EP3964467A1

EP3964467A1 - Textile machine and waste yarn amount calculation method

Info

Publication number: EP3964467A1
Application number: EP21193544.0A
Authority: EP
Inventors: Teruyuki Kasuga; Hironobu Shimo; Eshin FUKUZAWA
Original assignee: Murata Machinery Ltd
Current assignee: Murata Machinery Ltd
Priority date: 2020-09-04
Filing date: 2021-08-27
Publication date: 2022-03-09
Anticipated expiration: 2041-08-27
Also published as: JP2022043543A; EP3964467B1; CN114132801A

Abstract

An automatic winder (100) unwinds a yarn from a yarn feed bobbin and winds the yarn onto a package. The automatic winder (100) includes calculation sections (95b, 99b) that calculate a standard value of an amount of yarn to be discarded when drawing out the yarn from the yarn feed bobbin.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a configuration for acquiring the amount of waste yarn generated from a textile machine.

2. Description of the Related Art

In a textile machine such as an automatic winder, an unnecessary waste yarn is generated as the yarn or the like is processed. In a factory where a textile machine is operating, information on the amount of waste yarn emission is important from the viewpoint of, for example, preventing waste of resources.
Regarding management of waste yarns, CN 106048758 A discloses a configuration in which waste yarns generated in a spinning line are calculated and displayed on a display unit.
However, CN 106048758 A does not disclose any specific configuration regarding how to acquire waste yarns.
In a conventional textile machine, the amount of waste yarn cannot be grasped unless a weight scale is used to measure waste yarns collected from respective devices. The conventional configuration, therefore, leaves room for improvement, because it takes time and labor to acquire information on the amount of waste yarn.

BRIEF SUMMARY OF THE INVENTION

The present invention has been made in view of the above circumstances, and an object thereof is to provide a textile machine capable of acquiring a waste yarn amount without complicating the mechanical configuration.
The foregoing has described problems to be solved by the present invention. The following will describe solutions to the problems and advantageous effects thereof.
According to the viewpoint of the present invention, a textile machine having the following configuration is provided. That is, the textile machine unwinds a yarn from a yarn feed bobbin and winds the yarn onto a package. The textile machine includes a calculation section that calculate a standard value of an amount of yarn to be discarded emitted by yarn cutting accompanying a drawing operation of drawing out the yarn from the yarn feed bobbin.
As a result, the standard value of the waste yarn emission amount can be appropriately obtained by calculation with software without complicating the mechanical configuration.
The above-described textile machine preferably has the following configuration. That is, the textile machine includes an input unit capable of inputting a reference value serving as a reference for obtaining a standard value. The calculation section calculates the standard value on the basis of the input reference value.
As a result, when the operator inputs an appropriate value as the reference value of the waste yarn amount, a highly reliable standard value can be obtained as the waste yarn amount.
In the textile machine described above, a measurement assisting mode of assisting measurement for obtaining the reference value is executable, the measurement assisting mode preferably being a mode of stopping the drawing operation before cutting the yarn.
As a result, the textile machine performs a special operation that facilitates measurement of the waste yarn amount, whereby the operator can easily acquire the reference value of the waste yarn amount.
The above-described textile machine preferably has the following configuration. That is, in the textile machine, the drawing operation for drawing out the yarn from the yarn feed bobbin differs according to setting or status. The reference value can be input for each different drawing operation.
As a result, an appropriate standard value corresponding to the variation of the drawing operation can be obtained as the waste yarn amount.
The above-described textile machine preferably has the following configuration. That is, the textile machine includes a preparatory drawing device. The preparatory drawing device performs a drawing operation of sucking and drawing out a yarn end of the yarn feed bobbin before the yarn feed bobbin is supplied to a winding unit that unwinds the yarn from the yarn feed bobbin and winds the yarn onto a package. The calculation section calculates a standard value of the amount of yarn to be discarded at the time of the drawing operation of the preparatory drawing device.
As a result, the standard value of the waste yarn amount emitted in the preparatory drawing device can be obtained without complicating the mechanical configuration.
In the textile machine described above, it is preferable that the preparatory drawing device includes a control device that controls the pressure of the suction airflow for sucking the yarn.
As a result, the strength and the like of the suction airflow for sucking the yarn by the preparatory drawing device can be appropriately changed according to the waste yarn amount emitted by the preparatory drawing device.
The above-described textile machine preferably has the following configuration. That is, the textile machine includes a winding unit that unwinds a yarn from a yarn feed bobbin and winds the yarn onto a package. The winding unit includes a unit drawing device. The unit drawing device performs a drawing operation of sucking and drawing out the yarn from the yarn feed bobbin before joining the yarn on the package side and the yarn on the yarn feed bobbin side. The calculation section calculates a standard value of the amount of yarn to be discarded at the time of the drawing operation of the unit drawing device.
As a result, the standard value of the waste yarn amount emitted in the unit drawing device can be obtained without complicating the mechanical configuration.
The above-described textile machine preferably has the following configuration. That is, the textile machine includes an aggregate section and a display unit. The aggregate section aggregates the standard values calculated by the calculation section to obtain a total value. The display unit displays a total value aggregated by the aggregate section.
As a result, the status of the waste yarn amount can be grasped from a rough viewpoint.
In the textile machine described above, the display unit preferably displays the total value as the amount of yarn discarded in the entire textile machine.
As a result, for example, the operator can easily grasp the waste yarn amount emitted in the entire textile machine.
In the textile machine described above, the calculation section preferably compares the total value per unit time with a past total value per unit time, and issues a warning on the basis of the comparison result.
As a result, an abnormality occurring in the textile machine can be noticed and dealt with at an early stage.
A preparatory drawing device includes: a yarn suction tube that is a tubular member disposed in a vertical direction; a cutter provided downstream in a suction direction of the yarn suction tube and cutting the yarn in the drawing operation; and a yarn detection sensor that detects a yarn in the yarn suction tube to detect whether or not the yarn has been caught successfully. With this configuration, the amount of waste yarn when carrying out the yarn preparing operation of the yarn feed bobbin can be managed.
A waste yarn amount calculation method for calculating a standard value of an amount of waste yarn emitted by yarn cutting accompanying a drawing operation of drawing out a yarn from a yarn feed bobbin, the method including calculating a standard value of the amount of waste yarn to be discarded emitted by yarn cutting accompanying a drawing operation of drawing out the yarn from the yarn feed bobbin.
The standard value is calculated on the basis of a previously-entered reference value, and a setting or status of the drawing operation for drawing out the yarn from the yarn feed bobbin. The amount of waste yarn, which is the yarn to be discarded when carrying out a yarn preparing operation, can be managed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic plan view of an automatic winder according to an embodiment of the present invention;
FIG. 2 is a front view showing an overall configuration of the automatic winder;
FIG. 3 is a side view of a winder unit;
FIG. 4 is a side view showing a state of preparing a yarn end by a yarn end preparation device;
FIG. 5 is a block diagram of the automatic winder; and
FIG. 6 shows what is displayed on a display.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

An embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a schematic plan view of an automatic winder 100 according to an embodiment of the present invention. FIG. 2 is a front view showing an overall configuration of an automatic winder main body 1. FIG. 3 is a side view of a winder unit 1a. FIG. 4 is a side view showing a state of preparing a yarn end by a yarn end preparation device 9. FIG. 5 is a block diagram of the automatic winder 100. FIG. 6 shows what is displayed on a display 92.
The automatic winder (textile machine) 100 shown in FIG. 1 includes the automatic winder main body (textile machine main body) 1, a bobbin preparation system 2, and a bobbin feed device 3. The bobbin preparation system 2 and the bobbin feed device 3 constitute an automatic bobbin feed device 18.
In a factory where the automatic winder 100 is operating, a compressed air supply source 50 is installed. The compressed air supply source 50 is constituted by, for example, a compressor or the like. Compressed air is supplied to each device of the automatic winder 100 by the compressed air supply source 50, and is used in various applications.
A yarn feed bobbin 12 includes a bobbin tube 120 around which a spun yarn (yarn) 10 is wound. The spun yarn (yarn) 10 has been produced in an upstream process by a fine spinning machine 40.
Referring to FIG. 2, the automatic winder main body 1 includes, as main components, a plurality of winder units (winding units) 1a arranged side by side, a cotton collection box 19, a blower box 80, a control box 85, and a doffing cart 17. As shown in FIG. 1, the automatic winder main body 1 has a feed passage 4 through which a yarn feed bobbin 12 is automatically conveyed to each winder unit 1a. The automatic winder main body 1 also has a collection passage 5 through which a return bobbin 13 discharged from each winder unit 1a is conveyed.
The feed passage 4 and the collection passage 5, which are constituted by a belt conveyor or the like, are able to convey a conveyance tray 16. FIG. 1 shows only a few yarn feed bobbins 12 and a few return bobbins 13, but actually, many yarn feed bobbins 12 are conveyed through the feed passage 4 and many return bobbins 13 are conveyed through the collection passage 5.
Each winder unit 1a unwinds a spun yarn 10 from a yarn feed bobbin 12, and winds the unwound spun yarn 10 around a yarn winding tube 14 while traversing the spun yarn 10, to form a package 15. Hereinafter, the term "package 15" may sometimes refer to a yarn winding tube 14 having a spun yarn 10 wound thereon.
A blower 81 is disposed in the blower box 80. The blower 81 functions as a negative pressure source that provides a negative pressure for sucking yarn debris and the like. The plurality of winder units 1a are connected to a shared blower duct (not shown). The cotton collection box 19 is disposed on one side of the blower box 80. The blower 81 is connected to the blower duct through the cotton collection box 19. Disposed inside the cotton collection box 19 is a known filter member for catching fiber debris and yarn debris. This allows fiber debris and yarn debris emitted from the winder units 1a to be sucked through the duct and stored inside the cotton collection box 19.
An integrated control device 91 is disposed in the control box 85. As shown in FIG. 5, the integrated control device 91 is configured to be communicable with unit controllers 95, 95,... of the respective winder units 1a, 1a, .... The integrated control device 91 is also configured to be communicable with an automatic feed device controller 99 of the automatic bobbin feed device 18 which will be described later. The integrated control device 91 can transmit a signal to the blower 81 of the blower box 80 to control the magnitude of the negative pressure generated by the blower 81.
In this embodiment, the integrated control device 91, the unit controllers 95, 95,..., and the automatic feed device controller 99 are combined to serve as a waste yarn emission amount output device 150.
The integrated control device 91 is able to integrally control information on the respective winder units 1a and the like. The integrated control device 91 includes a display (display unit) 92, an input unit 93, and a main control unit 94, as shown in FIG. 2 and FIG. 4.
When appropriately operated by an operator, the display 92 displays an operating status of each winder unit 1a and/or information on yarn quality.
The input unit 93 has a plurality of input keys. The input unit 93 is used for the operator's selecting which information is to be displayed on the display 92. The input unit 93 receives setting about various operating statuses of each winder unit 1a and/or information on yarn quality as well as setting about operations of various devices in the automatic winder 100.
When one of the winder units 1a makes a package 15 fully wound (wound with a specified amount of spun yarn 10), the doffing cart 17 shown in FIG. 2 moves to a position corresponding to this winder unit 1a. After arriving at this winder unit 1a, the doffing cart 17 is able to automatically remove the fully wound package 15 and set a new yarn winding tube 14.
Here, referring to FIG. 2 and FIG. 3, the winder unit 1a will be described in detail. As shown in FIG. 2 and FIG. 3, the winder unit 1a is configured to unwind a spun yarn 10 from a yarn feed bobbin 12 and wind the unwound spun yarn 10 onto a yarn winding tube 14 of a yarn winding part 22 while traversing the spun yarn 10. The yarn winding part 22 includes a cradle 31 and a winding drum 30.
The cradle 31 is able to rotatably support the yarn winding tube 14 (or the package 15). The cradle 31 is also able to bring a periphery of the package 15 supported thereon into contact with a periphery of the winding drum 30.
As the winding of the spun yarn 10 onto the yarn winding tube 14 progresses, the diameter of the package 15 increases. The cradle 31 enables the yarn winding tube 14 supported thereon to move away from the winding drum 30. It therefore is possible to continue the winding even though the diameter of the package 15 is increasing.
The winding drum 30 makes the package 15 rotate while traversing the spun yarn 10 over a surface of the package 15. The winding drum 30 is driven and rotated by an electric motor 63. Driving and rotating the winding drum 30 with the periphery of the package 15 in contact with the winding drum 30 causes slave rotation of the package 15. The winding drum 30 has, on its outer peripheral surface, a traverse groove with a spiral shape. The traverse groove allows the spun yarn 10 unwound from the yarn feed bobbin 12 to be traversed over a constant width while the spun yarn 10 is being wound onto the surface of the package 15. As a result, the package 15 having a constant winding width can be obtained.
In this embodiment, a driving force of the electric motor 63 is transferred to the winding drum 30, so that the winding drum 30 causes a slave rotation of the yarn winding tube 14 and the package 15. It may also be acceptable that a driving force of the electric motor 63 is transferred directly to the yarn winding tube 14 to cause rotation of the yarn winding tube 14 and the package 15.
The winder unit 1a includes a bobbin setting part (yarn feed part) 20 that supports the yarn feed bobbin 12, and a yarn winding part (winding part) 22 that winds the spun yarn 10. A travel route for the spun yarn 10 is formed between the bobbin setting part 20 and the yarn winding part 22. The winder unit 1a has, in the middle of the travel route, an unwinding assist device 23, a lower yarn blow-up part 24, a tension application device 25, a yarn joining device 26, and a yarn quality measurement device 27, which are disposed in this order from the bobbin setting part 20 side toward the yarn winding part 22 side.
The unwinding assist device 23 assists in unwinding the spun yarn 10 from the yarn feed bobbin 12. The unwinding assist device 23 includes a movable member. The movable member is able to come into contact with a balloon which appears in an upper portion of the yarn feed bobbin 12 as a result of the spun yarn 10 unwound from the yarn feed bobbin 12 being swung around. The unwinding assist device 23 changes the position of the movable member, to appropriately control the size of the balloon.
The lower yarn blow-up part 24 injects compressed air upward. This allows a lower yarn fed from the yarn feed bobbin 12 to be blown up toward the yarn joining device 26.
The tension application device 25 applies a predetermined tension to the traveling spun yarn 10. The tension application device 25 of this embodiment has a gate type configuration in which a movable comb teeth is disposed against an immovable comb teeth. The movable comb teeth is configured to be rotated by a rotary solenoid so that the comb teeth has a meshed state or an unmeshed state.
The yarn quality measurement device 27 monitors, for example, the thickness of the spun yarn 10, to detect a yarn defect such as a slub. A cutter 39 is disposed near the yarn quality measurement device 27. The cutter 39 cuts the spun yarn 10 immediately when the yarn quality measurement device 27 detects a yarn defect.
When the spun yarn 10 is broken, the yarn joining device 26 joins a lower yarn on the yarn feed bobbin 12 side to an upper yarn on the package 15 side. The breakage of the spun yarn 10 is caused, for example, when the yarn quality measurement device 27 detects a yarn defect and therefore the cutter 39 cuts the spun yarn 10, when the spun yarn 10 unwound from the yarn feed bobbin 12 is disconnected, or when the yarn feed bobbin 12 is replaced. The yarn joining device 26 of this embodiment uses compressed air to join the yarns by, for example, twisting the upper and lower yarns together.
A lower yarn guide pipe (unit drawing device) 28 and an upper yarn guide pipe 29 are disposed below and above the yarn joining device 26, respectively. The lower yarn guide pipe 28 catches and guides the lower yarn on the yarn feed bobbin 12 side. The upper yarn guide pipe 29 catches and guides the upper yarn on the package 15 side. The lower yarn guide pipe 28 has a suction port 32 at its distal end, and the upper yarn guide pipe 29 has a suction mouth (suction port) 34 at its distal end. The lower yarn guide pipe 28 and the upper yarn guide pipe 29 are connected to the above-described blower duct. Accordingly, suction airflows for catching yarn ends can be generated at the suction port 32 and at the suction mouth 34.
With this configuration, when the yarn feed bobbin 12 is replaced, for example, a lower yarn of a yarn feed bobbin 12 is blown up by the lower yarn blow-up part 24. The lower yarn is caught by the suction port 32 of the lower yarn guide pipe 28 which is waiting beside the travel route for the spun yarn 10. Then, the lower yarn guide pipe 28 rotates upward about a shaft 33. The lower yarn is accordingly guided to the yarn joining device 26. Almost concurrently with this, the package 15 is driven in reverse rotation so that an upper yarn is unwound. The upper yarn is caught by the suction mouth 34 of the upper yarn guide pipe 29. Then, the upper yarn guide pipe 29 rotates downward about a shaft 35. The upper yarn is accordingly guided to the yarn joining device 26. In the yarn joining device 26, the lower yarn and the upper yarn are joined to each other.
The yarn joining device 26 includes a cutter (not shown). When the upper yarn and the lower yarn are joined to each other in the yarn joining device 26, an excess of the upper yarn and an excess of the lower yarn are cut by the cutter and removed. If the upper yarn unwound by the reverse rotation of the package 15 is long, the amount of waste yarn increases. Likewise, if the lower yarn unwound from the yarn feed bobbin 12 is long, the amount of waste yarn increases.
A yarn defect detected by the yarn quality measurement device 27 sometimes appears only in a short section and sometimes appears over a long section in the longitudinal direction of the spun yarn 10. After the yarn quality measurement device 27 detects a yarn defect and thus the cutter 39 cuts the spun yarn 10, a part of the spun yarn 10 containing the yarn defect is once wound into the package 15 which is rotating by inertia. When the package 15 is driven in reverse rotation, the rotation angle over which the package 15 is driven in reverse rotation is controlled in accordance with the length of the yarn defect, in order that the yarn defect can be entirely drawn out by the upper yarn guide pipe 29 for removal.
When the yarn quality measurement device 27 detects the yarn defect and cuts the spun yarn 10 with the cutter 39, the yarn defect does not appear on the lower yarn. Accordingly, it is sufficient if the lower yarn is pulled out as much as necessary to guide the yarn end to the yarn joining device 26. Thus, the length of the lower yarn sucked by the lower yarn guide pipe 28 is, in principle, constant.
In this respect, however, in a case where the spun yarn 10 wound on the yarn feed bobbin 12 has a local section where low quality portions concentrate, the cutter 39 frequently cuts the spun yarn 10 in this section. If such a spun yarn 10 was controlled as usual, cutting of the yarn, stopping of the winding, yarn joining, and resuming of the winding should be repeated, which largely deteriorates a yarn winding efficiency. In this embodiment, therefore, in a case where the yarn quality measurement device 27 detects a yarn defect and thus the spun yarn 10 is cut with some frequency, the winder unit 1a causes the lower yarn guide pipe 28 to keep sucking the spun yarn 10 from the yarn feed bobbin 12 supported on the bobbin setting part 20 for a longer period than usual. As a result, a section of the spun yarn 10 that is likely to contain many defective portions is not fed from the yarn feed bobbin 12 but is removed. Accordingly, the winding efficiency can be improved. Since the lower yarn guide pipe 28 of the winder unit 1a operates differently than normal, the amount of waste yarn sucked by the lower yarn guide pipe 28 becomes greater than normal.
The lower yarn is sucked by the lower yarn guide pipe 28 not only when a yarn defect is detected, but also when the yarn feed bobbin 12 is replaced in the bobbin setting part 20. The operation of the winder unit 1a at the time of replacing the yarn feed bobbin 12 is different from when a yarn defect is detected in that, the suction port 32 of the lower yarn guide pipe 28 is stopped directly above the yarn feed bobbin 12 for a time including a certain margin, so that the yarn blown up by the lower yarn blow-up part 24 can be reliably caught by the lower yarn guide pipe 28. Accordingly, the length in which the lower yarn is sucked by the lower yarn guide pipe 28 for yarn joining differs between when the yarn feed bobbin 12 is replaced and when a yarn defect is detected.
The above-described configuration enables each winder unit 1a of the automatic winder main body 1 to unwind a spun yarn 10 from the yarn feed bobbin 12 supported on the bobbin setting part 20 and wind the spun yarn 10 onto the yarn winding tube 14, to form the package 15 having a predetermined length.
The fine spinning machine 40 shown in FIG. 1 is configured as a ring fine spinning machine that winds a spun yarn 10 onto a bobbin tube 120, the spun yarn 10 having been produced from a roving being drafted and twisted. As a configuration of the ring fine spinning machine is well known, a detailed description thereof is omitted herein.
The bobbin feed device 3 is configured to set the yarn feed bobbin 12 fed from the fine spinning machine 40 onto the conveyance tray 16 one by one. As a result, the conveyance tray 16 supports the yarn feed bobbin 12 in a substantially upright posture.
The bobbin feed device 3 is, though not illustrated, provided with a bobbin individual feed device which is called a parts feeder (not shown), for enabling the yarn feed bobbins 12 to be aligned in a constant posture.
The yarn feed bobbin 12 which is conveyed in the parts feeder has a bunch winding so that that the spun yarn 10 cannot be unwound therefrom in the course of conveyance, as will be detailed later. The spun yarn 10, however, may be unwound from the yarn feed bobbin 12 due to some cause such as occurrence of breakage of the spun yarn 10 at a bunch winding portion. In view of this, the parts feeder is provided with a cutter for cutting the spun yarn 10 unwound from the yarn feed bobbin 12. This can prevent the spun yarn 10 from being entangled around peripheral members. A waste yarn emitted as a result of cutting by the cutter is sucked by a suction mechanism (not shown).
As mentioned above, the yarn feed bobbin 12 is placed on the conveyance tray 16 while being conveyed to the winder unit 1a through the feed passage 4, and the winder unit 1a unwinds the spun yarn 10. The return bobbin 13 obtained as a result of the unwinding of the spun yarn 10 remains placed on the conveyance tray 16 while being discharged from the winder unit 1a through the collection passage 5.
The bobbin preparation system 2 has a conveyance passage 6 through which the conveyance tray 16 is conveyed. The conveyance passage 6 connects the feed passage 4 and the collection passage 5 of the automatic winder main body 1 to each other.
To be specific, the conveyance passage 6 includes a feed conveyance passage 6a, a return conveyance passage 6b, a skip passage 6c, and a restoration passage 6d. The feed conveyance passage 6a feeds the yarn feed bobbin 12 to the automatic winder main body 1. The return conveyance passage 6b returns the return bobbin 13 discharged from the automatic winder main body 1 to the fine spinning machine 40. The skip passage 6c allows the conveyance tray 16 to be conveyed from the feed conveyance passage 6a to the return conveyance passage 6b (not via the winder unit 1a). The restoration passage 6d allows the conveyance tray 16 to be restored from the return conveyance passage 6b to the feed conveyance passage 6a.
The bobbin preparation system 2 is disposed between the automatic winder main body 1 and the bobbin feed device 3. The bobbin preparation system 2 includes a bunch unwinding device 7, a suction-type yarn end drawing device 8, a hitch-type yarn end drawing device 8a, and a yarn end preparation device (preparatory drawing device) 9. The bobbin preparation system 2 applies an appropriate treatment on the yarn feed bobbin 12 such that the automatic winder main body 1 can smoothly unwind the spun yarn 10, and then feeds the yarn feed bobbin 12 to the automatic winder main body 1.
The bunch unwinding device 7 unwinds the bunch winding of the yarn feed bobbin 12. When the fine spinning machine 40 forms the yarn feed bobbin 12, the fine spinning machine 40 creates a bottom bunch with the spun yarn 10 in a base portion of the bobbin tube 120. Thus, the yarn end is prevented from being greatly unwound during transportation of the yarn feed bobbin 12 and getting entangled with the surrounding members. The bunch unwinding device 7 unwinds (removes) this bunch, to free the yarn end. The bunch unwinding device 7 includes a bobbin rotation mechanism that rotates a fully wound bobbin 11a, a suction mechanism that sucks a spun yarn 10, and a cutting mechanism that cuts the spun yarn 10.
The suction-type yarn end drawing device 8 shown in FIG. 1 stimulates a surface of a yarn layer of the yarn feed bobbin 12 with a surface stimulus device, and then sucks and catches a yarn end, to draw out the yarn end from the yarn feed bobbin 12. The suction-type yarn end drawing device 8 also has a suction mechanism. The surface stimulus device may be configured to include, for example, a rubbing member capable of contacting and rubbing the surface of the yarn layer. The suction-type yarn end drawing device 8 includes an air cylinder for bringing the yarn feed bobbin 12 into contact with the rubbing member, and a cutter for cutting a yarn end that has been caught.
The hitch-type yarn end drawing device 8a hitches a yarn end in an outermost layer of the yarn feed bobbin 12 unwound by the bunch unwinding device 7, to catch the yarn end, and then draws out the yarn end from the yarn feed bobbin 12. The hitch-type yarn end drawing device 8a draws out the yarn end from the yarn feed bobbin 12 by hitching the yarn end, and blows the yarn end toward the vicinity of a distal end portion of the yarn feed bobbin 12 by means of a compressed air injection nozzle. Then, the yarn feed bobbin 12 is rotated so that a distal end side winding portion can be formed which is similar to that formed by the suction-type yarn end drawing device 8.
The yarn end of the yarn feed bobbin 12 can be caught with only one of or both of the suction-type yarn end drawing device 8 and the hitch-type yarn end drawing device 8a. It is sufficient that at least one of the suction-type yarn end drawing device 8 and the hook-type yarn end drawing device 8a is provided.
The yarn end preparation device 9 processes the yarn end drawn out by the suction-type yarn end drawing device 8 or the hitch-type yarn end drawing device 8a, for making preparation that enables the automatic winder main body 1 to smoothly draw out the yarn end from the yarn feed bobbin 12.
As shown in FIG. 4, the yarn end preparation device 9 includes a yarn suction tube 71, a cutter 72, a yarn holding lever 73, a yarn detection sensor 74, and a yarn sucking part 75.
The yarn suction tube 71 is a tubular member disposed in the vertical direction. A downward opening 71a is formed at an end of the yarn suction tube 71. A bellows portion is formed in the middle of the yarn suction tube 71. The yarn suction tube 71 can expand and contract in the vertical direction by deformation of the bellows portion.
A lower end portion of the yarn suction tube 71 is movable in the vertical direction by an appropriate actuator (not shown). The yarn suction tube 71 expands and contracts in conjunction with the movement of the lower end portion thereof. When the lower end portion of the yarn suction tube 71 is lowered with the yarn feed bobbin 12 set in a predetermined position of the yarn end preparation device 9, the opening 71a can cover a distal end portion 121 of the yarn feed bobbin 12 from above. The yarn suction tube 71 is connected to the blower box 80 via piping 76, and can suck the distal end side winding portion mentioned earlier.
The cutter 72 is disposed at a connecting portion of the yarn suction tube 71 and the piping 76. The cutter 72 can cut the spun yarn 10. In this embodiment, the cutter 72 also serves as a shutter member that opens and closes the flow path of the suction airflow. However, the shutter member may be provided separately from the cutter 72.
The yarn holding lever 73 is able to come into contact with the yarn feed bobbin 12. The yarn holding lever 73 is attached to an appropriate actuator (for example, a solenoid). By driving the actuator, the yarn holding lever 73 can be switched between a position in contact with and pressing the surface of the yarn feed bobbin 12 and a position away from the surface of the yarn feed bobbin 12. The yarn holding lever 73 comes into contact with the yarn feed bobbin 12 at an appropriate timing to prevent the spun yarn 10 from being excessively unwound from the yarn feed bobbin 12. As a result, an increase in the waste yarn amount can be prevented.
The yarn detection sensor 74 is attached to the piping 76. The yarn detection sensor 74 can detect the spun yarn 10 in the piping 76 to detect whether or not the spun yarn 10 has been caught successfully.
The yarn sucking part 75 is arranged below the conveyance path of the yarn feed bobbin 12. The yarn sucking part 75 is configured as a pipe-shaped member connected to the above-described blower duct, and a suction port 77 opened upward is formed at one end thereof. The suction port 77 can face a lower surface of the conveyance tray 16 supporting the yarn feed bobbin 12. A vertical through hole is formed in the conveyance tray 16. Accordingly, a suction airflow can be generated at an opening portion at the upper end of the bobbin tube 120 by sucking the air from the yarn sucking part 75. The yarn sucking part 75 is provided with a valve member 78 that opens and closes the flow path of the suction airflow.
When the yarn end preparation device 9 waits for the yarn feed bobbin 12, the yarn suction tube 71 is in a contracted state. The cutter 72 and the valve member 78 functioning as valves are in a closed state. When the yarn feed bobbin 12 is conveyed, the yarn end preparation device 9 opens the cutter 72 to generate a suction airflow inside the yarn suction tube 71, and sucks the above-described distal end side winding portion formed on the yarn feed bobbin 12 upward. As a result, the yarn end can be sucked and caught by the yarn suction tube 71. At this time, the yarn holding lever 73 operates to press the surface of the yarn feed bobbin 12 at an appropriate timing.
When the successful catching of the yarn end is detected by the yarn detection sensor 74, the yarn end preparation device 9 operates the cutter 72 to cut the spun yarn 10. The waste yarn emitted as a result of cutting by the cutter 72 is sucked by a suction mechanism including the blower 81 and the like.
The yarn detection sensor 74 may not detect the spun yarn 10 even after a certain period of time elapses after a suction airflow is generated in the yarn suction tube 71. In this case, the yarn end preparation device 9 lowers the lower end of the yarn suction tube 71 to insert the upper portion of the yarn feed bobbin 12 into the lower portion of the yarn suction tube 71. At this time, the yarn holding lever 73 is held at a position away from the yarn feed bobbin 12 so as not to interfere with the yarn suction tube 71. The yarn suction tube 71 is immediately returned to the original contracted state after being expanded.
Since the intensity of the suction airflow acting on the surface of the yarn feed bobbin 12 can be varied by the vertical reciprocating movement of the lower end of the yarn suction tube 71, the yarn end is easily unwound from the yarn feed bobbin 12. In this embodiment, the expansion and contraction of the yarn suction tube 71 is carried out a preset number of times. After the expansion/contraction operation of the yarn suction tube 71 ends, the yarn holding lever 73 presses the surface of the yarn feed bobbin 12 at an appropriate timing.
The yarn end preparation device 9 opens the valve member 78 substantially at the same time as when the spun yarn 10 detected by the yarn detection sensor 74 is cut by the cutter 72. Then, the yarn sucking part 75 generates a suction airflow in the conveyance tray 16 and in the shaft hole of the bobbin tube 120, to absorb and catch the yarn end through the opening at the upper end of the bobbin tube 120. In this manner, the preparation for putting the yarn end into the bobbin tube 120 from above can be ready. Thereafter, the yarn holding lever 73 is separated from the yarn feed bobbin 12, and the valve member 78 is closed.
With the configuration thus far described, the bobbin preparation system 2 removes a bunch winding of the yarn feed bobbin 12 fed from the bobbin feed device 3. The bobbin preparation system 2 prepares a yarn end of the yarn feed bobbin 12 so that the yarn end can be drawn out from the yarn feed bobbin 12, and then conveys the yarn feed bobbin 12 to the automatic winder main body 1.
Each of the winder units 1a (FIG. 2) included in the automatic winder main body 1 draws out the yarn end prepared by the bobbin preparation system 2, in the above-described manner. Then, the yarn joining device 26 capable of untwisting and connecting the yarn end joins the yarn end to the spun yarn 10 on the package 15 side. Then, the spun yarn 10 is wound onto the yarn winding tube 14, so that the package 15 is obtained.
The return bobbin 13, which was the yarn feed bobbin 12 before unwinding of the spun yarn 10 in each winder unit 1a, is returned to the fine spinning machine 40 via the collection passage 5 and the return conveyance passage 6b.
The return bobbin 13 discharged from each winder unit 1a is not necessarily an empty bobbin 11d (FIG. 1) from which the spun yarn 10 has been entirely unwound. The return bobbins 13 discharged from the winder units 1a may include a half yarn bobbin 11b or an extremely small yarn bobbin 11c for some reason. The half yarn bobbin 11b is wound with an amount of yarn that can be wound by the winder unit 1a. The extremely small yarn bobbin 11c is wound with a small amount of yarn that cannot be wound by the winder unit 1a.
Next, a process concerning the return bobbin 13 discharged from the automatic winder main body 1 will be briefly described.
In the return conveyance passage 6b through which the return bobbin 13 is returned to the fine spinning machine 40, a remaining yarn detection device 45 and a switching device 46 are provided in this order along the conveyance direction of the return bobbin 13. The remaining yarn detection device 45 detects the position of a remaining yarn brush (not shown) which turns along an outer peripheral surface of the return bobbin 13, and based on the detected position of the remaining yarn brush, determines whether or not any spun yarn 10 is wound on the bobbin tube 120. More specifically, the remaining yarn detection device 45 attempts to make the remaining yarn brush turn along the outer peripheral surface of the return bobbin 13 from the distal end portion toward the base portion of the return bobbin 13. If the remaining yarn brush is not caught on the peripheral surface of the bobbin 13, the remaining yarn detection device 45 determines that no spun yarn 10 is wound on the return bobbin 13. If the remaining yarn brush is caught on the outer peripheral surface of the return bobbin 13, the remaining yarn detection device 45 determines that a spun yarn 10 is wound on the bobbin 13.
Based on the determination made by the remaining yarn detection device 45, the switching device 46 selectively sends the return bobbin 13 to the feed conveyance passage 6a or returns the return bobbin 13 to the fine spinning machine 40. As a result, the empty bobbin 11d is returned to the fine spinning machine 40, while a return bobbin (the half yarn bobbin 11b and the extremely small yarn bobbin 11c) having a remaining yarn is restored to the feed conveyance passage 6a through the restoration passage 6d.
Accordingly, if a return bobbin 13 collected from the automatic winder main body 1 is wound with at least a predetermined amount of yarn, the return bobbin 13 is conveyed to the bobbin preparation system 2 so that the return bobbin 13 can be again subjected to winding in the automatic winder main body 1.
In the restoration passage 6d, a yarn amount detection device 47, a second remaining yarn detection device 48, and a remaining yarn processing device 49 are disposed in this order along the conveyance direction of the return bobbin 13. The yarn amount detection device 47 brings an arm (not shown) into contact with a return bobbin 13 being conveyed, and detects the position of the arm, to thereby detect the amount of yarn wound on the return bobbin 13. The second remaining yarn detection device 48, which has a configuration similar to that of the remaining yarn detection device 45, detects whether or not any spun yarn 10 is left on the return bobbin 13.
If the yarn amount detection device 47 detects a return bobbin 13 (extremely small yarn bobbin 11c) having a predetermined amount or less of remaining yarn, the remaining yarn processing device 49 clamps a base portion of the bobbin tube 120 with a clamper (not shown) while holding down an upper portion of the bobbin 13 with an air cylinder. In this state, the clamper is moved in the longitudinal direction of the bobbin tube 120 toward a distal end portion of the bobbin tube 120, so that a yarn wound on the extremely small yarn bobbin 11c is pulled out upward from the distal end portion of the bobbin tube 120. The remaining yarn thus pulled out is collected into the cotton collection box 19 by a suction device (not shown). Removal of the remaining yarn makes the extremely small yarn bobbin 11c turn into an empty bobbin 11d. Thereafter, the empty bobbin 11d is returned to the fine spinning machine 40 through the restoration passage 6d and the skip passage 6c.
In the automatic winder 100 having the above-described configuration, waste yarns are emitted from each device. Specific examples are as follows.
The yarn joining device 26 of the automatic winder main body 1, when twisting the spun yarn 10, cuts an excess of the upper yarn and an excess of the lower yarn with a cutter (not shown) . Consequently, waste yarns are emitted. Unwanted portions of the upper yarn and the lower yarn are sucked by the upper yarn guide pipe 29 and the lower yarn guide pipe 28.
The bunch unwinding device 7 unwinds a bunch winding of the yarn feed bobbin 12, and cuts the spun yarn 10 at an appropriate portion. A portion of the spun yarn 10 corresponding to the bunch winding becomes a waste yarn. The waste yarn is sucked by the suction mechanism.
In the suction-type yarn end drawing device 8 and the hitch-type yarn end drawing device 8a, an excess of the spun yarn 10 drawn out from the yarn feed bobbin 12 is cut into an appropriate length with a cutter (not shown). In the yarn end preparation device 9, too, the spun yarn 10 is cut with a cutter 72. Consequently, waste yarns are emitted. The waste yarn is sucked by the suction mechanism.
The remaining yarn processing device 49 pulls out a spun yarn 10 from the extremely small yarn bobbin 11c. The spun yarn 10 pulled out becomes a waste yarn. The waste yarn is sucked by the suction device.
In this embodiment, as thus far described, the yarn joining device 26 of the automatic winder main body 1 corresponds to one of the devices emitting waste yarns of the present invention. The bunch unwinding device 7, the suction-type yarn end drawing device 8, the hitch-type yarn end drawing device 8a, the yarn end preparation device 9, and the remaining yarn processing device 49 correspond to ones of the devices emitting waste yarns of the present invention. Waste yarns emitted from various devices flow on a suction airflow, and all of them are collected into the cotton collection box 19.
Hereinafter, the devices that emit waste yarns as mentioned above may be collectively referred to as waste yarn emission parts 90, 90... FIG. 5 shows only a few waste yarn emission parts 90, but actually, there are many waste yarn emission parts 90 as described above. Each of the waste yarn emission parts 90 is operated at a required timing, and waste yarns emitted from them have various lengths.
A unit controller 95 includes a storage section 95a and a calculation section 95b.
To be specific, the unit controller 95 is configured as a known computer. The computer includes a CPU, a ROM, a RAM, and the like. The ROM stores programs for controlling respective parts of the winder unit 1a and for acquiring various information. Cooperation of the above-described hardware and software enables the unit controller 95 to function as the storage section 95a, the calculation section 95b, and the like.
Upon a yarn joining operation (including an operation of replacing the yarn feed bobbin 12), the unit controller 95 acquires a waste yarn emission amount through calculation, and sends the waste yarn emission amount to the integrated control device 91.
The automatic bobbin feed device 18 includes the automatic feed device controller 99. The automatic feed device controller 99, like the unit controller 95, is configured as a known computer. The automatic feed device controller 99 includes a storage section 99a and a calculation section 99b.
Once the yarn end preparation device 9 or the like is operated, the automatic feed device controller 99 acquires a waste yarn emission amount through calculation, and sends the waste yarn emission amount to the integrated control device 91.
The integrated control device 91 receives data on the waste yarn emission amounts in the respective devices, from the unit controller 95 and the automatic feed device controller 99, so that the main control unit 94 obtains an aggregate of the data, and the like.
The main control unit 94 includes an aggregate section 94a.
The integrated control device 91 is configured as a known computer. The computer includes a CPU, a ROM, a RAM, and the like. The ROM stores programs for enabling the integrated control device 91 to display various information and to receive a setting operation from the operator. Cooperation of the above-described hardware and software enables the main control unit 94 to function as the aggregate section 94a.
The storage section 95a of the unit controller 95 and the storage section 99a of the automatic feed device controller 99 each store information necessary in calculation for obtaining a waste yarn emission length or each store a waste yarn emission length per one operation, with respect to each device. Hereinafter, the waste yarn emission length per operation may be referred to as a reference value.
A yarn joining operation of the winder unit 1a causes waste yarns to be emitted from both the upper yarn and the lower yarn. A waste yarn (first waste yarn) from the upper yarn is generated at a location downstream of a broken portion of the spun yarn 10 in the yarn travel direction. The waste yarn from the upper yarn is sucked by the upper yarn guide pipe 29, and is collected into the cotton collection box 19. A waste yarn (second waste yarn) from the lower yarn is generated at a location upstream of a broken portion of the spun yarn 10 in the yarn travel direction. The waste yarn from the lower yarn is sucked by the lower yarn guide pipe 28, and is collected into the cotton collection box 19.
With respect to the waste yarn from the upper yarn, a relationship between the angle through which the winding drum 30 is rotated in the reverse direction for unwinding of the upper yarn from the package 15 and a waste yarn emission length is stored in the storage section 95a. More specifically, a yarn detection sensor for detecting that the upper yarn has been unwound from the package 15 and drawn out is disposed at an appropriate position (for example, at the upper yarn guide pipe 29) in the winder unit 1a. To unwind the upper yarn from the package 15 for the purpose of a yarn joining operation, the winding drum 30 is rotated in the reverse direction so that the package 15 is rotated in a direction reverse to the direction in which the package 15 is rotated at a time of winding. While the package 15 is rotated in the reverse direction, the suction mouth 34 sucks a surface of the package 15 so that the upper yarn is drawn out and is sucked into the upper yarn guide pipe 29. Thereby, the upper yarn is caught by the upper yarn guide pipe 29, so that the upper yarn is allowed to be unwound from the package 15. The yarn detection sensor is able to detect this upper yarn. After the upper yarn is detected by the yarn detection sensor, a necessary amount of upper yarn is drawn out from the package 15. Then, the upper yarn guide pipe 29 is rotated downward to guide the upper yarn to the yarn joining device 26. Then, the reverse rotation of the winding drum 30 stops. The angle through which the winding drum 30 is rotated in the reverse direction in a period from when the upper yarn is detected by the yarn detection sensor to when the reverse rotation of the winding drum 30 stops is controlled in accordance with, for example, the length of a yarn defect detected by the yarn quality measurement device 27. As the accumulated angle through which the winding drum 30 is rotated in the reverse direction increases, the waste yarn emission length caused in the upper yarn increases. The storage section 95a stores this relationship in the form of a table, a formula, or the like.
With respect to the waste yarn from the lower yarn, a relationship between an operation type when the lower yarn guide pipe 28 sucks the lower yarn and a waste yarn emission length per operation is stored in the storage section 95a.
More specifically, to unwind the lower yarn from the yarn feed bobbin 12 for the purpose of a yarn joining operation, the lower yarn guide pipe 28 brings its suction port 32 close to a yarn travel route at a position slightly downstream of the yarn feed bobbin 12, as indicated by the dot and dash line in FIG. 3. The position of the lower yarn guide pipe 28 at this time may hereinafter be referred to as a sucking position. Making the lower yarn guide pipe 28 rest in this state allows the lower yarn unwound from the yarn feed bobbin 12 to be sucked into the lower yarn guide pipe 28 because of a suction airflow. In this manner, the lower yarn guide pipe 28 catches the lower yarn. In this state, the lower yarn guide pipe 28 rotates upward to guide the lower yarn to the yarn joining device 26.
The operation type of the winder unit 1a when the lower yarn guide pipe 28 sucks the yarn of the yarn feed bobbin 12 at the sucking position can be broadly categorized into three types (a) to (c).
The operation type (a) is most typical, and is a case of carrying out a yarn joining operation in accordance with detection of a yarn defect by the yarn quality measurement device 27.
As described above, the operation type (b) is a case of intentionally removing the yarn of the yarn feed bobbin 12 that is likely to have many defective portions for a long time.
The operation type (c) is a case of replacing the yarn feed bobbin 12 with a new yarn feed bobbin 12 in the bobbin setting part 20.
For example, the time during which the lower yarn guide pipe 28 is stationary at the sucking position differs for each type of operation. Accordingly, the length of the waste yarn unwound from the yarn feed bobbin 12 and discarded by one operation of the lower yarn guide pipe 28 also differs according to the different operation. The storage section 95a stores this relationship in the form of a table, for example.
A waste yarn is also generated in the case of the preparatory operation in the yarn end preparation device 9. The waste yarn is sucked by the yarn suction tube 71 and collected into the cotton collection box 19.
A relationship between an operation type when the integrated control device 91 of the yarn end preparation device 9 sucks the yarn of the yarn feed bobbin 12 and a waste yarn emission length per operation is stored in the storage section 99a.
Hereinafter, a specific description will be given. The operation type of the yarn end preparation device 9 when catching the spun yarn 10 of the yarn feed bobbin 12 can be broadly categorized into three types (1) to (3).
The operation type (1) is an operation of applying a suction flow to the yarn feed bobbin 12 without performing the expansion/contraction operation of the yarn suction tube 71, and pressing the yarn feed bobbin 12 with the yarn holding lever 73 after a predetermined time from the action start timing of the suction flow regardless of whether or not the spun yarn 10 is detected by the yarn detection sensor 74. Thereafter, the spun yarn 10 is detected by the yarn detection sensor 74.
The operation type (2) is an operation of applying a suction flow to the yarn feed bobbin 12 without performing the expansion/contraction operation of the yarn suction tube 71, and pressing the yarn feed bobbin 12 with the yarn holding lever 73 at a timing when the spun yarn 10 is detected by the yarn detection sensor 74.
The operation type (3) is an operation additionally performed when the catching of the spun yarn 10 fails in the operation type (1) or (2). In this operation type, the yarn holding lever 73 is once separated from the yarn feed bobbin 12, and then the expansion/contraction operation of the yarn suction tube 71 is performed a predetermined number of times to apply the suction flow to the yarn feed bobbin 12. After a predetermined time from the completion timing of the expansion/contraction operation, the yarn holding lever 73 is operated to press the yarn feed bobbin 12 again. Thereafter, the spun yarn 10 is detected by the yarn detection sensor 74.
Which one of the operation types (1) and (2) the yarn end preparation device 9 initially attempts to catch the spun yarn 10 can be selected by the operator in advance and be set using the input unit 93.
In the three operation types, the length of time during which the suction airflow of the yarn suction tube 71 acts on the yarn feed bobbin 12, the timing at which the yarn holding lever 73 presses the yarn feed bobbin 12, and the like are different. Accordingly, the length of waste yarn unwound from the yarn feed bobbin 12 and discarded by one operation of the yarn end preparation device 9 also differs according to the operation. The storage section 99a stores the relationship between the operation type and the waste yarn amount in the form of a table, for example.
Next, the influence of the negative pressure of the blower 81 and the yarn type on the waste yarn amount will be described.
In the automatic winder 100 of this embodiment, the strength (static pressure) of the negative pressure generated by the blower 81 of the blower box 80 can be changed in a stepwise manner, for example, by setting to the integrated control device 91. Furthermore, the yarn type of the spun yarn 10 wound by the automatic winder main body 1 can be changed according to the order to the factory. The yarn type referred to herein includes the count (thickness) of the spun yarn 10. Information on the yarn type of the spun yarn 10 to be wound is set in advance in the automatic winder 100 by operating the integrated control device 91.
When the lower yarn guide pipe 28 sucks the lower yarn of the yarn feed bobbin 12 at the sucking position, the length in which the spun yarn 10 is sucked differs according to the negative pressure of the blower 81 and the yarn type of the yarn feed bobbin 12 even if the same type of operation is performed. In view of this, the storage section 95a of the unit controller 95 of this embodiment can store the waste yarn amount not only for each operation type but also for each negative pressure of the blower 81 and for each yarn type.
Similarly, the storage section 99a of the automatic feed device controller 99 can store the waste yarn amount when the yarn suction tube 71 of the yarn end preparation device 9 sucks the spun yarn 10 of the yarn feed bobbin 12 not only for the operation type but also for each negative pressure of the blower 81 and for each yarn type.
Although details will be described later, it is difficult to logically calculate the length of the waste yarn amount emitted when the lower yarn guide pipe 28 sucks the lower yarn and the length of the waste yarn amount emitted when the yarn suction tube 71 of the yarn end preparation device 9 sucks the spun yarn 10. Therefore, the automatic winder main body 1 of this embodiment can receive input of a reference value by the operator as the waste yarn amount stored in the storage section 95a and the waste yarn amount stored in the storage section 99a. The calculation sections 95b and 99b calculate the waste yarn amount using the reference value. Due to the above circumstances, the waste yarn amount (amount of yarn to be discarded) calculated on the basis of the reference value is not a strict value but a rough standard value. Hereinafter, the waste yarn amount (amount of yarn to be discarded) calculated based on the reference value may be referred to as a standard value.
The reference value of the waste yarn amount is input by the operator operating the input unit 93 of the integrated control device 91 to input the numerical value of the length of the waste yarn. The reference value can be input for each operation type, for each negative pressure of the blower 81, and for each yarn type. The input numerical value is transmitted from the integrated control device 91 to the unit controller 95 or the automatic feed device controller 99, and is stored in the storage sections 95a, 99a.
Next, a special mode of the integrated control device 91 for facilitating measurement of the waste yarn amount will be described.
In the winder unit 1a, when the upper yarn guide pipe 29 sucks the yarn of the yarn feed bobbin 12, the length of the yarn unwound from the package 15 can be theoretically calculated to some extent on the basis of the cumulative angle of the reverse rotation of the winding drum 30. However, when the lower yarn guide pipe 28 sucks the lower yarn of the yarn feed bobbin 12, the length of the spun yarn 10 unwound from the yarn feed bobbin 12 is not actively controlled, and thus it is extremely difficult to theoretically calculate the length of the waste yarn. Similarly, when the yarn suction tube 71 of the yarn end preparation device 9 sucks the spun yarn 10 of the yarn feed bobbin 12, it is difficult to theoretically calculate the length of the waste yarn.
In view of this, the automatic winder 100 has a waste yarn amount measurement assisting mode (measurement assisting mode). In the waste yarn amount measurement assisting mode, when the lower yarn guide pipe 28 or the yarn suction tube 71 sucks the spun yarn 10 of the yarn feed bobbin 12, the operator can be assisted to measure the length to become the waste yarn.
For example, if the operator desires to know the waste yarn amount when the lower yarn guide pipe 28 sucks the lower yarn of the yarn feed bobbin 12, the operator instructs the integrated control device 91 to cause the lower yarn guide pipe 28 to perform a test operation by operating the input unit 93. At this time, normal operation of the automatic winder 100 is stopped.
In response to this instruction, the integrated control device 91 displays an operation type selection screen on the display 92. The operator instructs the lower yarn guide pipe 28 the aforementioned type (a) to (c) in which to perform the suction operation of the spun yarn 10 by operating the input unit 93. At this time, the operator also specifies the negative pressure of the blower 81 and the yarn type. The operator sets the yarn feed bobbin 12 of the corresponding yarn type in the bobbin setting part 20 of one specific winder unit 1a in advance.
This operation switches the integrated control device 91 from the normal mode to the waste yarn amount measurement assisting mode. In the waste yarn amount measurement assisting mode, the integrated control device 91 transmits a test operation signal to the unit controller 95 of the winder unit 1a. In addition, the integrated control device 91 controls the blower 81 to generate a negative pressure of an instructed magnitude.
In response to the test operation signal, the unit controller 95 experimentally operates the lower yarn guide pipe 28, and the like of the winder unit 1a with the selected operation type. As a result, the lower yarn on the yarn feed bobbin 12 side is unwound and sucked into the lower yarn guide pipe 28. The lower yarn caught by the lower yarn guide pipe 28 is guided to the yarn joining device 26, but unlike usual, the lower yarn is not cut in the yarn joining device 26, the yarn joining operation with the upper yarn is not performed, and the test operation ends. Accordingly, even if the test operation is performed, the extra lower yarn to be discarded is not sent to the cotton collection box 19 and remains inside the lower yarn guide pipe 28.
After the test operation ends, the operator manually pulls out all the lower yarn from the inside of the lower yarn guide pipe 28, and measures the length of the spun yarn 10 sucked by the lower yarn guide pipe 28. By adding the distance from the suction port 32 of the lower yarn guide pipe 28 to the yarn joining device 26 at the yarn cutting timing to this length, the length of the waste yarn amount to be discarded can be obtained easily. For the measurement, a general tool such as a tape measure can be used.
If the operator desires to know the waste yarn amount when the yarn suction tube 71 of the yarn end preparation device 9 sucks the spun yarn 10 of the yarn feed bobbin 12, the operator instructs the yarn end preparation device 9 to perform a test operation by operating the input unit 93. The operator further selects an operation type of the yarn end preparation device 9 from (1) to (3). At this time, the operator also specifies the negative pressure of the blower 81 and the yarn type, and sets the yarn feed bobbin 12 of the corresponding yarn type in the yarn end preparation device 9.
This operation switches the integrated control device 91 from the normal mode to the waste yarn amount measurement assisting mode. In the waste yarn amount measurement assisting mode, the integrated control device 91 controls the negative pressure of the blower 81 as instructed, and transmits a test operation signal to the automatic feed device controller 99. In response to the test operation signal, the automatic feed device controller 99 experimentally operates the yarn end preparation device 9 with the selected operation type. As a result, the spun yarn 10 of the yarn feed bobbin 12 is unwound and sucked into the yarn suction tube 71 and the piping 76. However, unlike usual, the spun yarn 10 is not cut by the cutter 72 of the yarn suction tube 71, and the test operation ends. Accordingly, even if the test operation is performed, the spun yarn 10 to be discarded remains inside the yarn suction tube 71 and the piping 76.
After the test operation ends, the operator measures the length of the spun yarn 10 sucked by the yarn suction tube 71 and the piping 76 by a tape measure or the like. By subtracting the distance from the opening 71a of the yarn suction tube 71 to the cutter 72 from this length, the length of the waste yarn amount to be discarded can be easily obtained.
When setting the above-described reference value in the automatic winder 100, the operator can use the length of the waste yarn amount obtained by operating the automatic winder 100 in the waste yarn amount measurement assisting mode as the reference value. As a result, the accuracy of the waste yarn amount output by the automatic winder 100 can be enhanced.
Next, conversion from the length to the weight of the waste yarn will be described.
A relationship between a yarn count (thickness) of the spun yarn 10 and a length of the spun yarn 10 per unit weight is stored in advance in the storage section 95a of the unit controller 95 and in the storage section 99a of the automatic feed device controller 99.
The calculation section 95b of the unit controller 95 calculates a waste yarn emission amount. To be specific, upon detecting an operation of the waste yarn emission part 90 of the winder unit 1a, the calculation section 95b divides a waste yarn emission length in each device, which is stored in the storage section 95a, by a length per unit weight of the spun yarn 10, to thereby calculate a waste yarn emission amount on a weight basis. The unit controller 95 sends the obtained waste yarn emission amount to the integrated control device 91.
In a case of a yarn joining operation of the winder unit 1a, the calculation section 95b obtains a waste yarn emission length of the upper yarn through calculation using, for example, the angle through which the winding drum 30 has been rotated in the reverse direction. The calculation section 95b obtains the waste yarn emission length (standard value) of the lower yarn according to which operation type the winder unit 1a sucked the lower yarn.
The calculation section 99b of the automatic feed device controller 99 calculates a waste yarn emission amount. To be specific, upon detecting an operation of the waste yarn emission part 90 of the automatic bobbin feed device 18, the calculation section 99b divides a waste yarn emission length in each device, which is stored in the storage section 99a, by a length per unit weight of the spun yarn 10, to thereby calculate a waste yarn emission amount on a weight basis. The automatic feed device controller 99 sends the obtained waste yarn emission amount to the integrated control device 91.
In the case of the operation of the yarn end preparation device 9, the calculation section 99b obtains the waste yarn emission length (standard value) according to which operation type the yarn end preparation device 9 sucked the yarn.
The integrated control device 91 accumulates the waste yarn emission amounts received from the unit controller 95 and the automatic feed device controller 99 while separating the amount corresponding to the automatic winder main body 1 from the amount corresponding to the automatic bobbin feed device 18. The integrated control device 91 stores an accumulated value corresponding to the automatic winder main body 1 and an accumulated value corresponding to the automatic bobbin feed device 18. Here, in regard to the accumulated value corresponding to the automatic winder main body 1, an accumulated value of the waste yarn emission amount is calculated for each winder unit 1a.
As shown in FIG. 6, the main control unit 94 outputs a result of the computation to a waste yarn amount display area 57 of the display 92. The display 92 can display both a waste yarn emission amount from the entire automatic winder 100 and a waste yarn emission amount from each winder unit 1a, as will be detailed later.
An exemplary display on the display 92 will now be described with reference to FIG. 6.
On the display screen of the display 92 shown in FIG. 6, a lot information display field 51 is arranged. The lot information display field 51 displays a yarn count and a yarn speed of the yarn received.
In the display screen, the numerical value display area 58 and the graph display area 62 are disposed. The numerical value display area 58 includes a waste yarn amount display area 57. The waste yarn amount display area 57 displays the amount of waste yarn emitted so far.
The graph display area 62 includes a transition graph area 61. In the transition graph area 61, a change of the waste yarn amount over time can be displayed in the form of a graph.
The numerical values displayed in the numerical value display area 58 and the graphs displayed in the graph display area 62 change over time. Display contents can be updated at appropriate time intervals (for example, every minute) during operation of the automatic winder 100, for example. Accordingly, information can be displayed almost on a real-time basis. This makes it possible for the operator to notice and deal with a change of the status early.
In the numerical value display area 58, at least the total amounts are displayed in the waste yarn amount display area 57. In the waste yarn amount display area 57, a total amount display area 57a displays the total waste yarn emission amount from the entire automatic winder 100. Disposed below the total amount display area 57a are particulars display areas 57b, 57c.
The particulars display area 57b in the upper stage displays a waste yarn emission amount from the automatic winder main body 1 (that is, from the plurality of winder units 1a as a whole). The total waste yarn emission amount, when displayed, may be divided into a total waste upper yarn emission amount and a total waste lower yarn emission amount from the automatic winder main body 1, though not shown in FIG. 6. The total waste lower yarn emission amount is the total of the above-described standard values. Such an itemized display can be achieved by: the calculation section 95b of the unit controller 95 calculating a waste upper yarn emission amount and a waste lower yarn emission amount separately from each other; and the unit controller 95 sending the respective waste yarn emission amounts thus calculated to the integrated control device 91.
The particulars display area 57c in the lower stage displays a waste yarn emission amount from the bobbin preparation system 2 and/or the bobbin feed device 3. Although not shown in FIG. 6, this waste yarn emission amount can also be displayed separately for the waste yarn emission amount in the suction-type yarn end drawing device 8 or the hitch-type yarn end drawing device 8a, the waste yarn emission amount in the yarn end preparation device 9, and the waste yarn emission amount in the bobbin feed device 3. The waste yarn emission amount in the yarn end preparation device 9 is the above-described standard value. Such an itemized display can be achieved by: the calculation section 99b of the automatic feed device controller 99 obtaining the waste yarn emission amount of each device; and the automatic feed device controller 99 sending the respective waste yarn emission amounts to the integrated control device 91.
As described above, the values of the particulars display areas 57b and 57c are the sum of the standard values added to other values. Accordingly, the total amount displayed in the total amount display area 57a can also be referred to as a standard value of the waste yarn emission amount in the entire automatic winder 100.
The waste yarn emission amount output device 150 of this embodiment is able to acquire a waste yarn emission amount through calculation based on stored information, and display the waste yarn emission amount on the display 92. Accordingly, information that is useful in terms of an environmental load and an effective use of resources can be obtained easily.
If the operator desires to know the amount of waste yarn emitted only from the yarn end preparation device 9, the object can be achieved, for example, by disposing a known filter member in the middle of the piping 76 and actually measuring the weight of the waste yarn collected by the filter member. However, in this case, the configuration becomes complicated, and maintenance of the newly installed filter member is also required. In this regard, in this embodiment, the information of the waste yarn emission amount can be obtained by software processing, and thus the configuration can be prevented from becoming complicated.
The integrated control device 91 has a function of monitoring a standard value of the waste yarn amount. For example, in a factory where work shifts are defined, the integrated control device 91 calculates a standard value of the waste yarn amount emitted in the most recent shift by the yarn end preparation device 9 and a standard value of the waste yarn amount emitted in the immediately preceding shift. In a conceivable example, one shift lasts eight hours. When the standard value of the waste yarn amount in the most recent shift exceeds a value obtained by adding a predetermined margin to the standard value of the waste yarn amount in the previous shift, the integrated control device 91 displays a warning on the display 92. With this, the operator can recognize the abnormality of the yarn end preparation device 9 at an early stage and deal with the abnormality. Similarly, the standard value of the waste yarn amount can be monitored for the lower yarn guide pipe 28. The unit time for calculating the standard value of the waste yarn amount is not limited to one shift, and can be, for example, one hour, one day, one week, and the like. The warning can also be issued by, for example, a buzzer or the like.
As described above, the automatic winder 100 of this embodiment unwinds the spun yarn 10 from the yarn feed bobbin 12 and winds the spun yarn 10 onto the package 15. The automatic winder 100 includes calculation sections 95b and 99b that calculate a standard value of the amount of the spun yarn 10 to be discarded when drawing out the spun yarn 10 from the yarn feed bobbin 12.
As a result, the standard value of the waste yarn emission amount can be appropriately obtained by calculation with software without complicating the mechanical configuration.
The automatic winder 100 of this embodiment includes the input unit 93 capable of inputting a reference value of the amount of the spun yarn 10 to be discarded when drawing out the spun yarn 10 from the yarn feed bobbin 12. The calculation sections 95b and 99b calculate a standard value on the basis of the input reference value.
As a result, when the operator inputs an appropriate value as the reference value of the waste yarn amount, a highly reliable standard value can be obtained as the waste yarn amount.
The automatic winder 100 of this embodiment can be switched to a waste yarn amount measurement assisting mode for supporting measurement for obtaining the reference value.
As a result, the automatic winder 100 performs a special operation that facilitates measurement of the waste yarn amount, whereby the operator can easily acquire the reference value of the waste yarn amount.
The automatic winder 100 of this embodiment performs a different drawing operation according to the setting or status to draw out the spun yarn 10 from the yarn feed bobbin 12. The reference value can be input for each drawing operation.
As a result, an appropriate standard value corresponding to the variation of the drawing operation can be obtained as the waste yarn amount.
The automatic winder 100 of this embodiment includes the yarn end preparation device 9. The yarn end preparation device 9 performs a drawing operation of sucking and drawing out the yarn end of the yarn feed bobbin 12 before the yarn feed bobbin 12 is supplied to the winder unit 1a that unwinds the spun yarn 10 from the yarn feed bobbin 12 and winds the spun yarn 10 onto the package 15. The calculation section 99b calculates a standard value of the amount of the spun yarn 10 to be discarded at the time of the drawing operation of the yarn end preparation device 9.
As a result, the standard value of the waste yarn amount emitted in the yarn end preparation device 9 can be obtained without complicating the mechanical configuration.
In the automatic winder 100, a single blower different from the above-described blower 81 may be provided as the negative pressure source connected to the yarn end preparation device 9. In this case, for example, the automatic feed device controller 99 can function as a control device that controls the pressure of the suction airflow of the yarn end preparation device 9 through the negative pressure of the blower of the yarn end preparation device 9.
In this configuration, the strength, and the like of the suction airflow generated by the yarn end preparation device 9 can be appropriately controlled according to the waste yarn amount emitted by the yarn end preparation device 9.
The automatic winder 100 of this embodiment includes the winder unit 1a that unwinds the spun yarn 10 from the yarn feed bobbin 12 and winds the spun yarn 10 onto the package 15. The winder unit 1a includes the lower yarn guide pipe 28. The lower yarn guide pipe 28 performs a drawing operation of sucking and drawing out the spun yarn 10 from the yarn feed bobbin 12 before joining the spun yarn 10 on the package 15 side and the spun yarn 10 on the yarn feed bobbin 12 side. The calculation section 95b calculates a standard value of the amount of the spun yarn 10 to be discarded at the time of the drawing operation of the lower yarn guide pipe 28.
As a result, the standard value of the waste yarn amount emitted in the lower yarn guide pipe 28 can be obtained without complicating the mechanical configuration.
The automatic winder 100 of this embodiment includes the aggregate section 94a and the display 92. The aggregate section 94a aggregates the standard values calculated by the calculation sections 95b and 99b. The display 92 displays the total value aggregated by the aggregate section 94a.
As a result, the status of the waste yarn amount can be grasped from a rough viewpoint.
In the automatic winder 100 of this embodiment, the total value is displayed as the amount of the spun yarn 10 discarded by the entire automatic winder 100.
As a result, for example, the operator can easily grasp the waste yarn amount emitted in the entire automatic winder 100.
In the automatic winder 100 of this embodiment, the calculation sections 95b and 99b compare the standard value per unit time with the value based on the past standard value per unit time, and issues a warning based on the comparison result.
As a result, an abnormality occurring in the automatic winder 100 can be noticed and dealt with at an early stage.
Although a preferred embodiment of the present invention has been described above, the configuration above can be modified, for example, as follows.
The lower yarn guide pipe 28 can carry out various operations other than those described in the above operation types. The same applies to the yarn end preparation device 9.
The lower yarn guide pipe 28 may be configured to perform only one type of operation. In this case, the waste yarn amount (reference value) per operation is not stored in the storage section 95a for each operation. The same applies to the yarn end preparation device 9.
In the automatic winder 100, the negative pressure of the blower 81 may be unchangeable. In this case, the reference value per operation is not stored in 95a and 99a for each negative pressure of the blower 81. The yarn type may be unchangeable.
The method of measuring the length of the waste yarn amount is arbitrary. In the automatic winder 100, the waste yarn amount measurement assisting mode can be omitted.
Although the automatic winder 100 described above is configured to have the yarn feed bobbin 12 automatically set, this configuration is not limitative. Alternatively, the operator may set the yarn feed bobbin 12 to the winder unit 1a by hand. In this case, the automatic bobbin feed device 18 may be omitted, and the automatic winder 100 can be operated solely. In such a configuration, the waste yarn emission amount output device is constituted by a combination of the integrated control device 91 with the unit controllers 95.
The integrated control device 91 can either output obtained information on a waste yarn emission amount to another computer that is in network connection with the integrated control device 91, or output the obtained information by printing it with a printer.
The waste yarn emission amount output device 150 may be configured to acquire and display the amount of emitted waste yarn, for various purposes and in various ways other than the ones illustrated in the embodiment above.
In the embodiment described above, the calculation section 95b of each unit controller 95 calculates a waste yarn emission amount from the corresponding winder unit 1a. Likewise, the calculation section 99b of the automatic feed device controller 99 calculates a waste yarn emission amount from the automatic bobbin feed device 18. These calculations, however, may be implemented by a calculation section included in the integrated control device 91 (main control unit 94).
In the embodiment described above, a result of calculating a waste yarn emission amount is displayed on the display included in the integrated control device 91. Alternatively, it may be acceptable that the winder unit 1a and the automatic bobbin feed device 18 have display units which display a result of calculating a waste yarn emission amount. In such a configuration, the waste yarn emission amount output device is included in each of the winder units 1a and in the automatic bobbin feed device 18.
Displaying on the display 92 is not limited to the example shown in FIG. 6, and what is displayed thereon, a layout thereof, and the like can be changed appropriately.

Claims

A textile machine (100) configured to unwind a yarn from a yarn feed bobbin (12) and to wind the yarn onto a package (15), the textile machine (100) comprising
a calculation section (95b, 99b) configured to calculate a standard value of an amount of waste yarn emitted by yarn cutting accompanying a drawing operation of drawing out a yarn from the yarn feed bobbin (12).
The textile machine (100) as claimed in claim 1 comprising
an input unit (93) configured to input a reference value serving as a reference for obtaining the standard value, wherein

the calculation section (95b, 99b) is configured to calculate the standard value on the basis of the input reference value.
The textile machine (100) as claimed in claim 2, configured to execute a measurement assisting mode of assisting measurement for obtaining the reference value, the measurement assisting mode being a mode of stopping the drawing operation before cutting the yarn.
The textile machine (100) as claimed in any one of claims 2 and 3, wherein
the drawing operation for drawing out a yarn from the yarn feed bobbin (12) differs according to a setting or a status, and

the reference value is input for each of the different drawing operations.
The textile machine (100) as claimed in any one of claims 1 to 4 comprising
a preparatory drawing device (9) configured to perform an operation of sucking and drawing out a yarn end of a yarn feed bobbin (12) before the yarn feed bobbin (12) is supplied to a winding unit (1a) that unwinds the yarn from the yarn feed bobbin (12) and winds the yarn onto a package (15), wherein

the calculation section (99b) is configured to calculate a standard value of the amount of yarn discarded during operation of the preparatory drawing device (9).
The textile machine (100) as claimed in claim 5 comprising
a control device (99) configured to control a pressure of a suction airflow for sucking a yarn by the preparatory drawing device (9).
The textile machine (100) as claimed in any one of claims 1 to 6 comprising
a winding unit (1a) configured to unwind a yarn from a yarn feed bobbin (12) and to wind the yarn onto a package (15), wherein

the winding unit (1a) includes a unit drawing device (28) configured to perform an operation of sucking and drawing out the yarn from the yarn feed bobbin (12) before joining the yarn on the package (15) side and the yarn on the yarn feed bobbin (12) side, and

the calculation section (95b) is configured to calculate a standard value of the amount of yarn discarded during operation of the unit drawing device (28).
The textile machine (100) as claimed in any one of claims 1 to 7 comprising
an aggregate section (94a) configured to aggregate the standard values calculated by the calculation section (95b, 99b) to obtain a total value, and

a display unit (92) configured to display a total value aggregated by the aggregate section (94a).
The textile machine (100) as claimed in claim 8, wherein
the display unit (92) is configured to display the total value as an amount of yarn discarded in the entire textile machine (100) .
The textile machine (100) as claimed in any one of claims 8 and 9, wherein
the calculation section (95b, 99b) is configured to compare the total value per unit time with a past total value per unit time, and to issue a warning on the basis of the comparison result.
The textile machine (100) as claimed in any one of claims 1 to 10, wherein
the preparatory drawing device (9) includes:
a yarn suction tube (71) that is a tubular member disposed in a vertical direction;

a cutter (72) provided downstream in a suction direction of the yarn suction tube (71) and configured to cut the yarn in the drawing operation; and

a yarn detection sensor (74) configured to detect a yarn in the yarn suction tube (71) to detect whether or not the yarn has been caught successfully.
A waste yarn amount calculation method for calculating a standard value of an amount of waste yarn emitted by yarn cutting accompanying a drawing operation of drawing out a yarn from a yarn feed bobbin (12), the method comprising
calculating the standard value of the amount of waste yarn.
The waste yarn amount calculation method as claimed in claim 12, wherein
the standard value is calculated on the basis of
a previously-entered reference value, and

the drawing operation for drawing out a yarn from the yarn feed bobbin (12).