the creel 10 respectively.
Alternatively, in some instances, the or each winder 40 may be located adjacent to the first side 13 of the creel 10 only, such as shown in
The winder 40 may comprise a storage buffer 42 configured to hold a single empty core 31. In the embodiment shown in
Alternatively, the storage buffer 42 may be a magazine which is adapted to hold a plurality of empty cores 31. An empty core 31 will be passed from the magazine to a winding head 41 when it is required for forming a new yarn package 30. The winding heads 41 may share a common magazine or, preferably, each winding area 41 may comprise its own distinct magazine, such that, for example, where there are three winding heads 41 there may be three magazines. The magazine may comprise a port which is sized to receive the empty cores 31. The empty cores 31 will be held in line in the magazine and sent to the winding head 41 in order when a new yarn package 30 is required.
The Gantry Frame
The gantry frame 50, as shown in
Brackets 54 are attached at spaced apart locations to the longitudinal members 52. The brackets 54 are positioned on the inner side of the longitudinal members 52 such that each bracket 54 on one longitudinal member 52 faces towards a bracket 54 on the other longitudinal member 52.
As shown in
Best shown in
A platform 57a is moveably connected to the vertical rail 57. The vertical platform 57a has rollers 57b which engage with a track 57c of the vertical rail 57 such that the vertical platform 57a is moveable vertically along the length of the vertical rail 57. A vertical motor 57d controls the motion of the vertical platform 57a. The vertical motor 57d preferably functions in a similar manner to the upper and lower motors 55d, 56d. Any one or more of the motors 55d, 56d, 57d may cooperate with a rack and pinion and bearing arrangement to accurately control the movement of the vertical rail 57 and/or vertical platform 57a.
An arm rail 58 is attached to the vertical platform 57a. The arm rail 58 extends longitudinally in the Y-direction as shown in
The Gripper Assembly
The gripper assembly 70 is connected to the gantry frame 50 via the rotatable connector 58a in a manner such that it is moveable vertically, horizontally, and rotatably. The gripper assembly 70 is preferably moveable between any of the package holders 20 of the first side 13 of the creel 10 and may provide a yarn package 30 to or retrieve an empty core 31 from a respective package holder 20, when required to do so. In addition, the gripper assembly 70 may be manipulated and positioned to provide an empty core 31 to or retrieve a wound yarn package 30 from the winder 40.
In the embodiment shown in
The gripper assembly 70 connects to a side of the rotatable connector 58a opposite to the arm rail 58. The gripper assembly 70 is rotatably connected to the rotatable connector 58a in a manner such that the gripper assembly 70 may be rotated between a first orientation where a front end 71 of the gripper assembly 70 faces towards the creel 10 in the Y-direction and a second position where the front end 71 of the gripper assembly 70 faces towards the winder 40 in the Y-direction. Thus, the movement of the rotatable connector 58a in the Y-direction may cause the gripper assembly 70 to move towards or away from the creel 10 when in the first orientation. Similarly, the movement of the rotatable connector 58a in the Y-direction may cause the gripper assembly 70 to move towards or away from the winder 40 in the second orientation. The connector motor 58d may control the rotation of the gripper assembly 70 between the first and second orientations. Alternatively, the gripper assembly 70 may comprise a separate motor which controls the rotation between the first and second orientations. The rotation of the gripper assembly 70 may be pneumatically controlled and may comprise hydraulic bump stops.
According to yet another embodiment (not shown), two winders 40 may be positioned on each side 13, 14 of the creel. In other words, two winders 40 are positioned adjacent to the first side 13 of the creel 10 and a further two winders 40 are positioned adjacent to the second side 14 of the creel 10. The winders 40 are preferably located at opposing ends of the creel 10. In this embodiment, a second upper rail and a second lower rail are located adjacent the second side 14 of the creel 10 between the creel 10 and the two winders 40. Further, adjacent to each side 13, 14 of the creel 10, the gantry 50 may comprise two vertical rails 57, each being moveable horizontally on respective upper and lower rails 55, 56. Two gripper assemblies 70 are thus moveable vertically and horizontally and rotatably on the respective vertical rails 57 on each side of the gantry 50, with each gripper assembly 70 being moveable on the gantry 50 between its respective winder 40 and the half of the package holders 20 of the respective side 13, 14 located towards the end of the creel 10 most proximal to the respective winder 40.
Referring now to
The head 74 has four tabs 74a which extend in the longitudinal direction towards the front end 71 of the gripper assembly 70. The tabs 74a are evenly spaced around the circumference of the head 74. The snout 75 comprises four ribs 75a which are parallel to the tabs 74a and extend longitudinally along the surface of the snout 75. The gripper assembly 70 further comprises four fingers 76. The four articulated fingers 76 extend along the snout 75. Each tab 74a is connected to each finger 76 at the rear of the respective finger 76 via two connectors 77, with a connector 77 located on either side of the tab 74a. Each finger 76 is connected to the respective rib 75a via two connectors 70 towards the front of the finger 76 with, one connector 77a,b on either side of the finger. Each finger 76 is also coupled to the respective rib 75a via two additional connectors 70c, 70d towards the rear of the finger 76 on either side of the finger 76. Together, the connectors 77 pivotally couple each of the respective fingers 76 to the respective ribs 75a and tabs 74b. The location of the pivotal connectors 77 are such that a longitudinal motion of the snout 75 relative to the head 74 will cause the fingers 76 to move radially relative to the snout 55.
The described arrangement of the head 74, snout 75, fingers 76, ribs 74a, tabs 75a and connectors 70 create a gripping jaw 78 which may be utilised to grasp the inner surface 31a of a yarn package 30. The jaw assembly 78 is configurable between a closed state, in which the fingers 76 lie against the snout 75, to an open state, in which the fingers 76 extend radially outwards and do not contact the snout 75.
The jaw assembly 78 is configured to grasp onto the core package 30 from within the core 31, to facilitate transport thereof. With the jaw assembly 78 in the closed state, the head 74 is driven forward and the snout 75 is inserted into the core 30. The jaw assembly 78 is then expanded to the open state, where the fingers 76 push outwardly against the inner surface 31a of the core 31. With the yarn package 30 now secured to the jaw assembly 78, the head 54 is retracted, removing the yarn package 30 from the winding machine 40.
The gripping action of the jaw 48 may be a reverse chuck arrangement. For example, the snout 75 may be moved longitudinally relative to the head 74. When the snout 75 moves longitudinally, the connectors 70 interact with the respective tabs 74a, ribs 75b and fingers 76 to cause a radial motion of the fingers 76. When the snout 75 moves longitudinally towards the front end 71 the fingers 76 will each move radially outwards from the snout 75. Similarly, when the snout 75 then moves longitudinally towards the rear end 72, the fingers 76 will each move radially inwards relative to the snout 75. The maximum inward radial movement of the fingers 76 will cause the fingers 76 to contact the ribs 75a. A pressurised fluid, such as pressurised air, may be utilised to cause a movement of the jaw 78. The motion of the fingers 76 of the jaw 78 radially inwards or outwards may be controlled by a controller.
As shown in
In order to align the jaw 78 correctly with a package holder 20, the gripper assembly 70 or creel 10 may comprise a sensor and/or camera (not shown). For example, the gripper assembly 70 or creel 10 may comprise a feature recognition camera that is configurable to align the jaw 78. The camera(s) or sensor(s) used may at least identify the corners of the creel 10 in order to manoeuvre and align the jaw 78 correctly with a desired package holder 20. The camera(s) or sensor(s) may be configured to identify each package holder 20 individually for accurate alignment. Similarly, camera(s) and/or sensor(s) may be utilised to manoeuvre and position the jaw 78 relative to a or the winder 10. The sensing system used may utilise LiDAR (light detection and ranging) for accurate positioning of the jaw 78.
The above description and accompanying figures show and describe a gripper assembly 70 which is operated and controlled through pneumatic actuators and the flow of pressurised gas, such as pressurised air. However, liquids can be substituted for the working fluids as described herein. Likewise, the gripper assembly 70 can be controlled and manipulated via mechanical or electrical means. A controller is preferably provided to control the movement and position of the gripper assembly 70. The gripper assembly 70 can be automated and utilise sensors to determine when an empty core 31 is to be removed from a creel position 20 or when a yarn package 30 is to be delivered to a creel position 20. Computer software is preferably provided to control the movement of the gripper assembly 70 and the processes of loading the packages 30 into the housings 22 of the creel 10.
Yarn Control Device
It is preferable for the gripper assembly 70 to controllably retain the yarn tail 33 of the respective yarn package 30. This process is facilitated by way of a yarn control device 101. It is to be understood that the yarn control device 101 can also be used for other yarn handling applications, outside of yarn handling system 1.
The body 102 is configured to received and guide the yarn 32 towards the operative region 105. The body 102 comprises a pair of angled jaws comprising an upper jaw 103 and a lower jaw 104 that converge at a slot 121 within the operative region 105 of the body 102. The jaws 103,104 have bevelled edges to allow the yarn 32 to travel across the jaws 103,104 without catching or snagging on the jaws 103,104.
On a first face of the body 102 is a plurality of supply ports for introducing fluids into the body 102, including the first fluid inlet 107 that introduces a first fluid into the body 102 to be expelled at the first fluid outlet 110. The first fluid can be a gas. The first fluid in one embodiment is air fed to the first fluid inlet 107 as compressed air. In
Further to the first fluid inlet 107 is a working fluid activation supply port 106 and a working fluid deactivation supply port 108. By introducing a working fluid into the body 102 the moveable member 109 is moved within the body 102 to contact and clamp the yarn 32 within the operative region 105. The working fluid can be a gas. The working fluid can be compressed air. The working fluid can be a liquid.
The moveable member 109 can be a piston configured to reciprocate within a bore or chamber 122 (not shown) of the body 102. As the working fluid is introduced into the chamber 122 the moveable member 109 is urged towards the operative region 105 to clamp the yarn 32 therein see
The body 102 provides an upper access panel 112 and a lower access panel 113 each mounted to the body 102 by at least one retaining screw 115. Removal of access panels 112 and 113 provides access to the internal components of the body 102. The body 102 includes a plurality of mounting holes 114 for mounting the body 102 to a support arm 120 to facilitate at least one of translational and rotational movement thereof.
The moveable member 109 has a head 111a that traverses the operative region 105 in anticipation of receiving the yarn tail 33, as illustrated in
As the moveable member 109 is activated by the working fluid the moveable member 109 traverses the operative region 105 until the shoulder 119 of contacts an upper surface 121a of the slot 121. As the shoulder 119 contacts the upper surface 121a the yarn 32 is trapped therebetween and can no longer move relative to the operative region 105. The yarn 32 is then clamped in position relative to the body 102, see
To release the yarn 32, the working fluid deactivation supply port 106 is opened, allowing the working fluid to enter a secondary chamber 125 (not shown) to drive the moveable member 109 away from the operative region 105. As each of supply ports 106 and 108 are inlets, the moveable member 109 can be driven back and forth by the introduction of the working fluid alternately between the first chamber 122 and the secondary chamber 125 from the respective supply ports 106, 108.
In
Where the yarn 32 is clamped in the operative region 105, the yarn tail 33 of the yarn 32 is trapped in fixed relationship with the body 102. When no fluid is directed to the first fluid outlet 110 the yarn tail 33 will trail from the operative region 105, as shown in
When the first fluid flow F is activated, the yarn tail 33 will be caught and entrained within the first fluid flow 102 and oriented to extend from the operative region 105 away from the body 102 parallel to the first fluid flow F. By moving the body 102 in at least one of translational movement and rotational movement for example in the direction indicated by arrow R in
The body 202 has a pair of jaws, illustrated as upper jaw 203 and lower jaw 204 with bevelled edges 203a, 204a respectively. A slot 221 is located where the two jaws 203, 204 converge to define an operative region 205 of the body 202.
Upper 212 and lower 213 access panels are provided for access to a first chamber 222 and a second chamber 225 for maintenance and replacement of the first moveable member 209 and second moveable member 239, respectively.
On an opposing face of the body to the pair of jaws 203, 204 are four supply ports, 206, 208, 240, 241 and a first fluid inlet 207. The first fluid inlet 207 is located centrally of the body 202 to introduce the first fluid into the body 202 in communication with a bore 227 for supplying the first fluid to a first fluid outlet 178. Below the first fluid inlet 207 is second fluid activation supply port 240 and second fluid deactivation supply port 241. Above the first fluid inlet 207 is a first fluid activation supply port 206 and first fluid deactivation supply port 208.
It is understood that the first and second working fluids can be a gas. The first and second working fluids can be compressed air. The first and second working fluids can be sourced from the same compressed air supply or two discrete air supplies. The first and second working fluids can be a liquid and can be sourced from two discrete fluid supplied or a single fluid supply.
In
The body 202 of the yarn control device 201 provides similar mounting features 214 to that of body 102 for driving the body 202 in at least one of translational movement and rotational movement.
The supply port arrangement shown in
The first working fluid is maintained within the body 202 and as such either liquids or gases can be selected to drive the moveable members 209, 239. The body port 206 is in fluid communication with the first chamber 222 via a communication channel 243, allowing the first working fluid to be forced into the chamber 222 on activation of fluid to the supply port 206. Each of the supply ports 206, 208, 240, 241 operate in the manner as described above in reference to supply port 240.
When the first working fluid enters the chamber 222 the first movable member 209 is driven towards the operative region 205. When the first movable member 209 is to be released the working fluid is driven to the first deactivation supply port 206 and the supply of first working fluid to the first activation supply port 206 is ceased. This drives the first movable member 209 away from the operative region 205 and towards the access panel 212, as shown in
The head 211 of the first moveable member is concave and has a greater diameter than a diameter of the head 226 of the second moveable member. When the second head 226 is driven into the first head 211 the yarn 32 is trapped in the aperture 218 formed in the operative region 205.
With the yarn control device 201 in the feeding mode, activating the first fluid flow F, will expel the first fluid from the first fluid outlet 210 to form the first fluid flow F. The first fluid outlet F is in close proximity to the operative region 205 and captures the yarn tail 33 of the restrained yarn 32. The yarn tail 33 becomes captured or entrained within the first fluid flow F directing the yarn tail 33 away from the body 202 perpendicularly to the body 202 and perpendicular to the bore 227.
As the yarn 32 is not clamped the first fluid flow captures the yarn tail 33 and draws the yarn 32 through the aperture 218 across the operative region 205 increasing a length of the yarn tail 33. When the yarn tail 33 reaches a sufficient length for threading into the creel 10 the first air flow F is deactivated and/or the first moveable member 209 is activated to clamp the yarn 32 and terminate the feeding mode.
This feeding mode of
In the clamping mode, the second movable member 239 is not activated and remains within chamber 225 in proximity to the lower access panel 213. Meanwhile, the first fluid activation supply port 206 is turned on, to drive the first working fluid into the first chamber 222 and drive the first moveable member 209 and the head 211 thereof into the operative region 205. The concave head 211 is driven into contact with a lower surface 221b of the slot 221 whereby the outer peripheral rim 211a clamps down over the yarn 32 securely holding the yarn 32 in place against the lower surface 221b of the slot 221.
In one embodiment, the chambers 222, 225 are cylindrical and the moveable members 209, 239 are also cylindrical, configured as pistons. The pistons are dimensioned to reciprocate back and forth within the respective chambers 222, 225 with O-rings 236 providing each piston with a sealing arrangement to manage the first and second working fluids within the body 202. These seals prevent leakage of the first and second working fluids within the respective chambers 222, 225. As such, the O-rings 236 improve operational efficiency of the yarn control device 201 and improve control over the working of the yarn control device 201. The first and second working fluids can be different fluids. In some embodiments, the first and second working fluids can be the same fluid.
The working fluid is then introduced into the body 202 to activate the second moveable member 239 and form the aperture 218 to constrain the yarn 32 therein illustrated in
Where the yarn tail 33 exceeds the predetermined length, the yarn tail 33 can be shortened by moving the yarn control device 201 relative to the yarn 32. As such, any relative movement therebetween can be used to decrease the length of the yarn tail 33.
In some embodiments, the yarn control device 101,201 can be used as part of a yarn handling device 301. The yarn handling device 301 includes the yarn control device 101, 201 and a moveable lance 302 that is independently moveable with respect to the yarn control device 101, 201. The moveable lance is shown in
In the illustrated embodiments, the yarn handling device 301 comprises the yarn control device 101. However, it is understood that the yarn control device 201 can also be used as a part of the yarn handling device 301.
The lance 302 includes a central bore 303 that feeds a nozzle 304. The nozzle 304 is adapted to discharge a second fluid flow F′ towards a target receiver. The target is a location to which the yarn tail 33 is to be fed. The central bore 303 is between 2 mm and 8 mm in diameter and preferably about 4.95 mm in diameter, and narrows to a secondary bore 303a of between 4 mm-10 mm and preferably about 8.65 mm in length.
The secondary bore 303a terminates at the tip of the nozzle 304, which is between 0.5 mm-2.5 mm in diameter and preferably about 1.5 mm in diameter. The step down in diameter between the central bore 303 of the lance 302 to the secondary bore 303a increases the velocity at which the second fluid is expelled from the nozzle 304.
The second fluid flow F′ is about between 50-150 litres/minute and preferably 113 litres/minute. The second fluid flow F′ has a pressure between 3 bar and 10 bar and preferably at a pressure of 7 bar.
The second fluid flow F′ is configured to have a higher flow rate than the first fluid flow F, such that the second fluid flow F′ can displace the entrained yarn tail 33 from the first fluid flow F to redirect the yarn tail 33 coaxially with the second fluid flow F′. The yarn tail 33 will be directed and urged towards which ever target location the second air flow F′ is directed at, such that the second fluid flow F′ expels the entrained yarn tail 33 from the first fluid flow F thereby delivering the yarn tail 33 to the target.
The above dimensions are directed to a specific working embodiment of the invention; however, it is contemplated that these dimensions and the pressure of the second fluid can be varied to provide a desired flow rate to complement a given yarn density. For example, a light weight yarn of low linear mass density referred to as deci-tex or dTex can be controlled with a low flow rate, while a heavier yarn of higher dTex can be controlled with a higher flow rate to influence and manipulate the yarn tail 33.
Accordingly, it is understood that in-use, with the yarn control device 101 in the operative configuration, the yarn 32 is clamped in the operative region 105 of the body 102 such that the first fluid flow F captures the yarn tail 33 and orients the yarn tail 33 coaxially with the first fluid flow F, as the body 102 is moved the first fluid flow F is reoriented to intersect the second fluid flow F′ from the nozzle 304. The yarn tail 33 is therefore directed towards the target.
Yarn Brake
The dispensing of yarn 32 from the yarn package 30 is controlled by a yarn brake 80, which will now be described in detail in reference to
The yarn brake 80 is used to control the dispensing of yarn 32 from the yarn package 30, such that once the yarn tail 33 arrives at the header 61 further dispensing of yarn 32 from the yarn package 30 is inhibited.
The yarn brake 80 comprises a support arm 81 and a frictional element in the form of brake finger 82. A linear actuator 83 extends along the support arm 81 and is coupled to the brake finger 82. The actuator 83 is shown as a pneumatic cylinder including a piston rod 83a, however other types of actuator are also contemplated.
Activation of the linear actuator 83 moves the brake finger 82 from a disengaged position to an engaged position.
In the embodiment illustrated in
Method of Automatically Loading and Unloading the Creel
Broadly speaking, operation of the system 1 comprises the following stages:
The following sections of the disclosure relates to processes (i) to (vii) as identified above.
Retrieving Empty Cores from the Creel
When located in the position as shown in
Once the fingers 76 have engaged the inner surface 31a of the core 31, the empty core 31 may be removed from the mounting bracket 21. The piston rod 79a is retracted and the head 74 to move longitudinally back towards the gripper body 73. The head 74 and snout 75 are thus removed from the housing 22. Furthermore, the empty core 31 is removed from the package holder 20.
Delivery of Empty Cores to the Winder
The pneumatic cylinder 79 is then activated to cause the piston rod 79a to extend outwardly in the longitudinal Y direction towards the winder 40, as shown in
The head 74 will be positioned at an empty core drop-off position adjacent to a port or other receiving section of the winder 40, which provides access to the storage buffer 42. The jaw 78 will close to release the empty core 31 to provide the empty core 31 to the port or receiving section of the winder 40. The winder 40 may have a means to collect the empty core 31 and to move it to the magazine or storage buffer 42 where appropriate. According to an embodiment, not shown in the Figures, the gripper assembly 70 may include a pushing member to push the empty core 31 through the port or receiving section of the winder 40 and into the storage buffer 42.
Once the empty core 31 has been provided to the magazine or storage buffer 42, as shown in
Winding of Yarn Packages
Turning now to
A length of the first span 34 and second span 35 of yarn on each yarn package 30 is variable, and dependent on (i) a designated package holder 20 to which the yarn package 30 will be attached, and (ii) the amount of yarn 32 required to be consumed by the production machine at the corresponding operating point. The total length of yarn wound onto each yarn package 30 is equal to the amount of yarn that is to be consumed by the production machine at a corresponding active operation site. Accordingly, an advantage provided by calculating the first and second spans 34 and 35 is a reduction in yarn wastage. This is because at the completion of the production of the yarn product, there is little to no yarn remaining on the yarn package 30. Accordingly, the now empty core 31 can be re-used by the winding machine 40 to form a new yarn package 30. This is to be contrasted with conventional production methods, where yarn remaining on the spool after a job has completed is disposed of, so as to allow the core 31 to be rewound for a subsequent job.
Before winding the first span of yarn 34 onto the empty core 31, the winding machine 40 receives an input indicating the amount of yarn required by the production machine and an assigned package holder 20 where the yarn package 30 will be placed. The winding machine 40 then determines the length of the second span of yarn 35, being equal to or slightly greater than the length of a yarn feed path P associated with the assigned package holder 20. It is envisaged that this process utilises a look-up table, where the yarn feed path P associated with each package holder 20 is predetermined and stored within the winding machine 40. The length of the first span of yarn 34 is then calculated by the winding machine 40, being equal to the total amount of yarn required by the production machine less the length of the second span 35.
Each respective package holder 20 is associated with its own yarn feed path P. The yarn feed path P is the path along which the yarn tail 33 of each yarn package 30 within the creel 10 is fed to its respective outlet within the header 61.
With reference to
The yarn feed path P further comprises a second portion extending along the non-rigid conduit 24b from the aperture 26 within the non-loading face to the corresponding outlet within the header 61.
Shown schematically in
Collection of Yarn Packages from the Winder
After following the above steps, there will be a package holder 20 in the creel 10 which is absent a package 30 or core 31 on its mounting bracket 21.
The yarn control device 101,201 can be configured in conjunction with the gripper assembly 70 when retrieving the yarn package 30 from the winder 40 and delivering the package 30 to the creel 10.
As previously described, the gripper assembly 70 is linearly moveable between the creel 10 and winder 40 along the gantry 50. As shown in
From the position shown in
When moved towards the yarn package 30, the jaw 78 is in a closed orientation such that the snout 75, including fingers 76, will be located within the centre of the core 31 as the head 74 approaches the package 30. When located in the position as shown in
Notably, after the winder 40 completes the winding of the package 20, the core 31 is released or “doffed” from the winder 40, and rests in a pick-up position, with the supply yarn 44 from the winder 40 being uncut or held in some way. This is shown in
As previously noted, the yarn control device 101, 201 uses V-shaped jaws to intersect and capture the yarn 33 before it is cut and still under control of the winder 40. This is shown in
Delivery of Yarn Packages to the Creel
The next stage is to deliver the yarn package 30 to the assigned package holder 20. This stage is shown in
Initially, the rotatable connector 58a is rotated such that the jaw 78 of the gripper assembly 70 is in the orientation where it faces the creel 10. In this step, the connector 58a is preferably rotated in the direction opposite to that which caused the gripper assembly 70 to move from facing the creel 10 to facing the winder 40.
Where necessary, the gripper assembly 70 will also be moved in the X and Z directions, by moving the arm platform 57a vertically along the vertical rail 57 in the Z direction and moving the upper and lower platforms 55a, 56a horizontally along the upper and lower rails 55, 56 in the X direction. The gripper assembly 70 holding package 30 will then be in the position shown in
The rotatable connector 58a is then moved in the Y-direction to cause the gripper assembly 70 holding package 30 to move towards and into the respective housing 22, as shown in
Once the yarn package 30 is located on the mounting bracket 21, the jaw 78 is activated once again in reverse to cause the fingers 76 to disengage from the inner surface 31a of the core 31 until the jaw 78 is in its closed position. At this point, the yarn package 30 is supported entirely by the mounting bracket 21.
After the package 30 is secure, the gripper assembly 70 may then be partially retracted by engaging the cylinder 79 to cause the piston rod 79a to retract, until the head 74 of the gripper assembly is outside of the housing 22, all the while maintaining control of the yarn tail 33 within the yarn control device 101. This is shown in
Threading of the Yarn Tail into the Conduit
Once the yarn package 30 is supported on the core mounting bracket 21, it is necessary for the yarn tail 33 to be fed towards its respective outlet 60 within Header 61 via the conduit 24. The first step of this process is to thread the yarn tail 33 into the conduit opening 25, as shown in
With reference to
With the head 74 providing the moveable lance 302, the nozzle 304 is thus brought into proximity with the conduit opening 25 as the gripper assembly 70 is urged forward and the package 30 is slid over the core mounting bracket 21. Preferably, in-use, the nozzle 304 is located about 3 mm±2 from the conduit opening 25. This optimum distance G between the nozzle 304 and the conduit opening 25 is approximately twice the diameter of the nozzle 304, illustrated in
Referring now to
The second fluid flow F′ has a greater fluid flow than the first fluid flow F. Accordingly, once the yarn tail 33 in the first fluid flow F crosses the second fluid flow F′, the yarn tail 33 is ejected from the first fluid flow F and fired into the conduit opening 25 and fed through both the rigid conduit 24a and the flexible conduit 24b to be received at the header 61.
The gripper assembly 60 is then fully retracted from the housing 22 to restart the process, as illustrated in
Feeding of Yarn to the Outlet
With the yarn package 30 now supported by the package holder 21 and the yarn tail 33 threaded into the conduit opening 25, a tension force T is applied to the yarn tail 33. The yarn 32 on the package 30 is thus drawn through the conduit 24 along the yarn feed path P. The tension force T is provided by the second air flow F′ from the nozzle 304. The second fluid stream F′ thus propels the yarn tail 33 into the conduit opening 25 and along the yarn feed path P to the header 61. The header 61 receives and stores the yarn tails 33 to prevent them being tangled or snagged if the yarn tails were to fall into the creel positions 20 beneath the header 61.
As described herein, in some embodiments, a second span of yarn 35 is wound onto the package 30 in a straight configuration, thereby defining a feeding yarn that continues to be unwound from the package 30 during the loading of the package 30 into the housing 22 of the creel 11. As previously noted, a specific length of feeding yarn 35 can be tailored to the location of the package 30 on the creel 10.
When feeding yarn 32 along the yarn feed path P, it is desirable to feed only the minimum length of yarn required to reach the respective outlet 60. This is to reduce the possibility of yarn from adjacent outlets 60 within the header 61 from becoming entangled with one another. This selective feeding is facilitated, at least in part, via yarn brake 80. Operation of the yarn brake 80 during the feeding process will now be described in reference to
After the yarn tail 33 has been inserted into the yarn conduit opening 25 the brake finger 82 is moved to the engaged position to make frictional contact with the first span 34 of the yarn package 30. This is shown in
Engagement between the brake finger 82 and the yarn 32 results in a frictional force R. The frictional force R is applied to an end of the first span 34, proximate to where the helical winding of the first span 34 transitions into the straight winding of the second span 35. The frictional force R acts in a direction opposite to the tension force T. As the brake finger 82 is engaged with the first span 34 of yarn only, the second span 35 of yarn is free to unwind unrestricted under the tension force T, enabling the yarn tail 33 to feed towards the header 61. This is shown in
After a predetermined duration of time, the tension force T is deactivated. Notably, as the friction force F applied by the yarn brake 80 inhibits dispensing of the first span 34 of yarn even with the tension force T being active, the predetermined time does not need to be accurately calculated for the yarn feed path P of each package holder 20. Rather, the predetermined time merely needs to be sufficient to feed the yarn tail 33 from the package holder 20 having the longest yarn feed path P. Accordingly, the tension force T is applied for the same predetermined time for each package holder 20 of the creel 10, simplifying the overall feeding process.
Once the tension force T is deactivated, the actuator 83 is deactivated, such that the brake finger 82 is returned to the disengaged position, outside of the housing 22, as shown in
The above processes may be repeated a plurality of times. Summarily, the process includes the steps of: maneuvering the gripper assembly 70 to retrieve the package 30 from the winder 40 and capture the yarn tail 33; delivering the package 30 to the housing 22 on the creel 10 and activating the first fluid flow F to orient the yarn tail 33; moving the body 102 to draw the yarn tail 33 across the second fluid flow F′ wherein the second fluid flow F′ drives the entrained yarn tail 33 from the first fluid flow F and into the opening 25 of the conduit 24, and delivering the yarn tail 33 to the header 61 by controllably feeding the yarn 32 along the conduit 24 with the assistance of yarn brake 80.
It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country.
In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2020903209 | Sep 2020 | AU | national |
| 2020903210 | Sep 2020 | AU | national |
| 2020903212 | Sep 2020 | AU | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/AU2021/051038 | 9/8/2021 | WO |
