GB2325206A - Yarn package transport system - Google Patents

Abstract

A system for transporting yarn packages having a wide end supported directly by a spool and a narrow end which is unsupported from a winding machine which feeds the packages on an output conveyor narrow end first comprises a chute for transporting the packages to a transport conveyor and a mechanism 400 for reorienting the packages so that the wide ends enter the chute first. The mechanism 400 is movable along a track and includes a portion 405 bearing cylinders 407,408 one of which bears an extension 412 for supporting the package for vertical and rotary movement to effect reorientation prior to sending the package down the chute.

Description

YARN PACKAGE TRANSPORT SYSTEM BACKGROUND OF THE INVENTION This invention relates to a system for transporting yarn packages from a textile machine, such as an open-end spinning machine, onto a transport conveyor such that the packages fall by gravity thereon without making contact with each other and are uniformly spaced on the transport conveyor at a predetermined distance from one another.

Various systems for transporting yarn packages are known in the art. Endless conveyor belts, such as those disclosed in U.S. Pat. No. 4,118,920 are a common means for transporting yarn packages from a textile machine to a subsequent station, such as a container. U.S. Pat. No. 3,906,712 teaches a means for correcting orientation of yarn packages after they have already been placed onto a conveyor belt. Other types of transporting systems include a package gripper with expanding means, such as that disclosed in U.S. Pat. No; 5,C62,261, and the overhead automated conveying system disclosed in U.S. Pat.

No. 4,979,360.

While the foregoing transporting systems may be deemed suitable for their respective intended purposes, none of these systems teach any means for transporting packages from a machine onto a conveyor, let alone a means which would uniformly space yarn packages from one another along the conveyor, prevent yarn package collisions, synchronize delivery from multiple yarn spinning machines, and prevent the damaging of certain types of yarn packages. Furthermore, all of these systems utilize complex automated machinery, comprised of a large number of moving components. Consequently, such machinery is expensive to operate and maintain and is subject to an increased risk of failure. Therefore, there is room for improvement within the art.

SUMMARY OF THE INVENTION It is an important object of the present invention to provide a package transport system which consistently deposits packages onto a conveyor at a uniform distance from one another.

It is a further object of the present invention to provide a package transport system which allows the packages to fall by gravity onto a conveyor.

It is a further object of the present invention to provide a package transport system which eliminates the need for moving parts.

It is a further object of the present invention to provide a package transport system which changes the orientation of the packages as they descend to a conveyor.

It is a further object of the invention to provide a package transport system that prevents yarn package collisions.

It is a further object of the invention to provide a package transport system that can synchronize delivery from multiple yarn spinning machines.

These as well as other objects are accomplished by a yarn package conveying system, comprising: a spinning machine having first and second rows of spinning stations; first and second output conveyors, each conveyor associated with one of the rows of spinning stations and having the capability to be started to feed yarn packages out of the spinning machine and stopped to prevent the feeding of yarn packages from the spinning machine; a transport conveyor located below the output conveyors for delivering yarn packages made by the spinning machine to a downstream location; first and second chutes, each chute for conveying a yarn package from one of the first and second output conveyors to the transport conveyor, wherein the exits to the first and second chutes are adjacent a side of the transport conveyor; a delaying mechanism, the delaying mechanism controlling the first and second output conveyors to prevent the collision of yarn packages on the transport conveyor.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a perspective view of the operation of a package transport system constructed in accordance with a preferred embodiment of the present invention; Figure 2 is a plan view of the package transport system illustrated in Figure 1, showing packages traveling down output conveyors of a textile machine, showing additional packages traveling down first and second chutes of the system, and showing the automatic control structure used to prevent yarn package collisions; Figure 3 is a side elevation view of the package transport system illustrated in Figure 2, showing, among other things, intermediate orientation of yarn packages as they undergo transition from the output conveyors to the chutes; Figure 4 is a sectional elevation view taken along line 44 of Figure 3; Figure 5 is a sectional elevation view taken along line 55 of Figure 3; Figure 6 is a sectional elevation view taken along line 66 of Figure 3; Figure 7 is a side elevation view of a package transport system constructed in accordance with the preferred embodiment of the present invention, illustrating the profiles of the chutes in their entirety; Figure 8 is a sectional elevation view of a chute taken along line 8-8 in Figure 7, showing a yarn package in phantom lines seated therein; Figure 9 is a perspective view of a yarn package moving off a first output conveyor of a textile machine just before it reaches a first chute of the package transport system; Figure 10 is a perspective view similar to Figure 9, except that it shows the package illustrated therein as having just been placed on the first chute of the package transport system; Figure 11 is a perspective view of a yarn package moving off a second output conveyor of a textile machine just before it reaches a second chute of the package transport system; Figure 12 is a perspective view similar to Figure 11, except that it shows the package illustrated therein as having just been placed on the second chute of the package transport system; Figure 13 is a schematic view of a plant in which multiple spinning machines deliver to a single transport conveyor and are controlled by a single common controller; Figure 14 is a schematic view of the inside of a spinning machine; Figure 15 is a plan view of showing how a yarn package is delivered from a winding machine; and Figure 16 is an elevational view showing a mechanism for reorienting a wound yarn package from unsupported narrow end leading to wide end leading.

DETAILED DESCRIPTION The drawings illustrate a package transport system 1 communicating with a textile machine 2, preferably an open-end spinning machine, and with a transport conveyor 4. The system 1 deposits yarn packages onto the transport conveyor 4 at a predetermined distance from one another, such that the yarn packages do not contact each other during any point as they are transferred to and from the system 1. Conveyor 4 feeds yarn packages to a yarn conditioning apparatus. Yarn conditioning apparatus is the two station steam setting device disclosed in US Patent Nos. 5,353,488; 5,410,788; 5,423,109; and 5,428,884.

Referring to Figure 1, a conventional open-end spinning machine 2 spins carded sliver into finished yarn packages 6, 8, 10, and 12, whereupon they are conveyed from a top portion of machine 2 in the direction of arrows 13 via first and second output conveyors 14 and 16, respectively (see Fig. 2) . Upon reaching the end of the output conveyors 14 and 16, the packages are transferred to the transport system 1, as shown by arrows 17, whereupon they fall by gravity through first and second chutes ;8 and 20, respectively, onto the transport conveyor 4 such that no two packages contact one another from the time of their production to the time they are deposited on the transport conveyor 4.

The first chute 18 communicates with the first output conveyor 14 and is attached thereto preferably with fastening means such as a mounting bracket 22 (Fig. 7) and one or more threaded fasteners (not shown). The first chute 18 is preferably configured as a rail, comprised of a pair of shaped tubular longitudinal members 24, 26 joined by a plurality of transverse members such as at 28. A first wedge-shaped mounting plate 27 interconnects the lower ends of the members 24 and 26 to a frame 5 of the transport conveyor 4.

The second chute 20 communicates with the second output conveyor 16; however, unlike first chute 18, second chute 20 is comprised of a pair of rails 30 and 32 for a predetermined length. These rails confine the top and bottom faces of a package such as at 10, ensuring that it descends along the path defined by the rails. When package 10 is first placed onto the second chute 20, it rests upon rail 32; however, its weight is transferred to rail 30 at a point along its path of travel.

Consequently, once it is deposited onto the transport conveyor 4, face 10a of package 10 points upwardly in the same manner as face 12a of package 12. Due to this upturning of faces, positions of packages traveling down the second output conveyor 16 are rotated 1800 from those of packages traveling down the first output conveyor 14 (see Fig. 2, packages 19 & 31) so that all transported packages have the same orientation on the transport conveyor 4, i.e., their lower faces have a greater diameter than the faces pointing upwardly.

Rail 32 is attached to the second output conveyor 16 in the same manner as is first chute 18 to the first output conveyor 14; i.e., preferably with a mounting bracket 34 (Fig.

7). As with the lower end of the first chute 18, the lower ends of second chute 20, or more particularly the rail 30, are interconnected to the transport conveyor frame 5 through a second wedge-shaped mounting plate 29.

Rails 30 and 32, as well as the rail comprising the first chute 18, are preferably constructed of stainless steel tubing. Rail 32, spaced equidistantly from rail 30 along its entire length, is interconnected to rail 30 by way of a plurality of retaining rings 36, 38, and 40 which are preferably attached to rails 30 and 32 by welds, although other fastening means are contemplated as being within the scope of the present invention.

The ring-rail connection in the preferred embodiment is best seen in Figure 8. A package traveling down second chute 20 is shown in phantom lines at 41.

Figure 1 additionally shows a means for retaining packages 8 and 12 on the transport conveyor 4 once they leave first chute 18 and second chute 20, respectively. In the preferred embodiment, this means is a retaining rail assembly elevated above transport conveyor 4, This retaining rail assembly includes a first bracket 33 mounted to frame 5 proximate a terminus of second chute 20, a second bracket 35 mounted to frame 5 and longitudinally spaced from first bracket 33, a third bracket 37 mounted to frame 5 and longitudinally spaced from second bracket 35, and a fourth bracket 39 mounted to frame 5 and longitudinally spaced from third bracket 37. Each of these brackets are preferably oriented transversely to the transport conveyor 4. A first retaining extension 43 originates proximate first bracket 33 and terminates at fourth bracket 39; a second retaining extension 45 originates proximate first bracket 33 and terminates at second bracket 35; a third retaining extension 47 originates proximate second bracket 35 and extends beyond fourth bracket 39; a fourth retaining extension 49 originates proximate third bracket 37 and terminates at fourth bracket 39, and a fifth retaining extension 51 originates proximate third bracket 37 and extends beyond fourth bracket 39. Retaining extensions 43, 45, 47, 49, and 51 are preferably constructed of tubular members of the type used in longitudinal members 26 and 28 of first chute 18.

Each of these extensions are connected to an interior face of an upper leg, such as at 37a, of associated brackets.

While the aforementioned structure for retaining packages 8 and 12 on the transport conveyor 4 is the preferred means, equivalent structures are contemplated as being within the scope of the present invention. For instance, instead of supporting tubular members, brackets mounted to frame 5 may support flat plates to retain packages on the transport conveyor 4.

Referring to Figures 2-6, packages 3, 7, 11, 15, and 19 are shown descending down first output conveyor 14 and first chute 18, while packages 21, 23, and 31 are shown descending down second output conveyor 16 and second chute 20. Package 15, shown in transition between the first output conveyor 14 and the first chute 18, assumes an intermediate position whereby it is rotating away from the spinning machine 2 about the point where the package 15 contacts member 24 of first chute 18 (see Fig. 5). Package 23 likewise undergoes such motion with respect to member 80 of second chute 20 (see Fig.

6). Once packages on the first chute complete the aforementioned transition, they assume the position shown at Figure 4, where a central longitudinal axis 7a of a package 7 is normal to a plane P containing members 24 and 26.

Figure 7 illustrates the profile of the package transport system 1. Although the rails comprising the chutes 18, 20 are preferably unitary, the profile of each of them includes several distinct geometric portions. Specifically, the profile of first chute 18 is defined by a first straight portion 42 inclined at an angle with respect to the transport conveyor 4, a second straight portion 44 substantially parallel to the transport conveyor 4, and an arcuate portion 46 joining portions 42 and 44. The profile of the rail 30 of second chute 20 is defined by a first arcuate portion 48, a second arcuate portion 50, a first straight portion 52 joining portions 48 and 50 and inclined at an angle with respect to the transport conveyor 4, and a second straight portion 54 extending from the second arcuate portion 50 in substantially parallel relation to the transport conveyor 4. The profile of rail 32 of second chute 20 is defined buy a straight portion 55, which is inclined at angle to the transport conveyor 4 and which is approximately 900 to the first straight portion 42 of first chute 18, and an arcuate portion 57.

The following dimensions of each portion of first chute 18 and of second chute 20 (rails 30 and 32) have been found to provide optimum uniformity in package transport: Portion Parameter Dimension First chute 18 first straight portion 42 length 1636 mm second straight portion 44 length 630 mm arcuate portion 46 radius 600 mm subtending angle 450 Rail 30 first arcuate portion 48 radius 450 mm subtending angle 90O second arcuate portion 50 radius 600 mm subtending angle 450 first straight portion 52 length 364 mm second straight portion 54 length 630 mm Rail 32 straight portion 55 length 220.5 mm arcuate portion 57 radius 600 mm subtending angle 450 Figures 9 and 10 illustrate the cause of the change in orientation a yarn package undergoes in moving from the first output conveyor 14 onto the first chute 18.

In Figure 9, a first package 56 having a central longitudinal axis 59 moves toward the end of the first output conveyor 14 in the direction shown by arrow 58. During this motion, axis 59 is substantially parallel to a longitudinal axis 61 of the first output conveyor 14. As front face 56a of package 56 passes the end of the first output conveyor 14, the package 56 travels over a pair of roller assemblies 71 hingedly mounted to the front output conveyor 14. Travel of the package 56 in the direction of arrow 58 halts when front face 56a contacts member 24 of chute 18 at a terminal portion 25 of the member 24, which may be flared outwardly from the remainder of member 24 through a flared portion 60. As shown in Figure 9, a retaining bar 62 is mounted alongside member 26 of first chute 18 to ensure that the package 56 does not fall from the first chute 18 upon transfer thereto. Mounting means for the retaining bar 62 comprises transverse plates 64, 66 welded to member 26 and accommodating lower ends of vertical sections 68, 70 of retaining bar 62 in slots 63, 65 formed within the plates 64, 66, respectively. This slotted attachment permits either or both ends of the retaining bar 62 to be moved toward or away from member 26, depending upon the size or configuration of the yarn package leaving the first output conveyor 14.

Referring to Figure 10, first package 56 has undergone a change in its orientation upon having been transferred to first chute 18. Axis 59 is now substantially perpendicular to the first straight portion 42 (Fig. 7) of first chute 18. Thus, package 56 has rotated approximately 900 from its position on the first output conveyor 14.

Figures 11 and 12 illustrate the cause of a similar change in orientation undergone by a package moving from the second output conveyor 16 onto the second chute 20.

In Figure 11, a second package 72 having a central longitudinal axis 74 moves toward the end of the second output conveyor 16 in the direction shown by arrow 76. During this motion, axis 74 is substantially parallel to a longitudinal axis 78 of the second output conveyor 16. As front face 72a of package 72 passes the end of the second output conveyor 16, the package 72 travels over a pair of roller assemblies 81 hingedly mounted to the second output conveyor 16. Motion in the direction of arrow 76 ceases when front face 72a of package 72 contacts a member 80 of rail 32 at a terminal portion 82 of the member 80. In a manner similar to terminal portion 25 of member 24 of the first chute 18, terminal portion .82 may be flared outwardly from the remainder of member 80 through a flared portion 84. Additionally, a member 86 of rail 32 may be provided with a retaining bar 88 disposed alongside it by means of transverse plates 90, 92 providing slotted mountings for the retaining bar 88 in the same manner as described with respect to retaining bar 62, namely, the ends of vertical portions 94, 96 of retaining bar 88 are journaled in slots within the transverse plates 90 and 92.

Referring to Figure 12, second package 74 has undergone a change in its orientation upon having been transferred to rail 32 of second chute 20. Axis 59 is now substantially perpendicular to the straight portion 55 (Fig. 7) of second chute 20. Second package 74 has therefore rotated approximately 900 from its position on the second output conveyor 16.

As second package 72 travels down the second chute 20, axis 74 becomes parallel to the transport conveyor 4 at a point where axis 74 and the profile of retaining ring 38 coincide, since retaining ring 38 lies in a plane which is parallel to the transport conveyor 4 (see, for example, package 21 in Fig.

3).

It is thus seen that a system for transporting yarn packages from a textile machine to a transport conveyor may be provided which permits the yarn packages to fall by gravity onto the transport conveyor at a uniform distance from one another such that the yarn packages do not contact one another.

As previously mentioned above, textile machine 2 is an open end spinning machine, made by Schlafhorst & Co. of Germany. As shown in Figure 14, these machines comprise two spaced-apart rows of open-end spinning stations 201. There are usually 240 or 248 spinning stations depending upon the model of the Schlafhorst being used. Sandwiched between the two rows of spinning stations are two conveyor belts 14, 16, one conveyor belt associated with each row of spinning stations.

The two conveyor belts are driven by a common shaft and motor (neither shown). Therefore, both conveyor belts 14, 16 must either move or be stationary: one conveyor belt cannot move while the other is stationary.

Figure 14 further depicts the operation of textile machine 2. In operation, each spinning station 201 is used to produce yarn packages P. When a yarn package P is finished, it is ejected by a not-shown means onto the stationary conveyor belt 14, 16 associated with that row of spinning stations, to await doffing, which will be described below. In theory, if all the spinning stations 201 are started at the same time, they would all finish producing their yarn package at the same time, i.e., the about 8-13 hours it normally takes a Schlafhorst to completely produce a yarn package P. At that time, the two stationary conveyor belts 14, 16 would be fully loaded with yarn packages P from each and every spinning station 201. The Schlafnorst is programmed to then "doff", or eject, all yarn packages P by some method, which in the instant invention comprises using the package transport system and method described in US Patent No. 5,373,930 and repeated herein.

However, in practical applications, this does not occur.

Events such as yarn breaks and tangles, which need to be manually repaired, slow down various yarn spinning stations in a truly random fashion. Thus, at the end of the about 8-13 hour time period, how many, and in what alignment, yarn packages P fill conveyor belts 14, 16 cannot be predicted and will simply be a hodge-podge of single and side-by-side yarn packages P, as shown in Figure 14.

To prevent yarn packages delivered via chutes 18, 20 from colliding, a delay mechanism for delaying the delivery of yarn packages P in certain situations is needed. The delivery system described in US Patent No. 5,373,930 and repeated herein is designed such that if yarn packages simultaneously enter chutes 18, 20 they will not collide upon reaching conveyor 4.

However, if yarn packages enter chutes 18, 20 other than simultaneously, care has to be taken to prevent a yarn package being fed down left chute 18 from hitting a previously fed yarn package that travelled down right chute 20, when they are both on conveyor 4. Thus, the delay mechanism will hold back the yarn package about to travel down left chute 18 until the yarn package that travelled down right chute 20 passes the exit to left chute 18, via transport conveyor 4.

As shown in Figure 2, the delay mechanism comprises: controller C with internal timers; sensors 100, 102, using reflectors 101, 103, and connected to controller C for determining whether a particular conveyor has a yarn package on it for delivery to one of chutes 18, 20; and switches 110, 115, also connected to controller C, for counting how many yarn packages are actually delivered and for starting the timers inside of controller C. Finally, controller C has lead 120 going to the not-shown conveyor belt motor of the Schlafhorst spinning machine 2 such thaL controller C can turn that motor on and off, starting and stopping conveyors 14, 16.

The delay mechanism operates as follows. Whenever a yarn package is sent down right chute 20 as detected by switch 115, if a subsequent yarn package is detected by left sensor 100, the motor of the Schlafhorst will be stopped for a delay period, thereby allowing the package that travelled down right chute 20 to pass the exit to left chute 18 via conveyor 4.

After that delay period, the Schlafhorst' 9 motor will be restarted, feeding the yarn package to be delivered via left chute 18 and, if present, a yarn package to be delivered via right chute 20. If another package is sent down right chute 20, sensor 102 and switch 115 will detect as such, and the delay process is repeated if another package is present for feeding down left chute 18. This delay results in the elimination of collisions between yarn packages on conveyor 4.

The delay period is about 12 seconds but is variable.

A plant may have any number of identical Schlafhorsts. In the Example shown in Figure 13, the plant has 6 identical Schlafhorsts Sl-S feeding to transport conveyor 4 using chutes 18, 20. However, there will usually be 12 Schlaffhorsts. In any event, only one Schlafhorst at a time will doff (deliver) and they will typically doff in numerical order, i.e., Sl, S2, S3 ... However, by providing the factory with an adjustable master controller C, any Schlafhorst Sn can be made to doff at any time. Accordingly, for example, should Schlafhorst S2, which is set to doff next become inoperative, controller C detects that situation and Schlafhorst S3 will be set to doff next so as to not stop the production line from operating.

When inoperative Schlafhorst S2 is fixed, it is then placed back in the doffing queue for doffing next. It is possible that when Schlafhorst S2 then doffs, packages from Schlafhorst S3 may be passing in front of Schlafhorst S2 on transport conveyor 4, thereby causing yarn package collisions.

Controller C prevents these collisions by use of another delay mechanism. Controller C is programmed with the amount of time it takes yarn packages to travel from one Schlafhorst, e.g., S3, past another one, e.g., S2, via transport conveyor 4. To prevent a collision of yarn packages, the previouslyinoperative Schlafhorst S2 will not be doffed until a predetermined amount of time suitable for having the last yarn package fed from Schlafhorst S3 to pass the Schlafhorst S2 has elapsed.

It is further conceived that the chute delivery system described herein can be used with Murata-type winding machines.

However, due to differences between how the yarn packages are delivered and formed with the Murata winding machine and the Schlafhorst, modifications are required.

As shown in Figure 15, yarn package W is fed along output conveyor belt 212 of winder 200. Rail 215 prevents yarn package W from rolling off of belt 212. Yarn package W is formed differently from those made by Schlafhorst spinning devices. In particular, the narrow end of yarn package W has an unsupported and sharply angled narrow portion 300. By unsupported, applicant means that the yarn is not resting directly against the core spool of yarn package W, as is the case with Schlafhorst-made packages. This unsupported and sharply angled narrow portion 300 is leading as yarn package W exits from winder 200.

This is where the problem begins. If yarn package W enters the chute with this end leading, the unsupported and sharply angled narrow portion 300 would hit against the various rails of the chute. Because this portion is unsupported and has a sharp angle, the result would be that end 300 would become deformed, partially unwinding and/or tangling. This renders yarn package W defective and ruined.

Thus, it has been found that to use this rail delivery system with yarn packages W coming from winder 200, yarn packages W must be rotated through 1800 before they enter the chute. This way the supported wide end of yar package W is first to enter the chute. This end is not as easily susceptible to unwinding and tangling as is the narrow end. To achieve this result, a reorienting mechanism is used to rotate yarn package W through 1800. While it is conceived that many different types of reorienting mechanisms may be used, in the preferred embodiment the mechanism comprises a robot mechanism 400 capable of moving along three (3) axes. As shown in Figure 16, mechanism 400 is mounted for movement along a first axis by being mounted for translational movement along a track 415 mounted to an overhead surface. Portion 405 has a motor therein (not shown) for imparting rotational movement upon one of cylinders 407, 408. Finally, cylinder 408 is mounted for up-down movement with respect to cylinder 407. This provides the third axis of movement. Cylinders 407 and 408 can be made to move with respect to each other by any suitable means such as hydraulics, jackscrews, etc. Protruding from cylinder 408 is extension 412 for entering into the hollow spool of yarn package W. Extension 412 has a high coefficient of friction so that yarn package W will not slide off of the extension. This is important because extension 412 is downwardly sloping to correspond to the downward slope of the yarn core spool.

The reorienting mechanism operates as follows. As shown in figure 16, in position A, robot 400 causes extension 412 to enter the core spool of yarn package W. Robot 400 will then lift up yarn package W, rotate it, and then translate it to position B, where it will have its wide end leading. Now yarn package W can be sent down a chute without fear of ruining the yarn package.

As the above description is merely exemplary in nature, being merely illustrative of the invention, many variations will become apparent to those of skill in the art. Such variations, however, are included within the spirit and scope of this invention as defined by the following appended claims.

Claims (4)

1. A system for transporting yarn packages having a wide supported end and an unsupported and sharply angled narrow end from a winding machine that feeds the packages on an output conveyor with their unsupported and sharply angled narrow end leading to a transport conveyor, comprising: a chute communicating with said output conveyor for transporting a package from an end of said first output conveyor to said transport conveyor; and a mechanism for reorienting said yarn package such that said wide supported end is the first to enter said chute.

2. The system according to claim 1, wherein said mechanism comprises a robot capable of three-dimensional movement and having an extension for entering the spool of said yarn package to move said yarn package along three axes te reorient said yarn package.

3. The system according to claim 2, further comprising: a track mounted to an overhead support; and wherein said robot further comprises: a first housing mounted to said track for translational movement with respect to said track; a first cylinder depending downwardly with respect to said first housing; a second cylinder depending downwardly with respect to said first cylinder and movable in an up-down direction with respect to said first cylinder; said extension protruding out of, and angled downwardly with respect to said second cylinder; and wherein at least one of said cylinders is mounted for rotation so as to allow the rotation of said extension.

4. A system according to claim 1 for transporting yam packages having a wide supported end and an unsupported and sharply angled narrow end substantially as hereinbefore described with reference to and as shown in Figures 15 and 16 of the accompanying drawings.