DE9422071U1 - Sample warping machine - Google Patents

Description

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DESCRIPTION

This invention relates to an electronically controlled sample warper that can warp yarns into a neatly layered state regardless of the warp length, thereby enabling the warping of long samples or products produced in small quantities.

Conventional electronically controlled pattern warping machines are exemplified in Japanese Patent Laid-Open Publication No. 62-62942, the machines generally comprising: a drive and a driven shaft 2, 3 projecting centrally from opposite ends of a hollow shaft 1 supported on the drive shaft side; a first small gear 5 loosely attached to the drive shaft 2 and fixed to a pulley 4; a second small gear 7 loosely attached to the driven shaft 3 and fixed to a yarn introduction lever 6; third and fourth small gears 9, 10 attached to opposite ends of an auxiliary shaft 8 extending through the hollow shaft 1 and meshing with the first and second gears 5, 7, respectively; drum frames 13, 14 mounted on the side of the hollow shaft 1 facing the driven shaft and each having an outer edge with alternating curved portions 11 and straight portions 12; a pair of rollers 15 mounted on the curved portion 11 of each of the drum frames 13, 14; a warping drum A loosely mounted on the hollow shaft 1 with horizontal drum spokes 16 supporting the rollers 15 around which conveyor belts 17 are wound. The conveyor belts 17 are simultaneously driven in a common amount of fine movement by a drive element 21 threadedly engaged with internally threaded shafts 20 of planetary gears 19 engaged with a sun gear 18 suitably driven from the outside; the planetary gears 19 simultaneously rotating when the sun gear rotates. The distal end of the yarn introduction lever 6 is bent inward to form a yarn introduction part 6' adjacent to the front end of the outer edge of the warping drum A. The warping machine further comprises: a shedding device

a shed and cut shed forming means for forming a shed and a cut shed by selecting the warping yarns (to be wound on the warping drum) above and below shed forming rods and cut shed forming rods; a total yarn counting means for turning on or off an up signal of a total counter for counting the total number of warping yarns; a total yarn completion terminating means for terminating the operation of the warping machine when the total number of warping yarns reaches a predetermined value; a conveyor belt leftward moving means for moving the conveyor belt to the left, a conveyor belt rightward moving means for moving the conveyor belt to the right; an operation/stop means for transmitting the rotation of a main motor 46 to the yarn introduction lever 6; a yarn selecting means for controlling a yarn selecting guide 27 and a yarn removing unit 32; a yarn pressure solenoid device for turning on and off a solenoid of a yarn relaxation preventing unit (yarn pressure unit) 60; and a winding counter device for counting the number of windings of the yarn and displaying the counted result. By selecting the yarn type 0-n and setting the yarn number, the number of repetitions, the winding number, the amount of movement of the conveyor belt, a desired warping pattern can be automatically obtained. The reference numerals used here are the same as those in an embodiment of this invention described below.

However, since this conventional warping machine uses an ordinary motor as the main motor, it is impossible to vary the rotation rate during operation, so that mis-catching and mis-changing, as well as yarn breakage during yarn changing, are inevitable. Furthermore, it is impossible to complete relaxation and perform jogging, thus providing insufficient operating efficiency. To adjust the density of warping yarns, the movement rate of the transport belt is determined by varying the gear ratio of speed change gears operatively linked to the main motor. Since the transport belt is moved even when idling, regular windings of the yarn on the warping drum are difficult to achieve, so that the tension and the warping length eventually vary during the winding operation.

In order to overcome the above-mentioned problems, proposals have been made to use an inverter motor or an AC servo motor in the warping machine (Japanese Patent Publication Nos. 64-10609 and 64-10610).

In a warping machine according to another previous proposal, a plurality of warping yarns can be wound simultaneously on a warping drum, while omitting a yarn changing step to eliminate any time loss in yarn changing and thereby reduce the warping time (Japanese Patent Publication No. 4-57776).

In the conventional electronically controlled pattern warping machines described above, in synchronization with the rotation of the yarn introduction lever 6 to wind the yarn 22 in a fixed position around the warping drum A by the required number of turns or windings (number of winding yarns × winding length), the transport belts 17 of the warping drum A are moved in the warping direction to determine the warping width. At this time, the operation of transporting or moving the transport belt 17 per revolution of the yarn introduction lever 6 is determined by (warping width / number of warping yarns) × (warping length / circumference of the warping drum). Accordingly, if the warping length is relatively small, approximately equal to the circumference of the warping drum, the amount of transport of the transport belts per revolution of the yarn introduction lever 6 will be larger than the diameter (thickness) of the yarn. The yarn can therefore be neatly wound on the warping drum with individual regularly spaced turns as shown in Fig. 38 of the accompanying drawings. After warping, the yarn can be evenly re-beamed onto a beam of a weaving machine in the form of a layer.

However, when the warping length is relatively large, e.g., nine times the circumference of the warping drum, the amount of transport of the transport belts per revolution of the yarn introduction lever 6 is considerably smaller than the diameter (thickness) of the yarn 22. This means that the yarn 22 is inevitably wound on the previously wound layers or windings of the yarn 22. In this case, however, because the yarn is wound on the warping drum A without restriction, it has an indefinitely wound structure as shown in Fig. 39. Accordingly, when the yarn windings are re-wound on beams on the loom in the form of layers, and in the reverse order of warping, e.g., 9-7-6-4-3-2-1,

the yarn can easily become tangled or tangled and therefore cannot be pulled out of the warping drum A.

In other words, in the case of a single winding (warping length = warping drum circumference), the transport belts 17 move by a distance equal to the warping density (warping yarn standard pitch) per revolution of the yarn introduction lever 6. In the case of multiple windings, such as ninth windings (warping length = warping drum circumference χ 9), on the other hand, the transport belts only move by a distance = [warping density (warping yarn standard pitch) / 9] per revolution of the yarn introduction lever 6. As a result, the yarn 22 is randomly layered as shown in Fig. 39.

Thus, depending on various conditions such as fabric density, yarn diameter or thickness and warping length, smooth and uniform yarn rewinding cannot actually be achieved when four or more winding layers of yarn are wound on the warping drum. There is therefore a significant need for an electronically controlled pattern warping machine that can wind yarns on the warping drum with yarn windings neatly layered in a regular sequence: 1-2-3-4-5-6-7-8-9 (nine windings).

In view of the above disadvantages of the prior art, it is an object of the invention to provide an electronically controlled pattern warping machine that can warp yarns on a warping drum with yarn windings neatly stacked in a regular sequence, thereby enabling the yarns to be easily re-arranged on beams on a weaving machine, even if the warping length, i.e. the number of multiple windings, is relatively large, such as four or more windings.

According to the invention, there is provided an electronically controlled pattern warping machine for automatically warping into a desired pattern of yarns by selecting the type of yarns from 0 to η and by adjusting the number of yarns, the number of repetitions, the number of windings, the amount of movement of a conveyor belt, which comprises: a drive shaft and a driven shaft which protrude centrally from opposite ends of a hollow shaft held on the drive shaft side; a first small gear loosely attached to the drive shaft and fixed to a pulley; a second small gear loosely attached to the driven shaft and fixed to a yarn introduction lever, the distal end of the yarn introduction lever being bent inwardly to form a yarn introduction lever arranged adjacent to the front end of the outer edge of the warping drum.

part; a third and a fourth small gear mounted on opposite ends of an auxiliary shaft extending through the hollow shaft and engaging with the first and second gears respectively for cooperation; drum frames mounted on the side of the hollow shaft facing the driven shaft and each having an outer edge with alternating curved portions and straight portions; a pair of rollers arranged on the curved portion of each of the drum frames; a warping drum mounted on the hollow shaft with horizontal drum spokes carrying the rollers around which conveyor belts are wound, the conveyor belts being simultaneously driven in a common amount of fine movement by a drive member threadedly engaged with internally threaded shafts of planetary gears engaging a sun gear suitably driven from the outside; the planetary gears rotating simultaneously as the sun gear rotates; a shedding device for forming a shed and a cut shed by selecting the warping yarns above and below shedding rods and cut shed forming rods; and a total yarn counting device for turning on or off an up signal of a total counter for counting the total number of warping yarns; a total yarn completion terminating device for terminating the operation of the warping machine when the total number of warping yarns reaches a predetermined value; a transport belt leftward moving device for moving the transport belt backwards, a transport belt rightward moving device for moving the transport belt rightward; an operation/stop device for transmitting the rotation of a main motor to the yarn introduction lever; a yarn selection device for controlling a yarn selection guide and a yarn removal unit; a yarn pressure solenoid device for turning on and off a solenoid of a yarn relaxation preventing unit; and a winding counting device for counting the number of windings of the yarn and for displaying the counted result, characterized in that the warping machine comprises: a guide device slidably mounted on each of the drum spokes at an end adjacent to the yarn introduction lever and slidable in the longitudinal direction of the drum spoke for guiding the yarn from the yarn introduction lever, the guide device being movable for each revolution of the yarn introduction lever in the warping direction by a first distance which is twice to half the thickness of the yarn, and

when the number of revolutions of the yarn introduction lever reaches a preset multi-winding value, the guide device rapidly moves back a second distance equal to the product of the first distance and the preset multi-winding value, thereby returning to its initial start position, and simultaneously with this rapid return of the guide device, the transport belts are moved in the warping direction a third distance equal to a longitudinal warping density, i.e. the warping width divided by the total number of yarns.

Alternatively, it can be provided that the yarn introduction lever is movable in the warping direction in such a way that for each revolution of the yarn introduction lever in the warping direction, the yarn introduction lever is moved by a first distance which is two to one half the thickness of the yarn, and when the number of revolutions of the yarn introduction lever reaches a preset multiple winding value, the yarn introduction lever is quickly moved back by a second distance which is equal to the product of the first distance and the multiple winding value, thereby returning to its initial start position, and the transport belts are moved simultaneously with the rapid return of the yarn introduction lever in the warping direction by a third distance which is equal to the longitudinal warping density, i.e. the warping width divided by the total number of yarns.

As a further alternative, it can be provided that the transport belts are movable in such a way that for each revolution of the yarn introduction lever the transport belts are moved in a direction opposite to the warping direction by a first distance which is two to half the thickness of the yarn, and when the number of revolutions of the yarn introduction lever reaches a preset multiple winding value, the transport belts are moved in the warping direction by a second distance which is the sum of a third distance Q which is equal to the first distance multiplied by the preset multiple winding value and a fourth distance which is equal to the longitudinal warping density, i.e. the warping width divided by the total number of yarns.

The invention further provides a warping method carried out by the above-described pattern warping machine, in which the yarn for the "n"th winding is wound on the warping drum so that the yarn at the beginning of the "n"th winding is arranged in front of an end of a yarn winding formed on the warping drum by the "n-1"th winding.

The above and other objects, features and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the accompanying drawings in which a preferred embodiment embodying the principles of this invention is shown by way of illustrative example.

Fig. 1 is a diagrammatic side view, with parts broken away, of an electronically controlled pattern warping machine according to this invention connected to a fixed warping beam;

Fig. 2 is a front elevation of the sample warping machine connected to a re-beaming device;

Fig. 3 is a plan view of the arrangement of the pattern warping machine, the fixed warping beam and the re-beaming device;

Fig. 4 is a side view of the sample warping machine;

, Fig. 5 is a cutaway side view of a yarn relaxation prevention unit;

Fig. 6 is a detailed front elevation of an area in Fig. 5;

Fig. 7 is a view of the arrangement of a yarn introduction lever and a slit plate;

Fig. 8 is a view showing how a stop plate is attached;

Fig. 9 is a view of a yarn selection guide;

Fig. 10 is a cross-sectional view of a guide unit moving mechanism;

Fig. 11 is a side view, partially in cross section, of the guide unit moving mechanism;

Fig. 12 is a cross-sectional view showing the engagement of gears in a drive system;

Fig. 13 is a side view of a winding state of a gear in the drive system, with parts omitted for clarity;

Fig. 14 is a side view of a guide device showing a guided yarn;

Fig. 15 is a cross-sectional view showing how a yarn is wound around tapes by the guide device;

Fig. 16 is a view of a front panel of a program setting unit;

Fig. 17 is a view of a front panel of a controller;

Fig. 18 is a block diagram showing the relationship between various parts of the pattern warping machine;

Fig. 19 is a block diagram showing the principle of a feeding operation of the guide device;

Fig. 20 is a flow chart showing the operation of a double winding termination circuit;

Fig. 21 is a flow chart showing the operation of a shedding circuit;

Fig. 22 is a flow chart showing the operation of a total yarn counting circuit;

Fig. 23 is a flow chart showing the operation of a total yarn completion termination circuit;

Fig. 24 is a flow chart showing the operation of a conveyor belt left-moving circuit;

Fig. 25 is a flow chart showing the operation of a conveyor belt right movement circuit;

Fig. 26 is a flow chart showing the operation of an operation/termination circuit;

Fig. 27 is a flow chart showing the operation of a yarn selecting circuit;

Fig. 28 is a flow chart showing the operation of a yarn pressing solenoid circuit;

Fig. 29 is a flow chart showing the operation of a multi-winding counter circuit;

Fig. 30 is a flow chart showing the operation of an inverting speed changing circuit;

Fig. 31 is a flow chart showing the operation of an AC servo control circuit;

Fig. 32 is a flow chart showing the operation of a guide device control circuit;

Fig. 33 is a flow chart showing the operation of an electromagnetic clutch control circuit for an upper drive system;

Fig. 34 is a flow chart showing the operation of an electromagnetic clutch control circuit for a lower drive system;

Fig. 35 is a timing chart showing the sequential operations of the warping machine;

Fig. 36 is a timing chart showing the sequential operations of the guide device;

Fig. 37 is a diagram of an example of yarn windings neatly layered in a regular order according to the present invention;

Fig. 38 is a diagram of a winding state of a conventional warping machine, in which the warping length is relatively small; and

Fig. 39 is a diagram of a winding state of the conventional warping machine, in which the warping length is relatively large.

Referring now to the drawings, in which like reference characters designate like or corresponding parts throughout the several views, there is shown in Figs. 1 to 4 an electrically controlled pattern warping machine W embodying the invention.

As shown in Figs. 1 to 4, the pattern warping machine W has a hollow shaft 1. A drive shaft 2 and a driven shaft 3 extend centrally from opposite ends of the hollow shaft 1. A first small gear and a pulley 99 are loosely attached to the drive shaft 2, both of which are fastened to a pulley 4. A second gear 7 is loosely attached to the driven shaft 3, to which a yarn introduction lever 6 is attached. The first small gear 5 and the second small gear 7 are respectively in engagement with a third small gear 9 and a fourth small gear 10, which are attached to opposite ends of a cooperating shaft 8 which extends through the hollow shaft 1. In this way, the first and second small gears 5, 7 are cooperatively connected to the third and fourth small gears 9, 10. The hollow shaft 1 is held on the drive shaft side; on the side of the hollow shaft 1 towards the driven shaft, a warping drum A is loosely attached.

The warping drum A is constructed from a pair of drum frames 13, 14 each having an outer edge with alternating curved and straight sections 11, 12. The warping drum A further includes a plurality of horizontal drum spokes 16, each of which carries at its opposite ends a pair of rollers 15, 15, each of which rests on the curved section 11 of each drum frame 13, 14. A conveyor belt 17 is wound around each pair of rollers 15, 15. All conveyor

t *

belts 17 are simultaneously driven in a common amount of fine motion by a drive member 21, which member is in threaded engagement with internally threaded shafts 20 of planetary gears 19, all of which are in engagement with a sun gear 18 for co-rotation therewith, the sun gear 18 being suitably driven from the exterior of the warping drum A. The distal end of the yarn insertion lever 6 is bent inwardly to form a yarn insertion part 6' which is disposed adjacent the front end of the outer edge of the warping drum A.

B designates a fixed warping beam for holding a plurality of bobbins, on which different yarns 22 of different colors are wound. The number 24 designates a guide plate for guiding the yarns 22 drawn off the bobbins; 25 a tension regulating device for adjusting the tension of the yarns 22; and 26 a thread rider ring.

Further, 27 designates yarn selection guides for selectively guiding the yarns 22 according to the commands of a program setting unit 78. A slotted plate 28 generates pulses in response to the rotation of the pulley 4 to actuate η rotary solenoids 29. A yarn selection guide 27 is attached to each rotary solenoid 29. When the individual rotary solenoid 29 is energized, the corresponding yarn selection guide 27 is moved angularly to advance to its operating position (faintly drawn position in Fig. 9); when the rotary solenoid 29 is turned off, the yarn selection guide 27 is reversely moved angularly to its original position (boldly drawn position in Fig. 9).

S denotes a stop plate supported on a base Y via a bracket T corresponding to the yarn selection guides 27. When the yarn selection guide 27 is advanced to its operating position at an angle, the stop plate S receives the distal end portion 27a of the yarn selection guide 27 to limit the movement of the yarn selection guide 27. A recess r is formed in the stop plate S in a portion engageable with the distal end portion 27a of the yarn selection guide 27. Since the distal end portion 27a of the yarn selection guide 27 is engageable with the surface of the stop plate S deeper than the normal surface, this recess r can reliably and smoothly catch the yarn during yarn exchange by the yarn selection guide 27. If this recess r did not exist, i.e., if the stop plate S were only held, the catching of the yarns could not be carried out accurately. Therefore, this recess r contributes greatly to

The configuration of the recess r may be such that the distal end portion 27a of the yarn selection guide 27 is brought deeply into engagement with the stop plate S on a rear surface thereof. Alternatively, projections or ridges may be formed on the stop plate S adjacent to such a contact surface. Also, only the contact surface of the stop plate S may be an elongated groove as shown.

59a denotes a guide rod projecting from the inner surface of a lower portion of a yarn introduction cover 59 for guiding a yarn, which is removed during yarn exchange to move to the lower side of the stop plate S. 30 and 31 denote a pair of guide rods for the yarns 22. 32 denotes a yarn removing unit for removing the yarn 22 while it is wound on the warping drum A in accordance with the instructions of the program setting unit 78.

33, 34 and 38 denote shedding rods for forming a shedding of the yarns 22; two of the rods 33, 38 are upper shedding rods, and the remaining rod 34 is a lower shedding rod. 35 and 37 denote cut shedding rods for separating the shedding bottom yarns into lower side yarns and upper side yarns; one of the rods 35 is a cut shedding top rod, and the other rod 37 is a cut shedding bottom rod. 39 denotes a yarn stop attached to the drum frame 13 for stopping a yarn immediately after shedding of broken yarn. The rewinding device C is constructed of a skeleton 40, a pair of rollers 41, 42, a zigzag comb 43, a roller 44 and a woven fabric beam 45.

46 designates a main motor, which can be an inverter motor to enable a change in speed, the termination of relaxation and jogging during operation of the warping machine, thereby achieving a greatly increased winding speed.

47 denotes a main speed change pulley; 58 a V-belt wound on and between the main speed change pulley 47 and an auxiliary speed change pulley 48; 49 a counter pulley coaxial with the auxiliary speed change pulley 48; 50 a brake actuating pinion for reciprocatingly moving a rack into and out of engagement with a brake hole (not shown) in a brake drum D

Bringing the rack, thereby regulating the rotation speed of the warping drum A as desired. 51 denotes a belt movement motor (AC servo motor); 52 a shaft lifter; 53 a driven gear; 54 a sprocket; 55 a chain; 56 a sprocket for driving the sun gear 18; 57 and 58 both V-belts; 59 a yarn introduction cover; and D a brake drum.

Numeral 60 denotes a yarn relaxation preventing unit fixed to the side wall of a horizontal drum spoke 16a or 16b under the warping drum A, which is close to the yarn selection guide 27. The yarn relaxation preventing unit 60 is preferably arranged on the drum spoke 16a arranged on the lowermost surface of the warping drum A, but it may also be arranged on the drum spoke 16b closest to the drum spoke 16a, which performs the same functions. 61 denotes a bracket by means of which the yarn relaxation preventing unit 60 is fixed to the side wall of the drum spoke 16a. 62 denotes a rotary disk constituting the yarn relaxation preventing unit 60. The rotary disk 62 has a yarn pressing cutout 63 formed by cutting away about one-fourth of the entire circumference of the disk 62, and is normally caused to rotate in one direction by a spiral return spring means 64. 65 denotes a stopper projecting from the metal fitting means 61 and engageable with the end surface of the yarn pressing cutout 63 to limit the rotation of the rotary disk 62. This stopper 65 serves to hold a removed yarn 22 in cooperation with the end surface of the yarn pressing cutout 63.

66 denotes a rotary solenoid attached to the bracket 61. The rotary solenoid 66, when energized, serves to bring the rotary disk 62 in the reverse direction. 67a, 67b and 67c are sensors for detecting the passage of the slot 28a of the slot plate 28. The slot 28a is designed to rotate synchronously with the yarn introduction lever 6. The sensors 67a, 67b, 67c further detect the rotation of the yarn introduction lever 6 by detecting the rotation of the slot 28a. These three sensors 67a, 67b, 67c are arranged at an angular distance of about 120". Among these three sensors, the sensor 67b is arranged adjacent to the lower side of the slot plate 28 to detect whether the yarn introduction lever 6 has passed the yarn relaxation preventing unit 60. Now, when the yarn to be removed next passes the yarn relaxation preventing unit 60 during winding, the sensor 67b is arranged adjacent to the lower side of the slot plate 28 to detect whether the yarn introduction lever 6 has passed the yarn relaxation preventing unit 60.

passes, the rotary solenoid 66 is energized by a signal from the program setting unit 78. Then, when the yarn introduction lever 6, i.e., the slot 28a, passes the sensor 67a spaced from the sensor 67b by approximately 240° in the direction of rotation, the rotary solenoid 66 is de-energized by a signal from the program setting unit 78. 68 denotes a cover attachment groove formed in the lower portion of the side wall of the drum spoke 16, in which a cover for preventing dirt or dust from entering the warping drum A is to be attached.

In Fig. 4, 69 denotes a movement-ZStop switching lever for switching the movement/stopping of the conveyor belt 17; 70 a locking lever for locking the warping drum A; 74 a shedding rod adjusting lever; 75 a shedding rod locking handle; 79 a control device; 80 a yarn tension unit arranged centrally on the straight part 12 of the warping drum A.

In Fig. 1, 87 denotes an upper limit switch attached to the upper portion of the fixed warping beam frame B, which is operated each time the yarn 22 is wound around the warping drum A. While the yarn 22 is wound on the warping drum A, when the yarn introduction lever 6 rotates, this upper limit switch 87 is turned on by the fed yarn 22. While the yarn introduction lever 6 rotates, even if the yarn 22 is not wound on the warping drum A, namely, when an erroneous change occurs, the upper limit switch 87 remains off and is never turned on. By utilizing the above-described operation of the upper limit switch 87, it is determined whether the upper limit switch 87 is turned on/off each time the yarn 22 is wound around the warping drum A. If the upper limit switch 87 is never turned on even if the yarn 22 has made one full revolution around the warping drum A, the operation of the electronically controlled pattern warping machine W is automatically terminated, so that troubles due to the erroneous change can be avoided.

Denoted at 88 is a lower limit switch arranged on the rider ring 26. When the yarn 22 is broken, the rider ring 26 falls to turn off the lower limit switch 88. Upon receipt of a signal from this lower limit switch 88, the operation of the pattern warping machine W is stopped, so that trouble due to yarn breakage can be avoided.

According to an important feature of the invention, a guide device G is slidably attached to each of the drum spokes 16 at an end adjacent to the yarn introduction part 6', and is slidable in the longitudinal direction of the drum spoke 16 for guiding the yarn out of the yarn introduction part 6'.

The guide device G includes a guide base 102 fixedly connected to a bracket 100, a yarn guide recess 104 formed at an upper portion of one end of the guide base 102, and a yarn guide ramp surface 106 provided above the yarn guide recess 104. The yarn 22 guided from the yarn introduction part 6' into the guide device G first slides along the yarn guide ramp surface 106, then moves into the yarn guide recess 104, and is finally wound around the conveyor belt 17, as shown in Fig. 14. The bracket 100 has a channel shape with a bottom plate 108 and a pair of side plates 110 extending vertically upward from opposite ends of the bottom plate 108. Two of the guide devices G are attached to the side plates 110 in opposite relation to each other.

Denoted at 112 is a sliding base fixed to the lower surface of the drum spoke 16. The sliding base 112 has a longitudinal guide groove 114 on its lower surface. 116 is a sliding unit fixed to an upper surface of the bottom plate 110 of the bracket 112. The sliding unit 116 has a guide rail 118 slidably received in the guide groove 114 on its upper surface. A rack 120 is fixed to the lower surface of the bottom plate 110 of the bracket 100 and is engaged with a clutch gear 124 attached to one end of a clutch shaft 122. The clutch gear 124 is brought into and out of engagement with the clutch shaft 112 by the on/off operation of an electromagnetic clutch 126. When the electromagnetic clutch 126 is turned on, rotation of the clutch shaft 122 causes the rack 120 to move the clamp 100 in a direction along the drum spoke 16, thereby moving the guide device G in the same direction (warping direction) by a predetermined distance or pitch per revolution of the clutch shaft 122 (this type of movement is hereinafter referred to as "pitch feed"). When the electromagnetic clutch 126 is turned off, rotation of the clutch shaft 122 is not transmitted to the rack 120, so that the pitch feed of the guide device

G does not take place. 128 denotes a worm gear fixed to the opposite end of the clutch shaft 122. The worm gear 128 is in engagement with a worm 130. 132 denotes a number of bearings; and 134 a bearing housing. The worm 130 has a worm pin 131 to which a sprocket 129 is fixed in concentric relation to the worm 130 (Fig. 11). The sprocket 129 is in engagement with a chain 136 which is drawn around an intermediate gear 138 provided corresponding to the sprocket 129.

In Fig. 11, 140 denotes a block member fixed to the rack 120. The block member 140 is connected to one end of a connecting pin 142. 144 denotes a holding member 144 fixed to the lower surface of one end of the slide base 112. The holding member 144 has a through hole 146 through which the opposite end of the connecting pin 142 slidably extends. A compression coil spring 148 is arranged around the outer surface of the connecting pin 142 to urge the rack 120 in a direction opposite to the direction of transport of the rack 120 caused by the worm gear 128. 150 denotes a cushion member. When the electromagnetic clutch 126 is turned on, the rotation of the clutch shaft 122 causes the standard pitch transport of the guide device G against the force of the spring 148. On the other hand, when the electromagnetic clutch 126 is turned off, the rotation of the clutch shaft 122 is not transmitted to the rack 120, so that the standard pitch transport of the guide device G does not take place. At the same time, the guide device G is quickly returned to its original start position by the force of the spring 148.

As shown in Fig. 12, a center gear 158 is rotatably mounted on the hollow shaft 1 of the warping drum A. 160 denotes a drive gear which is engaged with the center gear 158 and is driven by a servo motor 164 via a speed reducer 162. 166 denotes a transmission shaft fixed to the drum frame 13. The transmission shaft 166 carries at its front end a transmission gear 168 which is engaged with the center gear 158. 170 denotes a sprocket mounted on a center portion of the transmission shaft 166. The sprocket 170 is engaged with the chain 136.

As shown in Fig. 13, the sprockets 129, the intermediate sprockets 138 and the chains 136 drawn around the sprockets 170 are divided into four sets or groups.

In particular, a chain 136 is drawn around four sprockets 129, three intermediate gears 138 and a sprocket 170 to form a single drive system, so that there are four drive systems grouped into two upper drive systems M1 and M2 and two lower drive systems N1, N2.

A group of electromagnetic clutches 126, which are composed of corresponding electromagnetic clutches 126 on the corresponding clutch shafts 120 to which the sprockets 29 are respectively attached, are electrically divided into two circuits; one with an upper electromagnetic clutch group forms the upper two drive systems M1, M2, and the other with a lower electromagnetic clutch group forms the lower two drive systems N1, N2.

Fig. 16 shows the control part of the electronically controlled pattern warping machine W. The program setting unit 78 can set the 0-n number of yarn types, the number of yarn types, the number of repetitions and the amount of transport or movement of the guide device G by ten numeric key switches 0-9, a t switch, a ^ switch, a movement switch, a (11) switch, an end switch, a CLR (clear) switch and a paper transport switch. The program thus set can be printed out by a small printer and the contents of the program, i.e. address, setting of (11), yarn types, number of yarns and number of repetitions can be displayed by LEDs. The control part includes various switches for storing, executing and reading out, so that it is possible to display the preset states in operation and to correct the program when reading out.

The program setting unit 78 is electronically connected to a controller 79 via the yarn type signal, the yarn change signal and the count-up signal. When these signals are successively received, the preset program is repeated in order. The content of the program uses the four basic rules of arithmetic formulas. For example, the program in which ten windings of one yarn type, five windings of two yarn types and seven windings of three yarn types are repeated three times, and then six windings of four yarn types and two windings of five yarn types are added can be expressed as (1x10+2x5+3.7) ³ +4x6+5x2. As another example, a much more complex program can be made which is expressed as

{[(1x2+2x3) ³ +1x4] ⁵ +2x6} ⁷ +3x5. Once a program is set, it is protected by a backup battery unless the program is terminated.

The controller 79 shown in Fig. 17 controls the warping machine W. Specifically, the controller 79 controls, according to the program preset by the program setting unit 78, a relay 81 for an electromagnetic switch, a relay 82 for a 0-nth yarn type solenoid, a relay 83 for yarn pressure and yarn removal solenoids, a relay 84 for up-shedding, down-shedding, cut-up-shedding and cut-down-shedding solenoids, an indicator lamp 85, etc., all of which are electrically connected to the controller 79.

The electromagnetic switch relay 81 controls the on/off of the winding motor. The 0-n yarn type solenoid relay 82 controls the O-n yarn type solenoid when the yarn selection relay is on. The yarn pressing and yarn removing solenoid relay 83 controls the yarn pressing and yarn removing solenoids. The shedding up, shedding down, cut shedding up and cut shedding down relays 84 control the shedding up, shedding down, cut shedding up and cut shedding down solenoids, respectively.

The indicator lamps 85 are lamps for indicating the operating state of the warping machine W. Specifically, the indicator lamps 85 indicate the operation of the power supply, the rightward movement of the conveyor belt, the leftward movement of the conveyor belt, the upward shedding, the downward shedding, the power supply of the main motor, the double winding, the total number of yarns, the multi-winding. The operation switches 86 are switches for controlling the warping machine W. Specifically, the operation switches control the power supply, the automatic shutdown of the warping machine motor, the multi-winding setting, the conveyor belt movement termination, the rightward movement of the conveyor belt, the leftward movement of the conveyor belt, the upward shedding, the downward shedding, the power supply of the main motor, the shutdown of the main motor, the double winding reset switch, the total yarn counter, etc.

Photocell switches 67 are made up of three photocell switches 67a, 67b, 67c, which are held on the warping machine W. One of the three photocell switches 67a, 67b, 67c is arranged at the positions that generally divide the circumference into three parts.

net, namely for the timing between yarn selection, yarn pressure, yarn removal, shed formation, cut shed formation, counting up, etc.

A double winding termination switch 87 detects whether the yarns on the warping beam B for fixed supply yarn are wound twice at a time and transmits a signal to the controller 79. The warping machine W is further equipped with a yarn breakage detection switch for scraping the motor 46, various solenoids to be controlled by the relays described above, an electromagnetic switch, a mis-change indicator, etc.

Fig. 16 shows the control panel surface of the program setting unit 78, and Fig. 17 shows the control panel surface of the controller 79. In Fig. 16, PL1 designates a belt quick feed left movement indicator lamp; PL2 a belt quick feed right movement indicator lamp; PL3 a power supply indicator lamp; PL4 a main motor turn-on indicator lamp; PL5 an up-folding indicator lamp; PL6 a down-folding indicator lamp; PL7 a double winding completion indicator lamp; SS-O a power supply switch; SS-1 a midnight power source switch; SS-2 a main motor forward-reverse rotation switch; SS-3 a mischange switch switch; PS1 a belt quick feed left movement switch; PS2 a belt quick feed completion switch; PS3 a belt quick feed right movement switch; PS4, a main motor on switch; PS5, a main motor off switch; PS6, an up-shedding switch; PS7, a down-shedding switch; PS8, a multi-winding manual counting switch; PS9, a multi-winding counting reset switch; PS10, a double-winding reset switch; PS11, a main motor reverse rotation fine motion switch; RS1, a multi-winding setting switch; BU406D, a winding number setting unit; RS2, a warping yarn setting unit; and DS, a digital switch for setting the amount of conveyance of the guide unit G.

Furthermore, 72 denotes a warp yarn speed measuring device; 90 a warp length setting unit; and 92 a maximum number of revolutions setting dial of the main motor 46. The maximum number of revolutions of the main motor 46 can also be set by an setting device built into the inverter. 94 and 96 denote a belt feed right fine movement switch and a belt feed left fine movement switch, respectively. The two switches 94, 96 are correction switches with which

•♦ * *

Transport by a standard distance of the transport belt is possible with the mechanical switch when the main motor is switched off.

Although there is no illustration in the drawing, the warping machine further comprises an inverter for inputting an operation stop signal, a jogging signal, a multi-step speed change signal and a forward/backward rotation signal via the control device (sequence board) 79 for controlling the rotation of the main motor 46, and an AC servo motor control part for inputting a conveyor belt right movement signal, a conveyor belt left movement signal, an operation stop signal, the warping width, the number of warping yarns, the number of windings, a photocell signal, etc. via the control device (sequence board) 79, the multi-winding setting unit RS1 and the warping angle setting unit 90 for controlling the rotation angle of the conveyor belt motor 51.

The operation of the electronically controlled pattern warping machine W described above will now be described.

First, there are different numbers of yarns 22 depending on the pattern or design of a pattern. On the fixed warping beam B, bobbins are held on which different yarns of, e.g., &eegr; colors are wound respectively. A desired number of yarns 22 are drawn off from the bobbins and passed through the guide plate 24, the tension regulating device 25, the thread rider belt 26 and the selection guide 27 and pressed against the base Y by a yarn fixing device E with a permanent magnet. In this way, the yarns 22 are fixed.

Then, simultaneously with the operation of the warping machine W, the yarn introducing part 6' performs a circular movement above and below the warping drum A according to an arrangement preset and prepared by the program setting unit 78, to thereby wind the yarns 22 over the transport belts 17. At this time, the transport belts 17 are also moved in the direction of an arrow (to the right in Fig. 1) by the action of the internally threaded shafts 20. When the pulley 4 is rotated, pulses are generated by the contactor plate 28 to operate the rotary solenoids 29. When the selection guide 27 attached to the rotary solenoid 29 has been advanced to its operating position, the yarn 22 put under tension between a pair of guide rods 30, 31 is fed from the yarn introducing part 6'

and thereby wound around the conveyor belts 17. According to the next commands of the program setting unit 78, the wound yarn 22 is removed by the action of the yarn removing unit 32, and then another yarn is wound onto the conveyor belts 17 according to the next commands of the program setting unit 78.

The movements of the yarn 22 during the yarn change will now be described with reference to Fig. 9. The yarn 22a caught by the selection guide 27, which is initially located in the home position, takes its position 22b when the selection guide 27 is pivotally advanced to its operating position. From this position, the yarn 22b is wound around the warping drum A by the yarn introduction part ^61. 22c denotes the position in which the yarn 22 has been wound by one turn, and 22d denotes the position in which the yarn 22 has been wound two or more times. When the yarn 22d wound on the warping drum A is removed therefrom by the yarn removal unit 32, the yarn again takes its position 22b. Since the distal end 27a of the yarn selecting guide 27 is disposed in the recess r of the stop plate S, when the yarn selecting guide 27 is angularly advanced to its operating position to catch the removed yarn 22b, the yarn selecting guide 27 can catch the removed yarn 22b smoothly and reliably, thereby avoiding incidents such as double winding.

At this time, when the yarn 22 to be removed and thus the yarn introduction lever 6 has passed the yarn relaxation prevention unit 60, the sensor 67b performs an immediate detection so that the rotary solenoid 66 is actuated by a signal from the program setting unit 78 and the controller 79. In response to this actuation, the rotary solenoid 66 causes the rotary disk 62 to rotate in a direction against the bias of the spring element 64 so that the yarn located in the yarn pressing cutout 63 is pressed by the end surface of the yarn pressing cutout 63 and the stopper 65. This pressure lasts only for a short period of time, namely until the yarn introduction lever 6 reaches the position of the sensor 67a, whereupon the yarn relaxation prevention unit 60 remains in standby for the next possible yarn removal.

Upon completion of the yarn pressing by the rotary disk 62, the yarn selection guide 27 is returned to its original position, this removed yarn remaining taut due to the weight of the thread rider ring 26, and then

the yarn selection guide 27 waits for the next commands from the program setting unit 78 to execute windings of the yarn in a sequence according to a predetermined arrangement.

During winding, the shedding rods 33, 34, 38 carry out shedding, and the cut shedding rods 35, 37 divide the shedding yarns into a lower group of yarns and an upper group of yarns. In the wound yarns, the shedding yarns are cut by the action of the cut shedding rods 35, 37, and the lower group of yarns is stopped by the yarn stop 39 attached to the drum frame 13, while the upper group of yarns is guided into a fabric around the skeleton 40 of a rewinding unit C and then wound around it by the roller 41. After that, the yarns can be taken up from the roller 42 onto the woven fabric beam 49 via the roller 42, the zigzag comb 43 and the roller 44 without any difficulty.

The operation of the electronically controlled pattern warping machine according to this invention will now be described with reference to Figs. 20 to 34. The program is designed to carry out parallel processing in which successive routines "a" through "o" (Figs. 20-34) are repeated at intervals of approximately 0.5 to 1 ms.
a: Double winding termination circuit (Fig. 20)

The double winding detection sensors, namely the upper limit switches 87, are mounted on a warping beam frame for yarn feeding (Fig. 3). There are n sensors, one for each fed yarn. The single sensor 87 gives an output signal when the yarn 22 is wound onto the warping drum A by the yarn introducing part 6 ^' . When two or more yarns are simultaneously caught by the yarn introducing part 6' due to an accident during yarn selection, the output signal of the sensor 87 turns on the double winding indicator lamp. This output signal is connected in circuit to the warping termination switch SW for turning off the warping machine W. The release is made by a double winding reset switch.
b: Shed formation circuit (Fig. 21)

The shedding bar structure is made up of four types of shedding bars, i.e. upward shedding bars 33, 38, a downward shedding bar 34, a cutting upward shedding bar 35 and a cutting downward shedding bar 37. The

Solenoids are individually connected to each of the shedding rods 33 to 38. By the action of the individual solenoids, the yarns to be wound on the warping drum A are selectively brought up and down with respect to the individual shedding rod to perform shedding and cut shedding. The shedding at start-up can be selected with the up shedding switch and the down shedding switch.

In the shedding process, when the warper is operating while the yarn is not being replaced, and further when the count value is "0" (the number of windings indication is "0"), the three types of solenoids, namely the up-shedding solenoid, the cut-up-shedding solenoid and the cut-down-shedding solenoid, are turned on and turned off by the photocell C (67c). At the same time, the down-shedding indication lamp is turned on. When the count value is "0" (the number of windings indication is "0"), the three types of solenoids, namely the down-shedding solenoid, the cut-up-shedding solenoid and the cut-down-shedding solenoid, are turned on and turned off by the photocell C (67c). At the same time, the up-shedding indication lamp is turned on. At the next count value "0" (multi-winding display is "0"), the above procedures are repeated.

Thus, in the shedding process, while the yarn is not being changed, the individual solenoid moves one extra revolution (during the yarn change) compared to the operating time of each solenoid during the shedding process while the yarn is not being changed,
c: Total yarn counter circuit (Fig. 22)

In the circuit in which the up signal of the total yarn counter is on/off, when the counter is reset at the count value "0" (multiple winding indication is "0"), the up signal of the total yarn counter will be "on", and will be turned off by the photocell C (67c) to advance the total yarn counter.
d: Total game completion termination circuit (Fig. 23)

When the count result of the total yarn counter reaches a preset value, the total yarn completion indicator lamp is turned on. Since this on signal of the total yarn completion indicator lamp is connected in circuit to the warping machine stop switch, the warping machine is turned off. The release is made by the reset switch of the total yarn counter.

e: Transport belt left movement switch (Fig. 24) and f: Transport belt right movement switch (Fig. 25)

Since the conveyor belt of the sample warping machine according to the invention is not endless and is movable to the left and to the right, the conveyor belt can be moved independently by the left movement switch and the right movement switch to be placed in the start position and the rewind position. For safety, a belt right limit switch and a belt left limit switch are arranged at the right and left limits, respectively. When the left limit switch is operated during the left movement of the conveyor belt 17, the conveyor belt 17 is stopped. Similarly, when the right limit switch is operated during the right movement of the conveyor belt 17, the conveyor belt 17 is stopped.
g: Operating/shutdown circuit (Fig. 26)

This circuit transmits the rotation of the main motor 46 to the yarn introduction lever 6. After both the operation switch and the stop switch are turned on, a time of 1 second is inserted to become synchronous with a program part which discriminates whether there is operation when either operation or stop is performed.
h: Yarn selection circuit (Fig. 27)

This circuit controls the yarn selection and yarn removal solenoids.
i: Yarn pressure solenoid circuit (Fig. 28)

This circuit is designed to operate/deactivate the yarn pressure solenoid. After the yarn selection changeover signal is turned on, the yarn pressure solenoid is operated only from photocell B (67b) to photocell A (67a).
j: Multiple winding counting circuit (Fig. 29)

This switch counts the number of yarn turns on the warping drum A and displays the count value. The multi-winding count indicator increases by 1 by the output signal of the photocell A outside the yarn selection period. When the count value exceeds a preset winding value, the multi-winding indicator becomes "0".

k: Inverter speed change circuit (Fig. 30 )

Here, the "inverter" drives the main motor 56 in the pattern warper W, and is not an inverter attached to the rotary warper beam. This circuit discriminates whether the change signal output from the program setting unit 78 in synchronism with the photocell A (67a) during yarn change is on, and turns on a multi-step speed change signal (low speed signal) to rotate the main motor 46 at a low speed. Then, while confirming the on/off signal of the photocell C (67c), the circuit sets the number of idle rotations during which the multi-step speed change signal (low speed signal) remains on. Upon release from the idle rotation, the circuit turns off the multi-step speed change signal to rotate the main motor 46 at a high speed. The flow chart shows an example in which two idle rotations are performed.
I: AC servo control circuit (Fig. 31)

This circuit reads the warping width, the number of warping yarns and the number of yarn windings from the warping length setting unit 90 and the winding number setting unit RS1 and calculates the number of feed pulses per winding (provided that the AC servo motor is driven by the input of the pulse number). The circuit further calculates a corrected number when correction is required. Then, a discrimination is made as to whether it is in an idle rotation or not. If it is in an idle rotation, the control routine returns to the start and does not proceed. If it is not in an idle rotation, the circuit discriminates the on/off signal of the photocell A (67a) and outputs the calculated pulse number for rotating the conveyor belt motor 51 to rotate by an angle corresponding to the calculated pulse number. The above procedures are repeated.
m: Guide device control circuit (Fig. 32)

In the circuit, the amount of transport or movement (e.g. 0.5 mm) of the guide device G per revolution of the warping drum A is set by means of a digital switch DS (Fig. 17), and the number of feed pulses corresponding to the amount of transport (e.g. 0.5 mm) per revolution of the servo motor 164 at reduced speed is calculated, and the calculated number of feed pulses is output. Based on the output pulses, the servo motor 164

via a servo motor amplifier (motor drive). The operation of the servo motor 164 is translated into the amount of transport of the guide device G via the drive systems M1, M2, N1, N2, so that the transport/return of the guide device G is controlled by the on/off operation of the electromagnetic clutches 162 at a timing determined by corresponding signals from the photocell A (67a), the photocell B (67b) and the photocell C (67c). As described above, the standard pitch transport of the guide device G is carried out when the electromagnetic clutch 126 is turned on. Conversely, the guide device G is quickly returned to its initial start position by the force of the spring 148 when the electromagnetic clutch 126 is turned off. The above procedures are repeated.

The amount of conveyance of the guide device G is set to a predetermined value (e.g., 0.5 mm) per revolution of the yarn guide lever 6 in consideration of a preset multi-winding value. (In general, this conveyance amount may be in the range of 0.1 to 1.0 mm.) For example, when the conveyance amount of the guide device G is 0.5 mm and the number of multi-windings is set to 20, the guide device G is advanced in the warping direction by 9.5 mm, and upon output of a count-up signal, the advanced guide device G is quickly returned to its initial start position. The conveyance of the guide device G is controlled so that when the yarn guide lever 6 starts to rotate, the photocell B is passed every time the pulse number equivalent to the preset conveyance amount is output. Even if the yarn guide lever 6 passes the photocell A, no pulses are output under the condition that the start signal is off (during the fine angle movement) or there is a period of time between the change signal and the next photocell A signal.
n: Control circuit for the upper electromagnetic clutch group (Fig. 33)

The eight electromagnetic clutches in the upper control systems M1, M2 will be switched on in response to a signal from the photocell A. If the start signal is on, when the count-up signal (count-up for one yarn) is already on by the signal from the photocell B, the electromagnetic clutches of the upper control systems M1, M2 will be switched off.

&ogr;: Control circuit for the lower electromagnetic clutch group (Fig. 34)

The eight electromagnetic clutches in the lower control systems N1, N2 will be switched on in response to a signal from photocell B. When the start signal is on and when the count-up signal {count-up for one yarn) is already on by the signal from photocell C (when the alternating signal is off), the electromagnetic clutches of the upper control systems N1, N2 will be switched off. When the alternating signal is already on, the electromagnetic clutches in the lower control systems N1, N2 will be off in response to a second signal from photocell C, namely a signal from photocell C with the second winding.

A practical example is now described in which the winding of alternating two red yarns and two white yarns is repeated up to a total of 3600 and a warp width of 100 cm with a warp length (number of multiple windings) of 10.

First, the red yarn and the white yarn are set on the warping beam frame B and are guided through the guide plate 24, the tension regulating device 25 and the rider ring 26. The red yarn is guided through the number 0 guide of the yarn selection guide 27, and the white yarn is guided through the number 1 yarn selection guide 27. Then, the red and white yarns are pressed against the base Y by the yarn attachment E with the permanent magnet.

Second, a program is prepared according to the yarn setting of the yarn selection guide 27. The display of the programmed content is as follows:

Address Yarn type Number of yarns Number of repeats

000 0 , 002 000

001 1 002 000

At the same time, the number of multiple windings (i.e. 10) and the amount of movement of the conveyor belt (i.e. 100 cm when the total number of yarns reaches 3,600) are set. 3,600 is set in the total yarn counter.

When the yarn introduction lever 6 is angularly moved when the operation switch is on, the slit plate 28 is also angularly moved at the same rotational speed, and at the same time, the transport belt 17 is moved by a preset distance at a time from the front to the rear.

When the warper motor (main motor) 46 is rotated to place the yarn introduction lever 6 in the home position between the photocell A (67a) and the photocell B (67b) and the operation switch is turned on, the solenoid of the number O yarn selection guide 27 is energized, and at the same time, the up-shedding solenoid and the cut up-shedding and cut down-shedding solenoids are energized, and one second after that, the yarn introduction lever is angularly moved. At this time, the yarn introduction lever 6 catches the yarn of the number O yarn selection guide 27, i.e., the red yarn, and then rotates to start winding the red yarn around the warping drum A.

Then, by the action of the cut-up shedding solenoid and the cut-down shedding solenoid, a cut shed of the red yarn is formed. When the yarn passes the photocell C (67c), the single solenoid is turned off. Since, on the one hand, the cut shed rod is arranged between the photocell B (67b) and the photocell C (67c), and on the other hand, the shed rod is arranged between the photocell A (67a) and the photocell B (67b), only the cut shed of the red yarn is formed at the start. When the yarn introduction lever 6 passes the photocell A (67a) for the first winding, the multi-winding indication will be "1". When it passes the photocell A for the second winding, the multi-winding indication will be "2". Similarly, when the yarn introduction lever 6 passes the photocell A for the ninth winding, the multi-winding indication will be "9". When it passes the photocell A for the tenth winding, the multi-winding indication will be "0".

At the same time, the up-shedding solenoid and the cut-up-shedding and cut-down-shedding solenoids are energized, and the single solenoid is turned off when it passes the next photo line C, so that one shed and one cut shed are formed. At the same time, a total yarn count-up signal is output so that the total yarn counter indicates "1".

When the yarn feed lever 6 passes the photocell A for the eleventh winding, the multi-winding indicator will be "1". In the same manner as described above, the multi-winding indicator increases by 1 for each subsequent rotation of the yarn feed lever 6.

guide lever 6. That is, when the yarn introduction lever 6 passes the photocell A for the nineteenth winding, the multi-winding indication will be "9", and when it passes the photocell A for the twentieth winding, the multi-winding indication will be "0". When the number 0 yarn selection solenoid, the yarn removal solenoid, the down-shedding solenoid and the cut up-shedding solenoid and the cut down-shedding solenoid are simultaneously energized, the red yarn is removed from the yarn introduction lever 6 and therefore taken up in the number 0 yarn selection guide by the weight of the rider ring 26.

At this time, when the yarn introduction lever 6 passes the photocell B, the yarn pressure solenoid is energized to press the red yarn onto the warping drum A, so that no excessive yarn slack gets into the color of the warping drum A. When the yarn introduction lever 6 passes the next photocell C, the yarn removal solenoid is turned off. At the same time, the total yarn counter displays "2" when the total yarn count-up signal is output. When the yarn introduction lever 6 passes the photocell A (67a) for the twenty-first winding, the number 0 yarn selection solenoid is turned off and the number 1 yarn selection solenoid is energized (at this time, the multiple winding count does not count). The yarn introduction lever 6 catches the white yarn of the number 1 yarn selection solenoid to wind the white yarn around the warping drum A. The yarn pressure solenoid is also turned off.

When the yarn introduction lever 6 passes the next photocell C (67c), the number 1 yarn selection solenoid, the down-shed formation solenoid, the cut up-shed formation solenoid and the cut down-shed formation solenoid are turned off. In the same manner as described above, the multi-wind indicator increases by 1 for each subsequent rotation of the yarn introduction lever 6. When the yarn introduction lever 6 passes the photocell A (67a) for the twenty-ninth turn, the multi-wind indicator will be "9". When it passes the photocell A for the thirtieth turn, the multi-wind indicator will be "0". At the same time, the up-shed formation solenoid, the cut up-shed formation solenoid and the cut down-shed formation solenoid are energized. When the yarn introducing lever 6 passes the next photocell C (67c), the single solenoid is turned off to form a shed and a cut shed. Simultaneously with this, the total yarn count up signal is outputted so that the total yarn counter indicates "3".

When the yarn introducing lever 6 passes the photocell A (67a) for the thirty-first turn, the multi-winding display will be "1". The number on the display increases by 1 for each subsequent rotation of the yarn introducing lever 6 in the manner described above. When the yarn introducing lever 6 passes the photocell A (67a) for the fortieth turn, the multi-winding display will be "0". At the same time, the number 1 yarn selecting solenoid, the yarn removing solenoid, the down-shedding solenoid, the cut-up-shedding solenoid and the cut-down-shedding solenoid are energized to remove the white yarn from the yarn introducing lever 6 so that the white yarn is taken up into the number 1 yarn selecting guide by the weight of the rider ring 26. At the same time, when the yarn introducing lever 6 passes the photocell B (67b), the yarn pressing solenoid is energized to press the yarn onto the warping drum A. When it passes the next photocell C (67c), the yarn removing solenoid is turned off, whereupon the total yarn high count signal is output to make the total yarn counter display "4".

Then, when the yarn introducing lever 6 passes the photocell A (67a) for the forty-first winding, the number-1 yarn selecting solenoid is turned off and the number-O yarn selecting solenoid is energized (at this time, the multi-winding count does not count). The yarn introducing lever 6 catches the red yarn to wind it around the warping drum A, whereupon the yarn pressing solenoid is turned off. When it passes the next photocell C (67c), the number-O yarn selecting solenoid, the down-shedding solenoid, the cut-up-shedding solenoid, and the cut-down-shedding solenoid are turned off.

Accordingly, as long as there is no shutdown signal resulting from yarn breakage, double yarn stopping, mischange! and right limit switch and until the total yarn completion completion signal is input, the yarn introduction lever 6 is angularly moved and the single solenoid is energized/deenergized so that the transport belt continues to feed the yarn to perform the warping work.

Fig. 35 is a timing chart showing the operation of the electronically controlled pattern warping machine according to this invention. According to this timing chart, a double action of 0-kind yarn is wound twice, a double action of 1-kind yarn is wound twice, and this is repeated. Here, "double action" is a value set in the range of 0 to 19 by the multiple action setting.

switch preset value. The operating principle shown in this timing diagram is the same even if the preset multi-winding value is increased. The signals from these three photocell switches are called "photocell A", "photocell B" and "photocell C" here. The operation starts between photocell switch A and photocell switch B, after which photocell B - photocell C - photocell A - photocell B - photocell C - photocell A are output in sequence. After that, these signals are used to record the following timing.

A count signal is outputted each time the photocell A detects that the slot 28a of the slot plate 28 passes. The count signal is not outputted only once, after an alternating signal received from the program setting unit, because the yarn introduction lever 6 is angularly moved without a load. A count-up signal is outputted between the photocell A and the photocell C each time it reaches a preset multi-winding value. The count-up signal increments the total yarn counter. Thus, a count-up signal is transmitted to the program setting unit.

A changeover (yarn exchange) signal is transmitted from the program setting unit in synchronism with photocell A and is used when changing the yarn type. A selection signal transmits a signal to one of the 0-n type yarn solenoids when a corresponding one of the relays for the 0-n type yarn solenoids is turned on. This solenoid is turned on between the start time and photocell C, after which a confirmation is made as to whether the changeover signal is received. The solenoid is turned on between photocell A and the next photocell A ₁ is turned off for a short time (10 to 50 ms), immediately after which it is turned on, and will be turned on until the next photocell C.

The relays for 0, 1 type yarn solenoids are set in timing by the controller based on the yarn type setting signal transmitted from the program setting unit and are kept energized until a yarn change selection signal is output. The yarn removal solenoid signal is on between photocell A and photocell C after it is confirmed that a change signal has been received. The yarn pressure solenoid signal is on between photocell B and photocell A after the yarn removal solenoid signal was on.

The up-shelf solenoid signal and the down-shelf solenoid signal can be started from any signal and will alternately be on. Between the start and photocell C, each signal confirms that no up-shelf signal

On is during the yarn change and that a change signal is received. Then each signal will be On for a period of time from photocell A to the next photocell C. Although there is no illustration in the timing diagram in Fig. 35, both the cut up shedding and cut down shedding solenoid signals will be On when either the up shedding or down shedding signal is On.

Further, by varying the timing of the up-shedding and down-shedding solenoid signals, it is possible to form sheds of various kinds which can be directly re-weaved on the weaving beam 49. The warper starts its operation by turning on the start switch and stops its operation by turning on the stop switch. Alternatively, the warper can be stopped by the double winding completion switch for checking the state of winding of two or more yarns at a time, the mis-change signal for indicating the state of not winding the yarn during yarn change, the total yarn counter for indicating the completion of winding of the whole yarns, the yarn break detection signal for indicating the yarn break, etc.

Fig. 36 is a timing chart showing the operation typical of an electronically controlled pattern warping machine capable of warping yarns with yarn windings neatly layered on the warping drum A in regular order.

The timing chart in Fig. 36 illustrates the example in which the yarn is wound 19 times {19 turns) in the up-shedding mode (the shedding of the yarn to be wound on the warping drum A is started with the up-shedding). The yarn to be wound on the warping drum A is gripped at the yarn introduction part 6' aligned with the slot 28a of the slot plate 28, and this yarn introduction part 6' starts from between the photocell A and the photocell B.

The start switch is turned on, whereupon the yarn introduction lever 6 is angularly moved. At the same time, the electromagnetic clutches of all the guide devices G are turned on, so that all the guide devices G are in a state in which the standard pitch feed is carried out in response to the operation of the servo motor 164. The multi-winding count signal is outputted each time the photocell A detects that the slot 28a passes. The total yarn counting up signal will be on between the photocell A and the photocell C each time it reaches a preset multi-winding value (19 in the example in Fig. 36). As

As described above, the count-up signal increments the total yarn counter (in the timing chart shown in Fig. 36, the total yarn counter display is omitted).

When the yarn introduction lever 6 moves between the photocell B and the photocell C for the second winding, the servo motor will be turned on so that the standard pitch transport of the guide device G is carried out. Similarly, from the third winding to the nineteenth winding between the photocell B and the photocell C, the standard pitch transport of the guide device G is carried out. When the yarn introduction lever 6 passes the photocell A for the nineteenth winding, the multi-winding display will be "0" and the total yarn counter will count up by 1. With this count-up signal, the transport belt 17 is moved in the warping direction by a distance equal to the longitudinal warping density, as described later.

in the event that the yarn change is not carried out, the photocell B at the first winding of the yarn introduction lever 6 following the count-up signal and the photocell A at the second winding thereof, the upper electromagnetic clutch group will be switched off, so that the guide devices G connected to the upper electromagnetic clutch group are returned to their starting position by the forces of the springs 148. On the other hand, between the photocell C at the first winding of the yarn introduction lever 6 following the count-up signal and the photocell B at the second winding thereof, the lower electromagnetic clutches will be switched off, with the result that the guide devices G connected to the lower magnetic clutch group are returned to their starting position by the forces of the springs 148. The on/off timing of the lower electromagnetic clutch group is delayed from the on/off timing of the upper electromagnetic clutch group because the on/off operation must be carried out after the yarn passes the bottom of the warping drum! A.

When the yarn change is carried out, the on/off operation of the upper clutch group is carried out in the same way as when operating without yarn change. However, as far as the lower electromagnetic clutch group is concerned, this clutch group will be switched off between the photocell C at the second winding of the yarn introduction lever 6 following the high count signal and the photocell B at the third winding of the same. Thus, the guide devices G connected to the lower electromagnetic clutch group are controlled by the forces of the springs.

148 is returned to its initial position. This on/off timing of the lower electromagnetic clutch group is typical for the yarn change operation.

Following the count-up signal, when the yarn introduction lever 6 moves between the photocell B and the photocell C for the second winding, the servo motor 164 will be turned on so that the standard pitch feed of the guide device G is performed. In the same way, from the third winding to the nineteenth winding between the photocell B and the photocell C, the standard pitch feed of the guide device G is performed. When the yarn introduction lever 6 passes the photocell A for the nineteenth winding, the multi-winding display will be "0" and the total yarn counter will count up by 1. With this count-up signal, the transport belt 17 is moved in the warping direction by a distance equal to the longitudinal warping density, as described later. The above procedures are repeated to achieve proper winding of the warping yarns.

In the above embodiment, the guide means G for guiding a yarn from the yarn introduction lever 6 is slidably mounted on the drum spoke 16 at an end adjacent to the yarn introduction lever 6 and is slidable in the longitudinal direction of the drum spoke 16. For each revolution of the yarn introduction lever 6, the guide means G is moved in the warping direction by a distance P which is twice to half the thickness or diameter of the yarn 22. When the number of revolutions of the yarn introduction lever 6 reaches a preset multi-winding value, the guide means G is quickly moved back by a distance Q which is equal to the product of the distance P and the preset multi-winding value, thereby returning it to its initial start position. At the same time, the transport belts 17 are moved in the warping direction by a stretch R that is equal to the longitudinal warping density, namely the warping width divided by the total number of yarns (number of warping yarns). Thus, the yarn 22 can be wound onto the warping drum A with yarn windings neatly placed on top of one another in a regular sequence (see Fig. 37).

The distance P of the standard pitch transport of the guide device G is preferably in the range of 2 to 0.5 times the thickness of the yarn 22. The distance P can be outside the range specified above as long as proper winding according to the invention is possible.

The orderly winding can be carried out by any suitable means. For example, the yarn introduction lever 6 is made movable in the warping direction in such a way that the yarn introduction lever 6 is moved by a distance P equal to two to one half of the thickness of the yarn for each revolution of the yarn introduction lever 6 in the warping direction. When the number of revolutions of the yarn introduction lever 6 reaches a preset multiple winding value, the yarn introduction lever 6 is quickly moved back by a distance Q (distance P x preset multiple winding value), thereby returning it to its initial start position. Simultaneously with this, the transport belts 17 are moved in the warping direction by a distance R equal to the longitudinal warping density, that is, the warping width divided by the total number of yarns (number of warping yarns).

As a still further alternative, the transport belts 17 may be made movable in such a way that for each revolution of the yarn introduction lever 6 in a direction opposite to the warping direction, the transport belts 17 are moved by a distance P which is two to one half the thickness of the yarn 22, and when the number of revolutions of the yarn introduction lever 6 reaches a preset multiple winding value, the transport belts 17 are moved in the warping direction by a distance T which is the sum of the distance Q (distance P x preset multiple winding value) and a distance R which is equal to the longitudinal warping density, i.e. the warping width divided by the total number of yarns.

The warping method according to the invention is carried out in such a way that the yarn for the "n"-th winding is wound onto the warping drum A in such a way that at the start of the "n"-th winding the yarn is arranged in front of one end of a yarn winding formed on the warping drum by the "n-1"-th winding.

According to the orderly winding warping method of the present invention, the yarn wound at the beginning of a particular winding is located in front of the yarn wound in the previous winding.

In the above description, the yarn types are O-n, and η usually represents an integer up to 9, but may be more than 9. In the above description, the number of windings is 1-19, but should not be limited in any way to these specific numbers. The relay part, i.e. the driving part of the solenoid, may be a semiconductor, such as a transistor or a thyristor. The switch of each of the photocells A, B, C may be a magnet-sensitive element, a magnetic limit switch or

The controller is preferably constructed from a microcomputer, a memory, a TTL, a CMOS, a photocoupler or the like, but may also be an ordinary sequence controller.

As described above, according to the invention, since the yarn wound at the beginning of a certain winding is located before the yarn wound in the previous winding, it is possible to wind yarns on a warping drum with yarn windings neatly placed one on top of the other in a regular sequence, thereby enabling easy rewinding of the yarns on beams on a weaving machine, even if the warping length, i.e. the number of multiple windings, is relatively large, such as four or more windings.

Obviously, various minor changes and modifications of the invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced other than as specifically described.

Claims (27)

bbs PROTECTION CLAIMS 1. Electronically controlled pattern warping machine (W) for automatically warping yarns into a desired pattern, comprising a yarn introduction lever (6), a warping drum (A) and transport belts (17), characterized in that the yarn introduction lever (6) is movable in the warping direction in such a way that the yarn introduction lever (6) is moved for each revolution of the yarn introduction lever (6) in the warping direction by a first distance (P) which is two to one half the thickness of the yarn (22), and the yarn introduction lever (6), when the number of revolutions of the yarn introduction lever (6) reaches a preset multiple winding value, is rapidly moved back by a second distance (Q) which is equal to the product of the first distance (P) and the multiple winding value, thereby returning to its initial start position, and the transport belts (17) are moved simultaneously with the rapid return of the Yarn introduction lever (6) can be moved in the warping direction by a third distance (R) which is equal to the longitudinal warping density, i.e. the warping width divided by the total number of yarns. 2. Warping machine according to claim 1, with a drive shaft and a driven shaft (2, 3) which protrude centrally from opposite ends of a hollow shaft (1) held on the drive shaft side. 3. Warping machine according to claim 2, with a first small gear (5) loosely attached to the drive shaft (2) and fastened to a belt pulley (4). 4. Warping machine according to claim 2 or 3, with a second small gear (7) loosely attached to the driven shaft (3). 5. Warping machine according to claim 4, wherein the second small gear (7) is attached to the yarn introduction lever (6). 6. Warping machine according to one of the preceding claims, in which the distal end of the yarn introduction lever (6) is bent inwards to form a yarn introduction part (6') arranged adjacent to the front end of the outer edge of the warping drum (A). 7. Warping machine according to one of claims 4 to 6, with a third and a fourth small gear (9, 10) which are attached to opposite ends of an auxiliary shaft (8) extending through the hollow shaft (1) and are in engagement with the first and the second small gear (5, 7) for cooperation. 8. Warping machine according to one of claims 2 to 7, with drum frames (13, 14) attached to the side of the hollow shaft (1) towards the driven shaft and each having an outer edge with an alternating curved section (11) and a straight section (12). 9. Warping machine according to claim 8, with a pair of rollers (15) arranged on the curved portion (11) of each of the drum frames (13, 14). 10. Warping machine according to one of claims 2 to 9, wherein the warping drum (A) is loosely attached to the hollow shaft (1). 11. Warping machine according to one of the preceding claims, in which the warping drum (A) has horizontal drum spokes (16). 12. Warping machine according to claim 11, in which the spokes (16) carry the rollers (15) around which the transport belts (17) are wound. 13. Warping machine according to one of the preceding claims, in which the transport belts (17) are driven simultaneously with a common amount of fine movement. 14. Warping machine according to claim 13, in which a drive element (21) is provided for driving the transport belts (17), which is in threaded engagement with internally threaded shafts (20) of planetary gears (19) engaging with a sun gear (18) driven from the outside in a suitable manner. 15. Warping machine according to claim 14, wherein the planetary gears (19) rotate simultaneously when the sun gear (18) rotates. 16. Warping machine according to one of the preceding claims, with a shedding device for forming a shed and a cut shed by selecting the warping yarns above and below shedding rods (33, 38, 34) and cut shed forming rods (35, 37). 17. Warping machine according to one of the preceding claims, with a total yarn counting device for switching on or off an upward signal of a total counter for counting the total number of warping yarns. 18. A warping machine according to any preceding claim, comprising a total yarn completion termination device for terminating the operation of the warping machine when the total number of warping yarns reaches a predetermined value. 19. Warping machine according to one of the preceding claims, with a conveyor belt left-hand movement device for moving the conveyor belts (17) to the left. 20. Warping machine according to one of the preceding claims, with a conveyor belt right-hand movement device for moving the conveyor belts (17) to the right. 21. Warping machine according to one of the preceding claims, with an operation shutdown device for transmitting the rotation of a main motor (46) to the yarn introduction lever (6). 22. Warping machine according to one of the preceding claims, with a yarn selection device for controlling a yarn selection guide (27) and a yarn removal unit (32). 23. Warping machine according to one of the preceding claims, with a yarn pressure solenoid device for activating and deactivating a solenoid of a yarn relaxation prevention unit (60). 24. Warping machine according to one of the preceding claims, with a winding counting device for counting the number of windings of the yarn and for displaying the counted result. 25. Warping machine according to one of the preceding claims, in which types of yarns from 0 to &eegr; are selectable. 26. Warping machine according to one of the preceding claims, in which the number of yarns, the number of repetitions, the number of windings and/or the amount of movement of the transport belts (17) is adjustable. 27. Warping machine according to one of the preceding claims, designed to feed the yarn (22) for the "n"-th winding onto the Warping drum (A) so that the yarn (22) is arranged at the beginning of the "n"-th winding from one end of a yarn winding formed on the warping drum (A) by the "n-l"-th winding.