EP4729672A1

EP4729672A1 - Fiber bundle concentrating device in spinning frame

Info

Publication number: EP4729672A1
Application number: EP25206263.3A
Authority: EP
Inventors: Hisaaki Hayashi; Motohiro Kawai; Kyohei Kamiya; Yohei Nakada; Yasuhiro Uto; Takenao AOKI; Ravichandra; N Avinash NAYAK
Original assignee: Toyota Industries Corp
Current assignee: Toyota Industries Corp
Priority date: 2024-10-09
Filing date: 2025-10-02
Publication date: 2026-04-22
Also published as: JP2026067638A

Abstract

A fiber bundle concentrating device (20) includes a condensing unit (21) including delivery bottom rollers (23) arranged on a rotary shaft (23a), and countershafts (30) configured to rotate the rotary shaft. The countershafts each include a driving portion (31) configured to transmit rotation of the countershafts to the delivery bottom rollers. The driving portion is coupled to a driven portion (41) that transmits driving force to the rotary shaft. The countershafts include a first countershaft (30A) located at a first side in an axial direction (X) and a second countershaft (30B) located at a second side from the first countershaft. The driving portion (31) of the first countershaft (30A) is smaller than the driving portion of the second countershaft (30B) in dimension in the axial direction.

Description

BACKGROUND

1. Field

The present disclosure relates to a fiber bundle concentrating device in a spinning frame.

2. Description of Related Art

A fiber bundle concentrating device in a spinning frame concentrates fiber bundles drafted by a drafting device before the fiber bundles are twisted. The concentration of bundles, for example, reduces fuzzing and increases the strength of yarn. Thus, the quality of yarn is improved. JP2023-169860A describes an example of such a fiber bundle concentrating device that includes multiple condensing units and multiple countershafts. Each of the condensing units includes a rotary shaft and multiple delivery bottom rollers. The delivery bottom rollers are arranged on the rotary shaft to rotate integrally with the rotary shaft. The rotary shaft includes a driven gear. The countershafts include a driving gear. The driving gear meshes with the driven gear of the rotary shaft. Rotation of the driving gear with the countershaft rotates the driven gear of the rotary shaft. The rotation of the driven gear rotates the delivery bottom rollers together with the rotary shaft. As the delivery bottom rollers rotate, fiber bundles are transferred at a location where the delivery bottom rollers are arranged in the condensing units.
In the fiber bundle concentrating device, for example, the countershafts may experience thermal expansion in the axial direction as the ambient temperature increases, and thermal contraction in the axial direction as the ambient temperature decreases. Accordingly, the driving gear is displaced in the axial direction of the countershafts. To maintain the meshing of the driving gear with the driven gear regardless of such axial displacement of the driving gear, it is preferred that the driving gear be increased in dimension in the axial direction taking into consideration the displacement of the driving gear in the axial direction of the countershafts due to thermal expansion and contraction. However, as the drive gear is increased in dimension in the axial direction, the driving gear is more likely to collect fiber fly and trap an object.

SUMMARY

This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
In an aspect of the present disclosure, a fiber bundle concentrating device in a spinning frame includes multiple condensing units, multiple countershafts, a drive source, a coupling, and a driven portion. The condensing units are configured to concentrate a fiber bundle that is drafted. Each of the condensing units includes a rotary shaft, multiple delivery bottom rollers arranged on the rotary shaft and configured to transfer the fiber bundle, a suction portion configured to apply a suction action to the fiber bundle, multiple perforated aprons configured to rotate along the suction portion, and multiple delivery top rollers in contact with the delivery bottom rollers via the perforated aprons and configured to rotate together with the delivery bottom rollers. The countershafts are configured to rotate the rotary shaft. The countershafts are arranged next to each other in an axial direction of the countershafts. The countershafts have a first end located at a first side in the axial direction and a second end located at a second side in the axial direction. The drive source is configured to drive the countershafts from the first end. The coupling is configured to couple adjacent ones of the countershafts located adjacent to each other in the axial direction and rotate integrally with the countershafts. The driven portion is configured to transmit driving force to the rotary shaft. The countershafts are configured so that the second end is movable in the axial direction. The countershafts each include a driving portion configured to transmit rotation of the countershafts to the delivery bottom rollers. The driving portion is coupled to the driven portion. The countershafts include a first countershaft located at the first side in the axial direction and a second countershaft located at the second side from the first countershaft. The driving portion of the first countershaft is smaller than the driving portion of the second countershaft in dimension in the axial direction.
Other features and aspects will be apparent from the following detailed description, the drawings, and the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is a schematic diagram of a spinning frame.
Fig. 2 is a front view of the spinning frame shown in Fig. 1 with a condensing unit removed.
Fig. 3 is a diagram showing the condensing unit and a driving force transmission device of the spinning frame shown in Fig. 1.
Fig. 4 is a schematic diagram showing couplings and countershafts in the spinning frame shown in Fig. 1.
Fig. 5 is a diagram showing a first driving gear and an intermediate gear of the spinning frame shown in Fig. 1.
Fig. 6 is a diagram showing a second driving gear and an intermediate gear in the spinning frame shown in Fig. 1.
Fig. 7 is a schematic diagram showing another example of a fiber bundle concentrating device.

Throughout the drawings and the detailed description, the same reference numerals refer to the same elements. The drawings may not be to scale, and the relative size, proportions, and depiction of elements in the drawings may be exaggerated for clarity, illustration, and convenience.

DETAILED DESCRIPTION

This description provides a comprehensive understanding of the methods, apparatuses, and/or systems described. Modifications and equivalents of the methods, apparatuses, and/or systems described are apparent to one of ordinary skill in the art. Sequences of operations are exemplary, and may be changed as apparent to one of ordinary skill in the art, with the exception of operations necessarily occurring in a certain order. Descriptions of functions and constructions that are well known to one of ordinary skill in the art may be omitted.
Exemplary embodiments may have different forms, and are not limited to the examples described. However, the examples described are thorough and complete, and convey the full scope of the disclosure to one of ordinary skill in the art.
In this specification, "at least one of A and B" should be understood to mean "only A, only B, or both A and B."
An embodiment of a fiber bundle concentrating device in a spinning frame will now be described.

Spinning Frame

As shown in Fig. 1, a spinning frame 10 includes a drafting device 11 (only front roller pair 111 shown), a fiber bundle concentrating device 20, roller stands 50, support plates 51 arranged integrally with each roller stand 50, an out-end head 101, and a gear-end head 102. The direction in which the out-end head 101 and the gear-end head 102 are opposed to each other is referred to as a longitudinal direction X of the spinning frame 10.
The gear-end head 102 incorporates a front bottom roller driver 103 and a countershaft driver 104. Each of the front bottom roller driver 103 and the countershaft driver 104 is a motor. The front bottom roller driver 103 rotates a rotary shaft 112a of front bottom rollers 112 of the drafting device 11, which will be described later. The countershaft driver 104 rotates countershafts 30 of the fiber bundle concentrating device 20, which will be described later. In other words, the countershaft driver 104 is a drive source that drives the countershafts 30. The axial direction of the countershafts 30 conforms to the longitudinal direction X. With respect to the fiber bundle concentrating device 20, the gear-end head 102 is arranged at a first side in the axial direction of the countershafts 30, and the out-end head 101 is arranged at the opposite side, that is, a second side in the axial direction.
The roller stands 50 are arranged in the longitudinal direction X between the out-end head 101 and the gear-end head 102. The roller stands 50 are separated from each other at a fixed interval in the longitudinal direction X. The support plates 51 are fixed to opposite surfaces of each roller stand 50 in the longitudinal direction X.
The roller stands 50 support rotary bodies so that the rotary bodies are rotatable using bearings, which are not shown in the drawings. In Fig. 1, the roller stands 50 rotatably support the rotary shaft 112a of the front bottom rollers 112 and the countershafts 30.

Drafting Device

As shown in Figs. 1 and 3, the drafting device 11 includes the front roller pair 111. Although not shown, the drafting device 11 includes a back roller pair and a middle roller pair in addition to the front roller pair 111. The front roller pair 111 is arranged downstream of the back roller pair and the middle roller pair in a feeding direction of a fiber bundle F.
The front roller pair 111 includes a front bottom roller 112 and a front top roller 113. The front top roller 113 is formed of rubber. The front bottom roller 112 is formed of metal. The front bottom roller 112 is formed by enlarging the diameter of the rotary shaft 112a at multiple positions in the axial direction. Thus, the front bottom roller 112 rotates integrally with the rotary shaft 112a. The rotary shaft 112a, and therefore the front bottom roller 112, is rotated by the front bottom roller driver 103. The front top roller 113 is rotatably supported by a support arm, which is not shown in the drawings.
The drafting device 11 drafts the fiber bundle F using the difference in circumferential speed among the front roller pair 111, the middle roller pair, and the back roller pair. The fiber bundle F drafted by the drafting device 11 is fed out from the front roller pair 111 toward the fiber bundle concentrating device 20.

Fiber Bundle Concentrating Device

As shown in Fig. 1, the fiber bundle concentrating device 20 is arranged between the out-end head 101 and the gear-end head 102 in the longitudinal direction X. The fiber bundle concentrating device 20 includes multiple condensing units 21, the multiple countershafts 30, the countershaft driver 104, and multiple couplings 70. The fiber bundle concentrating device 20 includes the countershafts 30 and spindle groups, each of which includes eight spindles. Each countershaft 30 corresponds to one of the spindle groups.

Condensing Unit

The condensing unit 21 condenses the fiber bundle F that is drafted by the drafting device 11. The fiber bundle F, fed out by the front roller pair 111, is drawn and condensed by the condensing unit 21.
The condensing unit 21 includes multiple delivery bottom rollers 23, one suction portion 24, multiple perforated aprons 25, multiple guides 29, multiple delivery top rollers 26, and two end caps 21a. The number of delivery bottom rollers 23 is equal to the number of perforated aprons 25, the number of guides 29, and the number of delivery top rollers 26. In the embodiment, the condensing unit 21 includes eight delivery bottom rollers 23, eight perforated aprons 25, eight guides 29, and eight delivery top rollers 26.
The delivery bottom rollers 23 are arranged around a circumferential surface of a delivery rotary shaft 23a and rotate integrally with the delivery rotary shaft 23a. The delivery bottom rollers 23 are spaced apart from each other in the axial direction of the delivery rotary shaft 23a. The delivery rotary shaft 23a is configured to rotate the delivery bottom rollers 23.
The delivery rotary shaft 23a includes a driven gear 23b arranged on the circumferential surface of the delivery rotary shaft 23a. The driven gear 23b rotates integrally with the delivery rotary shaft 23a, and therefore the delivery bottom rollers 23. The delivery bottom rollers 23 and the delivery top rollers 26 nip the fiber bundle F and the perforated aprons 25 and transfer the condensed fiber bundle F while feeding out the condensed fiber bundle F in the feeding direction.
The suction portion 24 has the form of a pipe elongated in the longitudinal direction X. The suction portion 24 has multiple suction holes 24a. The suction holes 24a are separated from each other in the longitudinal direction X. The suction portion 24 applies a suction action to the fiber bundle F, which is fed out by the front roller pair 111 in the feeding direction, and condenses the fiber bundle F while drawing the fiber bundle F.
The perforated apron 25 is formed of an endless woven cloth that ensures air permeability. The perforated apron 25 extends around on the delivery bottom roller 23, a portion of the suction portion 24 where the suction holes 24a are formed, and the guide 29. The suction portion 24 applies a suction action to the fiber bundle F, which is transferred, via the perforated apron 25. The perforated apron 25 rotates along the suction portion 24, the delivery bottom roller 23, and the guide 29.
The delivery top roller 26 is formed from rubber. The delivery bottom roller 23 is arranged so as to be opposed to the delivery top roller 26. The perforated apron 25 passes between the delivery top roller 26 and the delivery bottom roller 23. The delivery bottom roller 23, which is in contact with the delivery top roller 26 via the perforated apron 25, rotates together with the delivery top roller 26.
The end caps 21a are arranged on opposite axial ends of the delivery rotary shaft 23a and the suction portion 24. The end caps 21a rotatably support the delivery rotary shaft 23a and support the suction portion 24.
As shown in Fig. 1, the condensing unit 21 is supported by the support plates 51, opposed to each other in the longitudinal direction X, between adjacent ones of the roller stands 50 in the longitudinal direction X. More specifically, when the end caps 21a are supported by the two support plates 51, the condensing unit 21 is supported by the roller stands 50.

Countershaft

As shown in Figs. 2 and 4, the countershafts 30 are arranged next to each other in the axial direction of the countershafts 30. The countershafts 30 are arranged between the gear-end head 102 and the out-end head 101 in the spinning frame 10. The countershafts 30 are arranged next to each other in the longitudinal direction X in a straight line. Each countershaft 30 rotates the delivery rotary shaft 23a of the delivery bottom rollers 23 via the driving force transmission device 40, which will be described later.
The countershaft 30 includes an elongated large diameter portion 301 and small diameter portions 302 extending from two axial ends of the large diameter portion 301. While the large diameter and small diameter portions have different diameters, in the schematic diagram of Fig. 4, the small diameter portion 302 and the large diameter portion 301 are illustrated as having the same diameter. The small diameter portion 302 and the large diameter portion 301 are arranged coaxially. The diameter of the large diameter portion 301 is entirely constant in the axial direction. Also, the diameter of the small diameter portion 302 is entirely constant in the axial direction. The large diameter portion 301 is larger in dimension in the axial direction than the small diameter portions 302. When the large diameter portion 301 is inserted through the roller stand 50, the countershaft 30 is rotatably supported by the roller stand 50. Alternatively, the countershaft 30 may be rotatably supported by the roller stands 50 when one of the small diameter portions 302, which are located at opposite axial ends, is greater in the axial direction than the other small diameter portion 302, and the one of the small diameter portions 302 is inserted through the roller stand 50.
One of the small diameter portions 302 of each countershaft 30 located closer to the gear-end head 102 is located adjacent to a roller stand 50 at the gear-end head 102 and is coupled by a coupling 70 to one of the small diameter portions 302 of another countershaft 30 that is inserted through the roller stand 50.
The countershaft driver 104 includes an output shaft 33 coupled by a coupling 70 to the countershaft 30 that is located closest to the gear-end head 102 among the countershafts 30. The output shaft 33 includes a large diameter portion 301 and a small diameter portion 302 arranged on one axial end of the large diameter portion 301. The output shaft 33 is smaller in length in the axial direction than the countershaft 30. However, the output shaft 33 may be greater than or equal to in length in the axial direction than the countershaft 30. The output shaft 33 is coupled to the countershaft driver 104 by an end of the large diameter portion 301 located opposite from the small diameter portion 302. The output shaft 33 is driven and rotated by the countershaft driver 104. The small diameter portion 302 of the output shaft 33 is coupled by a coupling 70 to the small diameter portion 302 of the countershaft 30 located adjacent to the output shaft 33 in the longitudinal direction X. The fiber bundle concentrating device 20 is located closer to the out-end head 101 than the output shaft 33 is.
Of the countershafts 30 arranged next to each other, the countershaft 30 located closest to the out-end head 101 is coupled by a coupling 70 to a support shaft 34. The support shaft 34 includes a large diameter portion 301 and a small diameter portion 302 arranged on one axial end of the large diameter portion 301. The support shaft 34 is smaller in length in the axial direction than the countershaft 30. However, the support shaft 34 may be greater than or equal to in length in the axial direction than the countershaft 30. The large diameter portion 301 of the support shaft 34 is rotatably supported by the out-end head 101 with a bearing 35 held by the out-end head 101. The small diameter portion 302 of the support shaft 34 is coupled by a coupling 70 to the small diameter portion 302 of the countershaft 30 located adjacent to the support shaft 34 in the longitudinal direction X. The support shaft 34 is supported by the out-end head 101 and is movable in the longitudinal direction X (the axial direction of the countershafts 30). Thus, of the countershafts 30 arranged next to each other, the countershaft 30 located closest to the out-end head 101 includes an end located at a second side (second end) that is movable in the longitudinal direction X (the axial direction of the countershafts 30). The fiber bundle concentrating device 20 is located farther from the out-end head 101 than the support shaft 34 is. That is, the fiber bundle concentrating device 20 is arranged between the output shaft 33 and the support shaft 34.

Coupling

As shown in Figs. 2 and 3, the coupling 70 includes a first coupling member 72, a second coupling member 73, and a bolt 80. Each of the first coupling member 72 and the second coupling member 73 is semi-cylindrical. The first coupling member 72 and the second coupling member 73 each include an accommodating recess 74. The accommodating recess 74 is configured to accommodate the small diameter portion 302. Each of the first coupling member 72 and the second coupling member 73 includes opposing surfaces 75 located at radially opposite sides of the accommodating recess 74.
The first coupling member 72 has insertion holes 72b. The insertion holes 72b are open in an outer surface of the first coupling member 72 and in the opposing surfaces 75. The insertion holes 72b are aligned with each other in the axial direction of the first coupling member 72 along the accommodating recess 74. The insertion holes 72b are located at opposite sides of the accommodating recess 74 so as to sandwich the accommodating recess 74.
The second coupling member 73 includes internal threads 77. The internal threads 77 connect an outer surface of the second coupling member 73 to the opposing surfaces 75. The internal threads 77 are aligned with each other in the axial direction of the second coupling member 73 along the accommodating recess 74. The internal threads 77 are located at opposite sides of the accommodating recess 74 so as to sandwich the accommodating recess 74. A positioning pin 78 projects from an inner surface of the second coupling member 73 defining the accommodating recess 74.
Bolts 80 are inserted through the insertion holes 72b of the first coupling member 72 and are coupled to the internal threads 77 in the second coupling member 73. When the bolts 80 are coupled to the internal threads 77, the first coupling member 72 and the second coupling member 73 are fastened to be located close to each other. The fastening by the bolts 80 form the coupling 70.
The small diameter portions 302 of adjacent ones of the countershafts 30, the output shaft 33 and the small diameter portion 302 of the countershaft 30 located adjacent to the output shaft 33, or the support shaft 34 and the small diameter portion 302 of the countershaft 30 located adjacent to the support shaft 34 are held between the accommodating recess 74 of the first coupling member 72 and the accommodating recess 74 of the second coupling member 73. As a result, all of the output shaft 33, the countershafts 30, and the support shaft 34 are all coupled and are integrally rotatable. Thus, the coupling 70 couples two of the countershafts 30 located adjacent to each other in the axial direction and rotates with the countershafts 30. The small diameter portions 302 contact the positioning pin 78. This hinders the countershafts 30 from moving toward the gear-end head 102 in the axial direction of the couplings 70.
As shown in Fig. 2, the countershaft 30 includes a driving gear 31, which is a driving portion. The driving gear 31 is arranged on one of two axial ends of the countershaft 30 located closer to the out-end head 101. The driving gear 31 transmits rotation of the countershaft 30 to the delivery bottom roller 23. More specifically, the driving gear 31 transmits driving force to the driven gear 23b arranged on the delivery rotary shaft 23a via an intermediate gear 41, which will be described below. Thus, the countershaft 30 rotates to rotate the delivery bottom roller 23 of each condensing unit 21.
When the countershaft driver 104 is driven to rotate the output shaft 33, the countershafts 30 and the support shaft 34 rotate synchronously with the output shaft 33. That is, the countershaft driver 104 drives the countershafts 30 from a first end of each countershaft 30. Of the countershafts 30 arranged next to each other, the countershaft 30 located closest to the gear-end head 102 has an end facing the output shaft 33, that is, an end located at the first side in the axial direction, defining a first end of the countershafts 30. Thus, the first end of the countershafts 30 is coupled to the output shaft 33 of the countershaft driver 104. Of the countershafts 30 arranged next to each other, the countershaft 30 located closest to the out-end head 101 has an end located at the side opposite from the countershaft driver 104, that is, an end located at a second side in the axial direction, defining a second end of the countershafts 30. The second end of the countershafts 30 is movable in the longitudinal direction X (axial direction of the countershafts 30).

Driving Force Transmission Device

The driving force transmission device 40 includes the driven gear 23b arranged on the delivery rotary shaft 23a, the driving gear 31 arranged on the countershaft 30, and the intermediate gear 41 meshing with the driven gear 23b and the driving gear 31. The driving force transmission device 40 couples the countershaft 30 to the delivery bottom roller 23.
The intermediate gear 41 is supported by the support plate 51 via a gear bracket 42. The gear bracket 42 is supported by one of the two support plates 51 located closer to the driving gear 31.
The countershaft driver 104 synchronously rotates all of the countershafts 30. When the countershaft 30 rotates, the driving gear 31 rotates together with the countershaft 30. Rotation of the driving gear 31 is transmitted to the intermediate gear 41 and rotates the intermediate gear 41. Rotation of the intermediate gear 41 is transmitted to the driven gear 23b. This results in rotation of the delivery rotary shaft 23a, which is integrated with the driven gear 23b, and therefore rotation of the delivery bottom roller 23. The driving gear 31 is coupled to the intermediate gear 41, which is a driven portion that transmits driving force to the delivery rotary shaft 23a.

Countershaft and Driving Force Transmission Device

Referring to Fig. 4, a gear-side coupling 70G refers to the coupling 70 that is located closest to the gear-end head 102 in the couplings 70 and couples the output shaft 33 and the countershaft 30. Also, an out-side coupling 70F refers to the couplings 70 that is located closest to the out-end head 101 in the couplings 70 and couples the support shaft 34 and the countershaft 30. The gap between the gear-side coupling 70G and the out-side coupling 70F is referred to as a pitch. The pitch is a distance between the center of the gear-side coupling 70G in the longitudinal direction X and the center of the out-side coupling 70F in the longitudinal direction X. That is, the pitch corresponds to the distance between the gear-side coupling 70G and the out-side coupling 70F. The pitch is also referred to as an overall length L.

The overall length L will now be described.

As shown in Fig. 1, the delivery bottom rollers 23 arranged next to each other in the longitudinal direction X are spaced apart from each other in the longitudinal direction X. The delivery bottom rollers 23 are located at equal intervals over the entirety of the spinning frame 10 in the longitudinal direction X. The gap between the delivery bottom rollers 23 located adjacent to each other in the longitudinal direction X is referred to as a gap KL. The number of delivery bottom rollers 23, or spindle, in a single unit is denoted by "m." In the present embodiment, m is eight. The number of countershafts 30 in the spinning frame 10 is denoted by "n." In the present embodiment, the number of countershafts 30 is an even number. The overall length L is determined by Equation 1. $L = KL \times m \times n$
The overall length L is determined by the gap between the delivery bottom rollers 23 located adjacent to each other in the longitudinal direction X, the number of spindles, and the number of countershafts 30.
A midpoint HP refers to a point between the gear-side coupling 70G and the out-side coupling 70F separated from each of the gear-side coupling 70G and the out-side coupling 70F by 1/2 of the overall length L. The midpoint HP is located on a coupling 70. The number of countershafts 30 arranged between the midpoint HP and the gear-end head 102 is equal to the number of countershafts 30 arranged between the midpoint HP and the out-end head 101. The coupling 70 located at the midpoint HP is referred to as a midpoint coupling 70H.
The distance between the center of the gear-side coupling 70G in the longitudinal direction X and the center of the midpoint coupling 70H in the longitudinal direction X is referred to as a first length L1. The distance between the center of the out-side coupling 70F in the longitudinal direction X and the center of the midpoint coupling 70H in the longitudinal direction X is referred to as a second length L2. The countershafts 30 that are located between the gear-side coupling 70G and the midpoint coupling 70H are referred to as first countershafts 30A. The countershafts 30 that are located between the out-side coupling 70F and the midpoint coupling 70H are referred to as second countershafts 30B. Therefore, the first length L1 corresponds to the length, in the axial direction, of a section defined by the first countershafts 30A and the couplings 70 corresponding to the first countershafts 30A. The second length L2 corresponds to the length, in the axial direction, of a section defined by the second countershafts 30B and the couplings 70 corresponding to the second countershafts 30B. The countershafts 30 include the first countershafts 30A, which are located closer in the axial direction to the countershaft driver 104 than the midpoint HP is, and the second countershafts 30B, which are located farther from the side of a drive source than the first countershafts 30A are, that is, at the opposite side of the midpoint HP from the countershaft driver 104.
The first length L1 is equal to the second length L2. Since the first length L1 is equal to the second length L2, the number of countershafts 30 determining the first length L1 is equal to the number of countershafts 30 determining the second length L2.
The portion between the gear-side coupling 70G and the midpoint coupling 70H is referred to as a first countershaft group 30L. The portion between the out-side coupling 70F and the midpoint coupling 70H is referred to as a second countershaft group 30R. The first countershaft group 30L corresponds to the section defined by the first countershafts 30A and the couplings 70. The first length L1 corresponds to the length of the first countershaft group 30L in the axial direction.
The second countershaft group 30R corresponds to the section defined by the second countershafts 30B and the couplings 70. The second length L2 corresponds to the length of the second countershaft group 30R in the axial direction. The overall length L is the length, in the axial direction, of a section that combines the section defined by the first countershafts 30A and the couplings 70 and the section defined by the second countershafts 30B and the couplings 70. That is, the overall length L is the length, in the axial direction, of the entire section including the first countershaft group 30L and the second countershaft group 30R. The midpoint HP, which corresponds to the border between the section defined by the first countershafts 30A and the couplings 70 and the section defined by the second countershafts 30B and the couplings 70, is located at a position that divides the overall length L in half.
The first countershafts 30A forming the first countershaft group 30L differ from the second countershafts 30B forming the second countershaft group 30R in dimension of the driving gear 31 in the axial direction of the countershafts 30. The driving gear 31 that is arranged on the first countershafts 30A is referred to as a first driving gear 311. The driving gear 31 that is arranged on the second countershafts 30B is referred to as a second driving gear 312. The first driving gear 311 is smaller than the second driving gear 312 in dimension in the axial direction.
The first driving gear 311 and the second driving gear 312 each project from the intermediate gear 41 at the first side and the second side, that is, opposite axial sides, when the countershafts 30 have no thermal expansion and contraction.
The countershafts 30 and the couplings 70 have a linear expansion coefficient α. The countershafts 30 and the couplings 70 are formed of the same carbon steel. Thus, the linear expansion coefficient of the countershafts 30 is equal to the linear expansion coefficient of the couplings 70.
The temperature of the countershafts 30 increases in accordance with operation of the spinning frame 10 and an increase in the ambient temperature. The temperature of the countershafts 30 decreases when the ambient temperature is low. The temperature of all of the countershafts 30 increases and decreases in the same manner. A temperature of the countershafts 30 used as reference is referred to as a reference temperature Tb. A temperature increased from the reference temperature Tb is denoted by ΔT. A temperature decreased from the reference temperature Tb is denoted by ΔT'. The reference temperature Tb may be changed in accordance with the land or the factory where the spinning frame 10 is installed.
When the countershafts 30 expand in the axial direction as the temperature increases, the extension amount of the first countershaft group 30L in the axial direction is denoted by s1, and the extension amount of the second countershaft group 30R in the axial direction is denoted by s2. The extension amounts s1 and s2 are determined by Equations 2 and 3. $s 1 = L 1 \times ΔT \times α$ $s 2 = (L 1 + L 2) \times ΔT \times α$
When the temperature increases, all of the countershafts 30 thermally expand and extend in the axial direction in the same manner. The extension amount of each countershaft 30 is accumulated in accordance with the number of countershafts 30. The second end of the countershafts 30 is displaced in the axial direction by a displacement amount obtained by adding a displacement amount of the first countershafts 30A and a displacement amount of the second countershafts 30B in the axial direction. Thus, the extension amount s2 (displacement amount) in the second countershaft group 30R is longer (greater) than the extension amount s1 (displacement amount) in the first countershaft group 30L. In other words, the displacement amount of the first countershafts 30A due to thermal expansion is small relative to that of the second countershafts 30B.
When all of the countershafts 30 thermally contract in the axial direction as the temperature decreases, the contraction amount of the first countershaft group 30L in the axial direction is denoted by t1, and the contraction amount of the second countershaft group 30R in the axial direction is denoted by t2. The contraction amounts t1 and t2 are determined by Equations 4 and 5. $t 1 = L 1 \times ΔT' \times α$ $t 2 = (L 1 + L 2) \times ΔT' \times α$
When the temperature decreases, all of the countershafts 30 thermally contract in the axial direction in the same manner. The contraction amount of each countershaft 30 is added in accordance with the number of countershafts 30. That is, the second end of the countershafts 30 is displaced in the axial direction by a displacement amount obtained by adding a displacement amount of the first countershafts 30A and a displacement amount of the second countershafts 30B in the axial direction. Thus, the contraction amount t2 (displacement amount) of the second countershaft group 30R is longer (greater) than the contraction amount t2 (displacement amount) of the first countershaft group 30L. In other words, the displacement amount of the first countershafts 30A resulting from thermal contraction is small relative to that of the second countershafts 30B.
The dimension of the intermediate gear 41 in the longitudinal direction X is denoted by u. The dimension u of the intermediate gear 41 is the same for the intermediate gear 41 that meshes with the first driving gear 311 of the first countershafts 30A and the intermediate gear 41 that meshes with the second driving gear 312 of the second countershaft 30B.
As shown in Figs. 5 and 6, the dimension of the first driving gear 311 in the axial direction is referred to as a first gear dimension w1. The dimension of the second driving gear 312 in the axial direction is referred to as a second gear dimension w2. The gear dimensions w1 and w2 are determined by Equations 6 and 7. $w 1 = u + s 1 + t 1$ $w 2 = u + s 2 + t 2$
At the reference temperature Tb, when the first driving gear 311 is meshed with the intermediate gear 41, a second-side end surface of the first driving gear 311 is located at a position separated from a second-side end surface of the intermediate gear 41 by the contraction amount t1. At the reference temperature Tb, when the first driving gear 311 is meshed with the intermediate gear 41, a first-side end surface of the first driving gear 311 is located at a position separated from a first-side end surface of the intermediate gear 41 by the extension amount s1.
At the reference temperature Tb, when the second driving gear 312 is meshed with the intermediate gear 41, a second-side end surface of the second driving gear 312 is located at a position separated from a second-side end surface of the intermediate gear 41 by the contraction amount t2. At the reference temperature Tb, when the second driving gear 312 is meshed with the intermediate gear 41, a first-side end surface of the second driving gear 312 is located at a position separated from a first-side end surface of the intermediate gear 41 by the extension amount s2.
Thus, at the reference temperature Tb, when meshed with the intermediate gear 41, each of the first driving gear 311 and the second driving gear 312 has margins at both sides of the intermediate gear 41 in the longitudinal direction X. In each of the first driving gear 311 and the second driving gear 312, the portion located at the second side from the intermediate gear 41 is smaller in dimension in the axial direction than the portion located at the first side from the intermediate gear 41.

Operation of Embodiment

When the temperature of the countershafts 30 becomes higher than the reference temperature Tb as the spinning frame 10 operates, the countershafts 30 extend in the axial direction due to thermal expansion. In this state, each countershaft 30 contacts the positioning pin 78 of the corresponding coupling 70. This restricts expansion of the countershaft 30 toward the first side. Thus, the countershaft 30 thermally expands toward the second side. As a result, the second end of the countershafts 30 is displaced.
As indicated by double-dashed lines in Fig. 5, the first driving gear 311 and the second driving gear 312 are both displaced toward the second side. The first driving gear 311 of the first countershaft 30A is displaced toward the second side by the extension amount s1 at a maximum. As indicated by double-dashed lines in Fig. 6, the second driving gear 312 of the second countershaft 30B is displaced toward the second side by the extension amount s2 at a maximum. That is, the first driving gear 311 and the second driving gear 312 are displaced by an amount corresponding to the margin for expansion. Therefore, even when the first countershafts 30A and the second countershafts 30B are displaced as a result of thermal expansion, each of the first driving gear 311 and the second driving gear 312 remains meshed with the intermediate gear 41.
When the temperature of the countershafts 30 becomes lower than the reference temperature Tb due to, for example, a low ambient temperature, the countershafts 30 thermally contract in the axial direction. In this state, each countershaft 30 contacts the positioning pin 78 of the corresponding coupling 70. This restricts displacement of the countershaft 30 toward the first side beyond the positioning pin 78.
The first driving gear 311 and the second driving gear 312 are both displaced toward the first side. The first driving gear 311 of the first countershaft 30A is displaced toward the first side by the contraction amount t1 at a maximum. The second driving gear 312 of the second countershaft 30B is displaced toward the first side by the contraction amount t2 at a maximum. That is, the first driving gear 311 and the second driving gear 312 are displaced by an amount corresponding to the margin for contraction. Therefore, even when the first countershafts 30A and the second countershafts 30B are displaced as a result of thermal contraction, each of the first driving gear 311 and the second driving gear 312 remains meshed with the intermediate gear 41.

Advantages of Embodiment

The above-described embodiment has the following advantages.

(1) The first countershafts 30A, which are located at the first side, are configured to have a smaller displacement amount in the axial direction due to thermal expansion and contraction than the second countershafts 30B, which are movable in the axial direction and are located at the second side. Thus, the driving gear 31 and the intermediate gear 41 remain coupled even when all of the driving gears 31 do not have the same dimension in the axial direction; more specifically, even when the first gear dimension w1 is smaller than the second gear dimension w2. With this structure, the area of the driving gears 31 in relation to the entire area is reduced as compared to a structure in which all of the driving gears 31 have the dimension of a second driving gear 312 in the axial direction. As a result, the driving gears 31 are less likely to collect fiber fly and trap an object while all of the driving gears 31 remain meshed with the intermediate gears 41. In addition, the manufacturing cost for processing the driving gears 31 is reduced.
(2) The first gear dimension w1 is set by Equation 6. The second gear dimension w2 is set by Equation 7. More specifically, the first gear dimension w1 and the second gear dimension w2 are set in accordance with the position of each countershaft 30 between the out-end head 101 and the gear-end head 102. Thus, two types of driving gears 31, that is, the first driving gear 311 having the first gear dimension w1 and the second driving gear 312 having the second gear dimension w2, suffice. The minimum number of types of the driving gear 31 and the countershafts 30 are set to limit collection of fiber fly and trapping of an object on the driving gears 31 while the driving gears 31 remain meshed with the intermediate gears 41.
(3) The countershafts 30 having the overall length L are set by two types of the first countershafts 30A and the second countershafts 30B. The first gear dimension w1 is set corresponding to the first countershafts 30A. The second gear dimension w2 is set corresponding to the second countershafts 30B. The countershafts 30 in two types suffice to reduce collection of fiber fly and trapping of an object on the driving gears 31 while the driving gears 31 remain meshed with the intermediate gears 41.
(4) The spinning frame 10 includes an even number of countershafts 30. The countershafts 30 having the overall length L are divided into the first countershafts 30A and the second countershafts 30B at a position of 1/2 of the overall length L. Thus, the spinning frame 10 may include the first countershafts 30A and the second countershafts 30B that are equal to each other in number. In addition, the switching between the first countershafts 30A and the second countershafts 30B may be performed at the position of 1/2 of the overall length L. This simplifies the task for installing the countershafts 30.
(5) For example, each driving gear 31 may have the minimum dimension in the axial direction in accordance with the position of the corresponding countershaft 30, and the countershaft 30 may be installed in the spinning frame 10. In such a structure, it is very difficult to adjust the position of the countershaft 30 taking into consideration changes in temperature and adjust the position of the countershaft 30 when coupled to the coupling 70. In contrast, in the present embodiment, the two types of the first driving gear 311 and the second driving gear 312 differ from each other in the dimension in the axial direction. This reduces collection of fiber fly and trapping of an object on the driving gears 31 while the driving gears 31 remain meshed with the intermediate gears 41.

Modified Examples

The present embodiment may be modified as follows. The present embodiment and the following modified examples can be combined as long as the combined modified examples remain technically consistent with each other.
As shown in Fig. 7, when the number of spindles m in the spinning frame 10 is the maximum number of spindles that can be installed in the spinning frame 10, the length between the gear-side coupling 70G and the out-side coupling 70F in the longitudinal direction X is referred to as a maximum length Lmax. The maximum length Lmax is equal to the overall length L. The section (the first countershaft group 30L) including the first countershafts 30A and the couplings 70 are arranged in a portion of the overall length L having 1/2 of the maximum length Lmax starting from the end at the first side. The section (the second countershaft group 30R) including the second countershafts 30B and the couplings 70 are arranged in the remaining section of the overall length L. When the number of spindles m is maximum, L1 = L2. As the number of spindles m decreases, the second length L2 decreases while the first length L1 remains the same. With this structure, the number of first countershafts 30A remains constant regardless of the number of spindles m. In the first countershaft 30, the dimension of the driving gear 31 in the axial direction is smaller, and the driving gear 31 is less likely to collect fiber fly and trap an object.
In this case, of the overall length L, the second length L2 of the second countershaft group 30R is shorter than the first length L1 of the first countershaft group 30L. As a result, in the countershafts 30, the number of first countershafts 30A is greater than the number of second countershafts 30B. That is, the number of first driving gears 311 is greater than the number of second driving gears 312. As a result, the driving gears 31 are less likely to collect fiber fly and trap an object. In addition, the manufacturing cost for processing the driving gears 31 is reduced.
When the number of countershafts 30 is an odd number, the border between the first countershaft group 30L and the second countershaft group 30R is located toward the first side from the position of 1/2 of the overall length L by an amount corresponding to one-half of a spindle group. Thus, when the number of countershafts 30 is an odd number, the border between the first countershaft group 30L and the second countershaft group 30R is proximate to one-half of the overall length L and is located at a position substantially one-half of the overall length L.
The number of countershafts 30 may be changed.
In the fiber bundle concentrating device 20, the countershafts 30 do not necessarily have to be divided for each spindle group. The number of countershafts 30 in each spindle group does not have to be one.
The material of the countershafts 30 and the couplings 70 may be a stainless steel material other than carbon steel or an aluminum alloy. In this case, the linear expansion coefficient α of the material is applied when setting the first gear dimension w1 and the second gear dimension w2.
At least one of the first countershafts 30A and the second countershafts 30B may be formed of shaft formation members that are coupled by the couplings 70.
The driven gear 23b and the driving gear 31 may be directly meshed with each other without using the intermediate gear 41 so that rotation of the countershaft 30 is directly transmitted to the driven gear 23b arranged on the delivery rotary shaft 23a. In this case, the driven gear 23b is a driven portion.
The driving portion of the countershaft 30 does not have to be the driving gear 31 and may be, for example, a friction surface or an uneven surface that has undergone surface roughening. The driven portion may be a friction belt or toothed belt engaged with the friction surface or the uneven surface.
Three or more types of the driving gear 31 may be arranged on the countershafts 30. Among the driving gears 31, those located toward the second side may have a larger dimension in the axial direction. In this case, it is preferred that the first countershafts 30A arranged in one-half of the overall length L each have the first driving gear 311, and countershafts 30 that are arranged in the other half of the overall length L each have a driving gear 31 having a larger dimension in the axial direction.
In the countershafts, at least one of the output shaft 33 and the support shaft 34 may be replaced with a countershaft 30.
In the fiber bundle concentrating device 20, the first end of the countershafts may be an end of the output shaft 33 or a countershaft 30 coupled to the countershaft driver 104 and located at the first side. The second end of the countershafts may be an end of the support shaft 34 or a countershaft 30 located at the second side.
Various changes in form and details may be made to the examples above without departing from the spirit and scope of the claims and their equivalents. The examples are for the sake of description only, and not for purposes of limitation. Descriptions of features in each example are to be considered as being applicable to similar features or aspects in other examples. Suitable results may be achieved if sequences are performed in a different order, and/or if components in a described system, architecture, device, or circuit are combined differently, and/or replaced or supplemented by other components or their equivalents. The scope of the disclosure is not defined by the detailed description, but by the claims and their equivalents. All variations within the scope of the claims and their equivalents are included in the disclosure.

Claims

A fiber bundle concentrating device (20) in a spinning frame (10), the fiber bundle concentrating device (20), comprising:
multiple condensing units (21) configured to concentrate a fiber bundle (F) that is drafted, each of the condensing units (21) including a rotary shaft (23a), multiple delivery bottom rollers (23) arranged on the rotary shaft (23a) and configured to transfer the fiber bundle (F), a suction portion (24) configured to apply a suction action to the fiber bundle (F), multiple perforated aprons (25) configured to rotate along the suction portion (24), and multiple delivery top rollers (26) in contact with the delivery bottom rollers (23) via the perforated aprons (25) and configured to rotate together with the delivery bottom rollers (23);

multiple countershafts (30) configured to rotate the rotary shaft (23a), the countershafts (30) being arranged next to each other in an axial direction of the countershafts (30), the countershafts (30) having a first end located at a first side in the axial direction and a second end located at a second side in the axial direction;

a drive source (104) configured to drive the countershafts (30) from the first end;

a coupling (70) configured to couple adjacent ones of the countershafts (30) located adjacent to each other in the axial direction and rotate integrally with the countershafts (30); and

a driven portion (41) configured to transmit driving force to the rotary shaft (23a), wherein

the countershafts (30) are configured so that the second end is movable in the axial direction,

the countershafts (30) each include a driving portion (31) configured to transmit rotation of the countershafts (30) to the delivery bottom rollers (23),

the driving portion (31) is coupled to the driven portion (41),

the countershafts (30) include a first countershaft (30A) located at the first side in the axial direction and a second countershaft (30B) located at the second side from the first countershaft (30A), and

the driving portion (31) of the first countershaft (30A) is smaller than the driving portion (31) of the second countershaft (30B) in dimension in the axial direction.
The fiber bundle concentrating device (20) according to claim 1, wherein
when a section defined by the first countershaft (30A) and the coupling (70) corresponding to the first countershaft (30A) has a length in the axial direction denoted by L1,

a section defined by the second countershaft (30B) and the coupling (70) corresponding to the second countershaft (30B) has a length in the axial direction denoted by L2,

the coupling (70), the first countershaft (30A), and the second countershaft (30B) have a linear expansion coefficient denoted by α,

a temperature increased from a reference temperature is denoted by ΔT, and

a temperature decreased from the reference temperature is denoted by ΔT',

equations s1 = L1 × ΔT × α and s2 = (L1 + L2) × ΔT × α are obtained, where in accordance with the temperature increased, s1 denotes an extension amount of the section defined by the first countershaft (30A) and the coupling (70) corresponding to the first countershaft (30A) in the axial direction, and s2 denotes an extension amount of the section defined by the second countershaft (30B) and the coupling (70) corresponding to the second countershaft (30B) in the axial direction,

equations t1 = L1 × ΔT' × α and t2 = (L1 + L2) × ΔT' × α are obtained, where in accordance with the temperature decreased, t1 denotes a contraction amount of the section defined by the first countershaft (30A) and the coupling (70) corresponding to the first countershaft (30A) in the axial direction, and t2 denotes a contraction amount of the section defined by the second countershaft (30B) and the coupling (70) corresponding to the second countershaft (30B) in the axial direction, and

equations w1 = u + s1 + t1 and w2 = u + s2 + t2 are satisfied, where w1 denotes a dimension of the driving portion (31) of the first countershaft (30A) in the axial direction, and w2 denotes a dimension of the driving portion (31) of the second countershaft (30B) in the axial direction, and u denotes a dimension of the driven portion (41) in the axial direction.
The fiber bundle concentrating device (20) according to claim 1 or 2, wherein
an overall length refers to a length, in the axial direction, of a section that combines the section defined by the first countershaft (30A) and the coupling (70) corresponding to the first countershaft (30A) and the section defined by the second countershaft (30B) and the coupling (70) corresponding to the second countershaft (30B), and

a border between the section defined by the first countershaft (30A) and the coupling (70) corresponding to the first countershaft (30A) and the section defined by the second countershaft (30B) and the coupling (70) corresponding to the second countershaft (30B) is located at a position that divides the overall length in substantially in half.
The fiber bundle concentrating device (20) according to claim 1 or 2, wherein
the spinning frame (10) includes an out-end head (101) and a gear-end head (102),

the countershafts (30) are arranged between the out-end head (101) and the gear-end head (102),

the first end is coupled to the drive source (104), and the second end is configured to be movable in the axial direction,

a maximum length refers to a length of the countershafts (30) in the axial direction when a maximum number of spindles are installed in the spinning frame (10),

an overall length refers to a length, in the axial direction, of a section that combines the section defined by the first countershaft (30A) and the coupling (70) corresponding to the first countershaft (30A) and the section defined by the second countershaft (30B) and the coupling (70) corresponding to the second countershaft (30B),

the section defined by the first countershaft (30A) and the coupling (70) corresponding to the first countershaft (30A) is arranged in a portion of the overall length having 1/2 of the maximum length starting from the first end of the section defined by the first countershaft (30A) and the coupling (70) corresponding to the first countershaft (30A), and

the section defined by the second countershaft (30B) and the coupling (70) corresponding to the second countershaft (30B) is arranged in a remaining portion of the overall length.
The fiber bundle concentrating device (20) according to claim 2, wherein
the spinning frame (10) includes an out-end head (101) and a gear-end head (102),

the countershafts (30) are arranged between the out-end head (101) and the gear-end head (102),

the first end is coupled to the drive source (104), and the second end is configured to be movable in the axial direction, and

in a positional relationship between the driven portion (41) and the driving portion (31) at the reference temperature, the extension amount is provided at the first side of the driven portion (41), and the contraction amount is provided at the second side of the driven portion (41).