GB2521613A

GB2521613A - Yarn storage apparatus

Info

Publication number: GB2521613A
Application number: GB1322865.5A
Authority: GB
Inventors: David John Watson; David Waite
Original assignee: Griffith Textile Machines Ltd
Current assignee: Griffith Textile Machines Ltd
Priority date: 2013-12-23
Filing date: 2013-12-23
Publication date: 2015-07-01
Anticipated expiration: 2033-12-23
Also published as: GB201322865D0; GB2521613B

Abstract

A yarn storage apparatus 10 comprises a plurality of yarn storage tubes 12 arranged in an inclined position so that a first end 14 of each yarn storage tube is higher than the second end 16. Each yarn storage tube 12 includes a yarn outlet 20 at or towards the first end 14 to dispense yarn 18 and a load plate 22 slidable along the hollow interior of the yarn storage tube 12. The load plate 22 includes a plate element 24 having a first face 26 to rest against windings of yarn 18, an opening 28 to allow yarn to pass through the plate element 24 towards the yarn outlet 20 and a fence element 30 extending from a second opposing face 32 of the plate element 24 towards the yarn outlet. The fence element 30 divides the hollow interior of the yarn storage tube 12 so as to form a passage on one side thereof for yarn passing from the opening 28 in the plate element 24 towards the yarn outlet 20 and to form a cage on the other side thereof to receive at least one load element 40. The load element 40 is received in the cage so as to apply a load to the second face 32 of the plate element 24 and to urge the first face 26 of the plate element 24 against windings of yarn 18 stored in the yarn storage tube 12. The load element 40 may be spherical such as a glass marble or steel ball or it may be elongate with wheels (54, 56 fig. 6). Also disclosed is an insertion tool 44 to connect ends of yarn 18 stored in the yarn storage tubes 12 into yarn consuming apparatus. The insertion tool 44 comprises an elongate insertion element 46 having a handle at one end and a gripper for yarn (47 fig. 3) at the other end. The gripper (47 fig. 3) may comprise jaws or a piece of fabric with burrs or hooks. A guide 48 may be rotatably mounted on the elongate element 46.

Description

YARN STORAGE APPARATUS

The invention relates to a yarn storage apparatus to supply yarn to a yarn consuming apparatus, the yarn storage apparatus including a plurality of yarn storage tubes to store S windings of yarn for delivery to the yarn consuming apparatus.

Examples of yarn consuming apparatuses include, but are not limited to, textile forming machines such as Axminster gripper looms: velvet weaving looms and warp knitting machines.

In textile fabric forming machines a large number of yarns are commonly needed for insertion into the fabric forming process. This is typically the case in looms and warp knitting machines and is achieved either by storing the yarns on a large number of packages or creels, or by winding all the yarns from a store onto one large drum or beam, In some cases, for instance in patterned carpet weaving and in sample weaving of fabrics with multi-coloured warp, the warp preparation is time consuming and wasteful in yarn.

This is because it is difficult to ensure that exactly the correct length of yarn is on each package for a given requirement.

EP 0 422 093 discloses a yarn storage apparatus that seeks to overcome these disadvantages through the use of yarn storage tubes to store windings of yarn. Each of the yarn storage tubes includes a discharge opening at one end and a yarn insertion opening at its opposite end. The yarn storage apparatus also includes at least one yarn loading means so as to allow yarn to be loaded into each of the yarn storage tubes via the yarn insertion opening without interrupting the fabric forming process.

So as to prevent windings of yarn falling over within a yarn storage tube, which might otherwise lead to tangling to the yarn, it is known to apply a press-on force to the windings of yarn through the use of a spring located between the windings of yarn and the discharge opening.

EP 2 271 569 discloses an arrangement that is intended to reduce tangling of yarn stored within a yarn storage tube. In this arrangement each of a plurality of yarn storage tubes is inclined so that the discharge opening is higher than the yarn insertion opening and a ball is placed in the yarn storage tube, between the windings of yarn and the discharge opening, to apply a press-on force to the windings. The size of the ball is chosen so that the ball guides yarn via its external circumference in the direction of the discharge opening.

According to an aspect of the invention there is provided a yarn storage apparatus to supply yarn to a yarn consuming apparatus comprising a plurality of yarn storage tubes that are arranged in an inclined position so that a first end of each yarn storage tube is higher than a second end of the yarn storage tube, each yarn storage tube defining a hollow interior to store windings of yarn and including a yarn outlet at or towards the first end to dispense yarn from the yarn storage tube, each yarn storage tube further including io a load plate arranged in use for sliding movement along the length of the hollow interior of the yarn storage tube, the load plate including a plate element having a first face to rest against windings of yarn stored in the yarn storage tube and an opening provided in the plate element to allow yarn to pass through the plate element towards the yarn outlet, the load plate further including a fence element arranged to extend from a second opposing face of the plate element and towards the yarn outlet, the fence element dividing the hollow interior of the yarn storage tube so as to form a passage on one side of the fence element for yarn passing from the opening in the plate element towards the yarn outlet and to form a cage with one or more side walls of the yarn storage tube on the other side of the fence element to receive at least one load element, the or each load element being received in use in the cage so as to apply a load to the second face of the plate element and urge the first face of the plate element against windings of yarn stored in the yarn storage tube.

The inclusion of a fence element in each load plate to divide the hollow interior of the respective yarn storage tube between the windings of yarn and the yarn outlet results in the creation of a yarn passage on one side of the fence element and a cage to receive one or more load elements on the other side of the fence element. This allows the or each load element to be held captive in use so as to prevent contact between the or each load element and yarn passing through the opening in the plate element towards the yarn outlet and thereby prevent the yarn from becoming trapped between the or each load element and one or more side walls of the yarn storage tube.

This is advantageous because contact between the load element and the yarn during passage of the yarn past the load element otherwise increases the tension of the yarn as it is drawn from the yarn storage tube and into the yarn consuming apparatus. Eliminating contact between the or each load element and the yarn in each of the yarn storage tubes, and thereby preventing the yarn from becoming trapped between the or each load element and one or more side walls of the yarn storage tube, helps to maintain the yarn drawn from each of the yarn storage tubes at a constant and lower tension than would otherwise be the case. It also helps to ensure that the tension of the yarn drawn from each of the yarn storage tubes is essentially the same. This in turn reduces the risk of imperfections being introduced into the fabric produced on the yarn consuming apparatus as a result of variations in the tensions of the yarns delivered from the yarn storage tubes. Reducing the tension of each of the yarns being supplied from the yarn storage tubes by ensuring that there is no contact between the load element and the yarn also improves the efficiency of the yarn consuming apparatus and the overall quality of the fabric produced on the yarn consuming apparatus.

It also reduces the risk of the yarns becoming stretched as a result of the yarn becoming trapped between the or each load element and the one or more side walls of the yarn storage tube. Stretching affects the quality of the yarn and thus affects the quality of any fabric produced by the yarn consuming apparatus. It also increases the risk of yarn breakage, which would lead to stoppage of the yarn consuming apparatus whilst the broken yarn is re-connected. Stretching can also result in less yarn being required by a given process, which would lead to yarn wastage at the end of the process.

Accordingly the invention allows for greater control of the measured length of yarn in that it allows an operator to more accurately determine the amount of yarn that must be stored in each yarn storage tube in order to complete a particular job and thereby minimise wastage of yarn that might otherwise be caused by stretching of the yarn in the event the yarn was to become trapped between the or each load element and the one or more side walls of the yarn storage tube.

In order to form a cage with the one or more side walls of each yarn storage tube the fence element may be a planar structure extending essentially perpendicularly from the second opposing face of the plate element.

In preferred embodiments of the invention, the centre of the opening in the plate element of each load plate and the fence element extending from the second face of the plate element are offset in opposite directions relative to a centrally located longitudinal axis of the respective yarn storage tube.

The positions of the fence element and the opening in the plate element relative to the centrally located longitudinal axis of the respective yarn storage tube results in the creation of a line of sight route for yarn being dispensed from the hollow interior of the yarn storage tube via the opening in the plate element to the yarn outlet.

This arrangement further helps to maintain a constant yarn tension as the yarn is dispensed from each of the yarn storage tubes. It also helps to ensure that the tension of the yarn being dispensed from each of the yarn storage tubes is essentially the same by ensuring that the route from the hollow interior of each storage tube to the respective yarn outlet is as direct as possible.

The creation of a line of sight route from the hollow interior of each yarn storage tube to the yarn outlet, via the opening in the respective plate element, also readily facilitates the insertion of a tool to retrieve an end of the windings of yarn during the initial connection of the yarn ends into a yarn consuming apparatus or in the event of a breakage resulting in a lost yarn end during operation of the yarn consuming apparatus.

In the absence of the fence element, the or each load element would not be restrained against one or more side walls of the respective yarn storage tube. The or each load element would therefore block or at least make it difficult to insert a tool to retrieve an end of the windings of yarn.

It will be appreciated that reducing the amount of time that is required to retrieve an end of the windings of yarn stored in a yarn storage tube greatly reduces the amount of time that is required to connect the yarn storage apparatus to a yarn consuming apparatus during setup. It also greatly reduces the amount of time that is required to re-connect a yarn end in the event of a yarn breakage.

It will also be appreciated that the creation of a line of sight route from the hollow interior of each yarn storage tube to the yarn outlet, via the opening in the respective plate element, greatly improves the likelihood that the yarn storage apparatus will be set up correctly and that the yarn will be directed through the opening in the plate element in each yarn storage tube. Consistent threading of yarn through the openings in plate elements helps to ensure that the tension of the yarn drawn from each of the yarn storage tubes is essentially the same.

as In arrangements where the load element presents a blockage in the yarn storage tube, making it difficult to retrieve an end of the windings of yarn stored in the yarn storage tube, it is less likely that the yarn will be threaded consistently in each and every yarn storage tube. The time taken to retrieve a yarn end in such arrangements means that an operator is less able due to the amount of time that would be required to re-direct the yarn and ensure that it is threaded consistently in each and every yarn storage tube. This can lead to inconsistencies in the tension of the yarn drawn from each of the yarn storage tubes.

The creation of a line of sight route from the hollow interior of each yarn storage tube to the yarn outlet also greatly assists pulling through of any waste yarn at the end of a job on the yarn consuming apparatus. When the yarn consuming apparatus is an Axminster weaving loom, for example, waste yarn must be pulled through each yarn storage tube, via the yarn outlet, once the fabric being woven on the loom is complete. This pull through procedure is performed by hand so that the waste yarn can be disposed of and the yarn required for the next weaving job, which is stored behind the waste yarn in each yarn storage tube, may be connected into the loom It will be appreciated that creation of the line of sight route greatly facilitates this manual procedure.

So as to create the desired line of sight route from the hollow interior of each yarn storage tube to the yarn outlet, via the opening in the respective plate element, the fence element of each load plate is preferably arranged relative to the centrally located longitudinal axis of the respective yarn storage tube so that a maximum circle inscribed within the cage defined between the fence element and the one or more side walls of the yarn storage tube has a diameter that is equal to or less than 48% of the diameter of a maximum circle inscribed within the cross-section of the yarn storage tube.

Locating the fence element so that the diameter of a maximum circle inscribed within the resultant cage defined between the fence element and the one or more side walls of the yarn storage tube is equal to or less than 48% of the diameter of a maximum circle inscribed within the cross-section of the yarn storage tube, allows for the creation of a relatively large passage on the other side of the fence element for passage of the yarn via the opening in the plate element to the yarn outlet. This in turn allows for the creation of a so relatively large opening in the plate element.

The use of a relatively large opening in the plate element of the load plate helps to knock knots and tangles out of the yarn as it is drawn through the opening towards the yarn outlet.

as In the event movement of the yarn through the opening in the plate element of the load plate, which drawings any such knots and tangles into contact with the plate element, is not sufficient to knock out the knots and tangles from the yarn, the relatively large size of the opening allows the knots and tangles to pass through the toad plate and towards the yarn outlet.

This is advantageous in that it prevents any such knots and tangtes becoming trapped against the first face of the plate element which would otherwise cause the load plate to be drawn out of the yarn storage tube as the yarn is drawn out of the yarn storage tube by the yarn consuming apparatus. Instead it allows passage of any such knots and tangtes out of the yarn storage tube where they are either knocked out by, for example, beat up bars in the event the yarn consuming apparatus is an Axminster gripper loom, or by the io operator.

Referring to yarn consuming apparatuses in the form of Axminster gripper looms, the applicant has found that the ability of the relatively large opening in the plate element to knock knots and tangles out of the yarn as it is drawn through the opening towards the yarn outlet means that beat up bars may be removed from the loom and are no longer essential to operation of the loom.

It will be appreciated that removal of any such knots and tangles by an operator would require the yarn consuming apparatus to be stopped. It will however also be appreciated that the operator would then be in a position to readily and immediately re-connect the end of the yarn into the yarn consuming apparatus without having to retrieve a lost end. This is greatly preferred and significantly quicker than dealing with any such knots and tangles that could otherwise become trapped below the load plate.

The use of a load plate having a fence element to define a cage with one or more side walls of the respective yarn storage tube provides great flexibility in terms of the nature of the load element that might be used to produce the required press-on force.

In embodiments where the yarn is relatively light weight and a relatively tow press-on force so is required, for example, a singte load element may be received in the cage.

In other embodiments, where the yarn is relatively heavy and a relatively large press-on force is required, for example, two or more load elements may be received in the cage so as to increase the press-on force provided by the load plate to windings of yarn stored in the respective yarn storage tube. In such embodiments, the load elements may be arranged to rest one on top of the other against the second face of the plate element so as to apply a load to the second face of the plate element and urge the first face of the plate element against the windings of yarn stored in the yarn storage tube.

The provision of the fence element to divide the hollow interior ensures that any such load s elements cannot contact yarn passing through the outlet in the plate element towards the yarn outlet. Accordingly the number and nature of bad elements received in the cage cannot effect dispensing of yarn from the opening in the plate element towards the yarn outlet. This allows an operator to choose from a wide range of different load elements so as to obtain the required press-on force from the load plate. This flexibility allows an io operator to tailor the load applied to the plate element of the load plate depending on the nature of the yarn being stored in the yarn storage tubes and the nature of the yarn consuming apparatus.

It will be appreciated that each of the load elements must move with the plate element along the length of the respective yarn storage tube as yarn is dispensed from the yarn storage tube and the number of windings of yarn stored in the yarn storage tube is reduced.

In particularly preferred embodiments, each load element is spherical in shape and the fence element is arranged to extend from the second opposing face of the plate element.

The use of one or more spherical load elements ensures smooth movement of each of the load plates along the respective yarn storage tubes in use.

Preferably the or each load element is chosen from the group consisting of a steel ball and a glass marble It is envisaged however that in other embodiments the load element may be made from any material that allows the creation of a load element of a size and mass that will be received within the cage defined between the fence element and the one or more side walls of the respective yarn storage tube and will apply the required load to the second face of the plate element.

In other embodiment, for example, the load element may be provided in the form of an elongate element having one or more wheels mounted thereon so as to protrude from an elongate edge of the elongate element. The load element may then be secured or otherwise held in position within the cage so as to extend from the fence element towards the one or more side walls of the respective yarn storage tube so that the or each wheel contacts the or a side wall of the yarn storage tube so as to facilitate rolling movement of the or each wheel along the side wall and thereby facilitate movement of the load element along the length of the yarn storage tube.

In such embodiments it is envisaged that the load element may be formed integrally with the fence element.

The yarn storage apparatus may further comprise an insertion tool to retrieve the end of windings of yarn stored in the hollow interior of each of the yarn storage tubes. The insertion tool may include an elongate insertion element having a handle at a first end and a gripper at a second end for insertion into each of the yarn storage tubes to retrieve a yarn end through the opening in the plate element of the respective load plate.

The provision of an insertion tool to retrieve yarn ends greatly improves user efficiency and hence greatly improves the speed with which the yarn storage apparatus may be set up and connected to a yarn consuming apparatus. It also greatly improves the speed with which a lost yarn might be retrieved in the event of a yarn breakage.

The provision of an insertion tool to retrieve yarn ends is particularly advantageous when the yarn storage apparatus is used in combination with an Axminster gripper loom. Beat-up bars provided on such looms tend to block access to the yarn storage tubes and make it difficult if not impossible to remove the load plates from the yarn storage tubes during set up and in the event of a yarn breakage. Accordingly the provision of an insertion tool that can be inserted readily into each of the yarn storage tubes to retrieve a lost end without having to remove the load plate is particularly useful.

The insertion tool may further include a guide mounted on the elongate insertion element.

In such embodiments, the guide is shaped to contact each yarn storage tube on opposite sides of the hollow interior when the elongate insertion element is inserted into the yarn insertion tube so as to align the elongate insertion element with the opening in the plate element of the respective load plate and guide further movement of the elongate insertion element into the yarn storage tube so that the gripper at the second end of the elongate insertion element is directed through the opening in the plate element.

as The provision of the guide ensures that the elongate insertion element is directed through the opening in the plate element without any user input to guide the elongate insertion element. a

It will be appreciated that the provision of the guide on the elongate insertion element is particularly advantageous when access to the yarn storage tubes is limited, and/or visibility into the yarn storage tubes is limited.

The elongate insertion element is preferably rotatable relative to the guide. This increases the likelihood of the gripper on the second end of the elongate insertion element retrieving a lost end of yarn when the gripper is inserted into a yarn storage tube and through the opening in the respective plate element.

It will be appreciated that any form of gripper suitable for gripping a piece of yarn could be provided at the second end of the elongate insertion element.

In embodiments of the invention, the gripper may include a piece of fabric attached to the second end of the elongate insertion element so as to present a plurality of burrs formed on its surface.

In other embodiments the gripper may include a pair of jaw elements, at least one of the jaw elements being pivotably mounted for movement relative to the other jaw element at the second end of the elongate insertion element to open and close jaws defined by the jaw elements.

In further embodiments, the gripper may include at least one hook, and in yet further embodiments the gripper may include a vacuum device to grab the yarn end by means of suction.

Whilst it is envisaged that the required amount of yarn for a particular operation might be loaded into the yarn storage tubes at the outset, it is also envisaged that in embodiments of the invention each yarn storage tube may include a yarn inlet at or towards the second end to load yarn into the yarn storage tube and the yarn storage apparatus may further include at least one yarn loader operably associated with each yarn storage tube to insert yarn into the hollow interior of the yarn storage tube.

The provision of at least one yarn loader allows yarn to be loaded into each of the yarn storage tubes without interrupting operation of the yarn consuming apparatus.

It is envisaged that each of the yarn storage tubes might be square, hexagonal or octagonal in cross-section.

Embodiments of the invention will now be described, by way of non-limiting examples, with reference to the accompanying drawings in which: Figure 1 is a schematic view of a yarn storage apparatus according to an embodiment of the invention; Figure 2 shows a yarn storage tube and an insertion element of the yarn storage apparatus shown in Figure 1; Figure 3 shows a side view of the yarn storage tube and the insertion element of Figure 2; Figure 4 shows a cross-sectional view of the yarn storage tube and the insertion element along the line I-I of Figure 3; Figure 5 illustrates the effect of using spherical load elements of differing sizes in a yarn storage tube; and Figure 6 shows a load plate incorporating a load element according to another embodiment of the invention.

A yarn storage apparatus 10 according to an embodiment of the invention is shown in Figure 1.

The yarn storage apparatus 10 includes a plurality of yarn storage tubes 12. The yarn storage tubes 12 are inclined so that a first end 14 of each yarn storage tube 12 is higher than a second end 16 of the yarn storage tube 12.

Each of the yarn storage tubes 12 defines a hollow interior to store windings of yarn 18 and includes a yarn outlet 20 at or towards the first end 14 to dispense yarn from the yarn storage tube 12.

Each yarn storage tube 12 further includes a load plate 22 arranged in use for sliding movement along the length of the hollow interior of the yarn storage tube 12. The load plate 22, which is shown in more detail in Figure 2, includes a plate element 24 having a first face 26 to rest against windings of yarn 18 stored in the yarn storage tube 12 and an opening 28 provided in the plate element 24 to allow yarn to pass through the plate element 24 towards the yarn outlet 20.

The load plate 22 further includes a fence element 30 arranged to extend from a second opposing face 32 of the plate element 24 and towards the yarn outlet 20. The fence element 30 divides the hollow interior of the yarn storage tube 12 so as to form a passage on one side of the fence element 30 for yarn passing from the opening 28 in the plate element 24 towards the yarn outlet 20 and to form a cage with the adjacent side walls 34,36 of the yarn storage tube 12 on the other side of the fence element 30.

The fence element 30 is a planar structure extending es5entially perpendicularly from the second opposing face 32 of the plate element 24. In the embodiment shown in Figure 2, io the fence element 30 includes a plurality of openings or windows 38 extending through the fence element 30. These opening or windows 38 reduce the amount of material required to form the fence element 32. It will be appreciated that in other embodiments the fence element 32 may be formed as a solid member with no openings.

The centre of the opening 28 in the plate element 24 and the fence element 32 extending from the second face 32 of the plate element 24 are offset in opposite directions relative to a centrally located longitudinal axis A of the yarn storage tube 12.

In the embodiment shown in Figures 1 to 3, the fence element 32 is arranged to extend from the second face 32 of the plate element 24 so that the cage defined between the fence element 32 and the side walls 3436 of the yarn storage tube 12 inscribes a maximum circle having a diameter that is 48% of the diameter of a maximum circle inscribed within the cross-section of the yarn storage tube 12.

The opening 28 in the plate element 24 of the load plate 22 shown in Figure 2 is circular, having a diameter of 25mm. The opening 28 is positioned so that the fence element 32 extends across an edge of the opening 28, thereby forming a secant across the opening 28.

ao This arrangement results in a relatively large opening 28 in the plate element 24 for yarn to pass through. The advantages associated with the provision of a relatively large opening will become apparent below.

In the embodiment shown in Figures 1 and 2, each of the yarn storage tubes 12 has a square cross-section and the plate element 24 of each load plate 22 is generally square in shape so as to orient the load plate 22 within the respective yarn storage tube 12 and allow sliding movement of the load plate 22 along the length thereof. The length of each yarn storage tube 12 is in the range of 1.5m to 3m.

Previously the maximum possible length of a yarn storage tube 12 was considered to be 2m.

In other embodiments it is envisaged that the length of each yarn storage tube 12 may be further increased to increase the capacity of the yarn storage tube 12. In other embodiments for example, as outlined below, the length of each yarn storage tub 12 may be increased to be in excess of 3m.

It is envisaged that in other embodiments each of the yarn storage tubes 12 could have a different shape. Each of the yarn storage tubes 12 may, for example, have a hexagonal or octagonal cross-section.

Whilst it is acknowledged that each of the yarn storage tubes 12 could have a circular cross-section, it is preferred that the yarn storage tubes 12 are shaped so as to present relatively planar side walls so as to facilitate positioning of adjacent yarn storage tubes 12 relative to each other in a regular array with minimal space between adjacent yarn storage tubes 12. This ensures efficient use of space.

During use of the yarn storage apparatus 10 shown in Figure 1, windings of yarn 18 are inserted into the hollow interior of each of the yarn storage tubes 12. The windings of yarn 18 may be introduced via the first end of each of the yarn storage tubes 12 before locating the yarn store apparatus 10 in position relative to a yarn consuming apparatus. Ends of the windings of yarn 18 stored in the yarn storage tubes 12 are then fed into the yarn consuming apparatus so that, during operation of the yarn consuming apparatus, yarn is drawn from the yarn storage tubes 12 into the yarn consuming apparatus.

As outlined above, examples of yarn consuming apparatuses include, but are not limited to, Axminster gripper looms, velvet weaving looms and warp knitting machines.

Alternatively, in other embodiments of the invention not shown in the figures, windings of yarn 18 may be loaded into the yarn storage tubes 12 through the use of a yarn loader that is operably associated with each of the yarn storage tubes 12. The yarn loader inserts yarn via a yarn inlet at the second end 16 of the yarn storage tube 12 so as to create windings of yarn 18 in the hollow interior of the yarn storage tube 12.

In such other embodiments of the invention, the yarn loader may be provided in the form of a rotatable wheel located in the hollow interior at or towards the second end 16 of each of the yarn storage tubes 12, which operates in combination with a flow of air. The flow of air drives yarn into the hollow interior of the yarn storage tube 12 whilst the yarn loader in the yarn storage tube 12 rotates to direct the yarn and create windings of yarn 18 in the hollow interior of the yarn storage tube 12.

The use of a yarn loader to load yarn into each of the yarn storage tubes 12 via a yarn inlet at or towards the second end 16 of the yarn storage tube 12 is advantageous because it allows yarn to be loaded into the yarn storage tube 12 during use. This allows the windings of yarn 18 to be topped up without having to interrupt operation of the yarn consuming apparatus consuming yarn from the yarn storage tubes 12 of the yarn storage apparatus 10.

The load plate 22 of each yarn storage tube 12 is located in the hollow interior of the yarn storage tube 12 so that the first face 26 of the plate element 24 rests on the windings of yarn 18 stored in the hollow interior of the yarn storage tube 12.

In the event windings of yarn 18 are loaded into the hollow interior of each of the yarn storage tubes 12, via a yarn inlet at the second end 16 of the yarn storage tube 12, the load plate 22 slides along the length of the hollow interior of the yarn storage tube 12, towards the first end 14, as more yarn is loaded into the yarn storage tube 12.

In order to apply a press-on force to the windings of yarn 18, and thereby reduce the risk of the windings of yarn 18 falling over within the hollowing interior of the yarn storage tube 12, a load element 40 is located in the cage defined between the fence element 32 and the side walls 34,36 of the yarn storage tube 12. The load element 40 rests on the second face 32 of the plate element 24 and urges the first face 26 of the plate element 24 against the windings of yarn 18.

In the embodiment shown in Figure 2, the load element 40 is provided in the form of a steel ball. It is envisaged that in other embodiments a glass marble may be used instead of a steel ball.

It is also envisaged that in further embodiments a plurality of load elements may be inserted into the cage so as to provide a greater load to urge the first face 26 of the plate element 24 against the windings of yarn 18. Such embodiments are particularly useful when a relatively heavy yarn is stored in the hollow interior of the yarn storage tube 12 that requires a larger press-on force than is achieved through the use of a single steel ball.

The use of a spherical load element 40 is preferred because the absence of edges on the external surface of such a load element 40 reduces the risk of the load element becoming trapped or wedged and thus preventing movement of the load plate 22 along the length of the hollow interior of the yarn storage tube 12, either during insertion or dispensing of yarn from the yarn storage tube 12.

It is also however envisaged that in yet further embodiments the load plate 22 located in each of the yarn storage tubes 12 may employ a non-spherical load element 40 received in the cage defined between the fence element 32 of the load plate 22 and the side walls 3436 of the respective yarn storage tube 12.

In the embodiment shown in Figure 2, the fence element 30 of the load plate 22 located in each of the yarn storage tubes 12 includes a trap element 42 formed at an end of the fence element 30 remote from the plate element 24. The trap element 42 extends generally perpendicularly from the end of the fence element 30 to as to extend towards the side walls 3436 of the respective yarn storage tube 12 and thereby prevent removal of the load element 40 from the cage.

In order to locate the load element 42 in the cage, the load element 42 is located between the trap element 42 and the plate element 24 before the load plate 22 is inserted into the yarn storage tube 12.

It will be appreciated that the press-on force provided by the load element 40 in each yarn storage tube 12 will be determined by the size and mass of the load element 40 and the angle of inclination of the yarn storage tube 12.

In the embodiment shown in Figure 2, the yarn storage tubes 12 are inclined at an angle e of 6 relative to the horizontal. It will be appreciated that the angle may be varied in other embodiments depending on the weight of the yarn stored in the yarn storage tubes 12 and the size and/or mass of the load element 40.

It should also be borne in mind however that the mass of the load element 40 must be sufficient to overcome any flow of air directed from the first end 14 of the yarn storage tube 12 towards the second end 16 of the yarn storage tube 12 in embodiments where a yarn winder is provided within the hollow interior of yarn storage tube 12.

In such embodiments, as outlined above, the flow of air is provided to drive the yarn into the hollow interior of the yarn storage tube 12 and the mass of the load element 40 must be sufficient so as to ensure that the flow of air does not drive the load plate 22 out of the yarn storage tube 12. In the absence of the load plate 22, there will be no resistance applied to the windings of yarn 18 and the flow of air will cause the windings of yarn 18 to unwind up the hollow interior of the yarn storage tube 12.

In order to connect ends of the windings of yarn 18 stored in the yarn storage tubes 12 into the yarn consuming apparatus, the yarn storage apparatus 10 further includes at least one insertion tool 44.

The insertion tool 44 includes an elongate insertion element 46 having a handle (not shown) at a first end and a gripper 47 (Figure 3) at a second end for insertion into each of the yarn storage tubes 12 to retrieve the end of the windings of yarn 18 stored in the yarn storage tube 12.

The insertion tool 44 further includes a guide 48 mounted on the elongate insertion element 46. The guide 48 is a generally planar member and is shaped so that curved edges 50 of the guide 48 are received in opposing corners of a yarn storage tube 12 on insertion of the elongate insertion element 46 into the yarn storage tube 12.

The guide 48 is mounted on the elongate insertion element 46 so that when the curved edges 50 of the guide 48 are received in opposing corners of the yarn storage tube 12, the elongate insertion element 46 is aligned with the opening 28 in the plate element 24. This allows efficient and reliable insertion of the insertion tool 46 into each of the yarn storage tubes 12, particularly when access to the yarn storage tubes is limited, and/or visibility into the yarn storage tubes is limited.

The gripper provided at the first end of the elongate insertion element 46 includes a piece of fabric that is formed so as to present a plurality of burrs or hooks on at least one side.

The piece of fabric is attached to the elongate insertion element 46 so as to present the burrs or hooks to grip yarn. It is envisaged that a piece of Velcro (RTM) would be suitable for the purposes of forming the gripper.

On insertion of the gripper through the opening 28 in the plate element 24, the elongate insertion element 46 is rotatable relative to the guide 48 until the operator feels resistance to rotation and is therefore alerted to the attachment of yarn to the gripper.

Rotating the elongate insertion element maximises the exposure of the burrs on the piece of fabric secured to the first end of the elongate insertion element 46 and thereby maximises the possibility of the burrs gripping yarn. The applicant has found that in reality this rotation results in a 100% success rate, yarn becoming attached to the burrs on the piece of fabric 10 times out of 10.

Once the gripper grips the yarn, the elongate insertion element 46 is withdrawn through the opening 28 in the plate element 24, drawing the yarn with it. This arrangement ensures that the yarn is threaded through the opening 28 in the plate element 24 and allows the operator to connect the end of the windings of yarn 18 stored in the hollow interior of the is yarn storage tube 12 into the yarn consuming apparatus.

The insertion toot 44 is inserted in turn into each of the yarn storage tubes 12 until the windings of yarn 18 stored in the hollow interiors of the yarn storage tubes 12 are connected into the yarn consuming apparatus.

During operation of the yarn consuming apparatus, the elongate insertion element 46 of the insertion tool 44 is again inserted into one or more of the yarn storage tubes 12 in the event of a yarn breakage. The insertion tool 44 provides a relatively quick and efficient option for retrieving the lost end of the windings of yarn 18 in such situations and thereby allows efficient re-connection of the respective yarn into the yarn consuming apparatus.

This in turn allows the yarn consuming apparatus to be re-started in a quick and efficient manner.

It will be appreciated that quick and efficient retrieval of lost yarn ends is particularly so beneficial during the operation of a yarn consuming apparatus.

The advantages associated with the use of the insertion tool 44 are achieved through the creation of a line of sight from the yarn outlet 20 to the windings of yarn 18 via the opening 28 in the plate element 24. In other yarn storage apparatuses, where there is no such clear line of sight from the yarn outlet to the windings of yarn 18, the operator must either remove the load being used to apply a press-on force to the windings of yarn 18 in order to retrieve the lost end of yarn or spend time trying to guide a tool around the load so as to access the windings of yarn 18.

In certain circumstances, removal of the load is not possible. When the yarn consuming apparatus is an Axminster gripper loom, for example, the presence of beat up bars in the loom means that removal of the load from each of the yarn storage tubes is not possible.

As such, in such circumstances, the only means for retrieving a lost end of yarn is to spend time trying to guide a tool around the load so as to access the windings of yarn 18.

The applicant has found that in circumstances where the load obscures access to the windings of yarn 18, because a spherical load is used and is sized so as to guide the yarn via its external circumference, for example, an operator must make multiple attempts to retrieve a lost or broken yarn. In such arrangements, the load is typically sized so as to have a diameter that is in the range of 90-99% of the diameter of the maximum circle is inscribed within the hollow interior of the yarn storage tube. This can lead to a downtime of the yarn consuming apparatus for 10-20 minutes.

In the event the yarn consuming apparatus is an Axminster gripper loom that is operated to produce 60 rows of tufted carpet per minute, a downtime of 10 minutes equates to 600 rows. In a 4 metre wide product, there are 276 rows per metre. Accordingly this in turn equates to a loss of 2.17 lines per metre, which again in turn results in a loss in production of 8.7m2. Assuming a sales price of £20 per square metre of carpet, this loss equates to £174 per 10 minute stop.

In contrast, the applicant has found that the creation of a line of sight from the yarn outlet to the windings of yarn 18 via the opening 28 in the plate element 24, which facilitates use of the insertion tool 44, results in a stoppage time of 1-2 minutes to retrieve a lost or broken yarn.

Again assuming the yarn consuming apparatus is an Axminster gripper loom that is operated to produce 60 rows of tufted carpet per minute, a downtime of 1 minute equates to 60 rows. This in turn results in a loss in production of 0.87m2 and a loss of £17.40 per 1 minute stop.

The affect of using a load having a diameter that is 90-99% of the diameter of a maximum circle inscribed within the hollow interior of one of the yarn storage tubes 12 on the line of sight between the yarn outlet 20 and the windings of yarn 18 is illustrated in Figure 5.

As is shown in Figure 5, the use of a load having a diameter that is 90-99% of the diameter of a maximum circle inscribed within the hollow interior of one of the yarn storage tubes 12 results in no line of sight between the yarn outlet 20 and the windings of yarn 18. An operator must then seek to guide a retrieval tool around the load in order to retrieve a lost or broken yarn.

Referring to Figure 5 it can be seen that the use of a load having a diameter that is 60% of the diameter of the maximum circle inscribed within the hollow interior of one of the yarn io storage tubes 12 results in the creation of a line of sight between the yarn outlet 20 and the windings of yarn 18.

It is however apparent from Figure 5 that this line of sight is greatly increased on the use of a load having a diameter that is 46% of the diameter of the maximum circle inscribed within the hollow interior of the yarn storage tube 12. This in turn makes it significantly easier to reliably insert and guide the gripper provided at the first end of the elongate insertion element 46 of the insertion tool 44 through the opening 28 in the plate element 28.

The use of a load having a diameter that is 48% of the diameter of the maximum circle inscribed within the hollow interior of the yarn storage tube 12 also results in a smaller load and thus a smaller press-on force applied to the windings of yarn 18 stored in the yarn storage tube 12. This in turn reduces the tension of the yarn as it is drawn from the yarn storage tube 12, when compared with the use of a load having a diameter that is 96% of the diameter of the maximum circle inscribed within the hollow interior of the yarn storage tube 12, whilst still providing sufficient press-on force to prevent the windings of yarn 18 from falling over.

More specifically, the applicant has compared the load produced on windings of yarn 18 stored in a yarn storage tube 12 having a square cross-section, each side of the square cross-section having a length of 51.6mm through the use of a load element 40 in the form of a steel ball having a diameter of 25mm and a glass marble having a diameter of 50mm.

A steel ball having a diameter of 25mm is 46% of the diameter of the maximum circle inscribed within the hollow interior of the yarn storage tube 12 and a glass marble having a diameter of 50mm is 96% of the diameter of the maximum circle inscribed within the hollow interior of the yarn storage tube 12. The applicant has discovered that the 25mm steel ball produces approximately 1/3 of the load produced by the 50mm glass marble.

This in turn reduces the tension of the yarn by approximately 75%.

The use of a steel ball having a diameter of 25mm compared to a glass marble having a diameter of 50mm equates to a reduction in mass of 43%. This reduction in mass and resultant reduction in tension allows for an increase in the length of the yarn storage tube 12 from 2m to 3m, 2m conventionally being considered the maximum possible length of yarn storage tube 12. This in turn increases the capacity of the yarn storage tube 12.

A yarn storage tube 12 having a length of 2m has a capacity to hold 400m in length of 660 Tex yarn whereas a yarn storage tube 12 having a length of 3m has a capacity to hold 60Gm in length of 660 Tex yarn. This makes the line of sight route even more important.

It is envisaged that further increases in the capacity of each yarn storage tube 12 may be is achieved by further reducing the tension of the yarn.

Such an increase in capacity of the yarn storage tube 12 reduces the need to revisit the yarn storage tube 12 during operation of the yarn consuming apparatus to load additional yarn into the yarn storage tube 12.

As outlined above, the provision of a fence element 30 on each load plate 22 means that the load element 40 for insertion into the cage defined between the fence element 30 and the side walls 34,36 of the respective yarn storage tube 12 may be provided in any form and made from any material so long as the load element 40 in use applies the load to the second opposing face 32 of the plate element 24 that is required to apply the desired press-on force to windings of yarn 18 stored in the hollow interior of the yarn storage tube 12.

An example of one other such load element 40 is shown in Figure 6, which shows a load plate according to another embodiment of the invention.

The load plate 22 shown in Figure 6 is substantially the same as the load plate 22 shown in Figures 3 and 4 and the same reference numerals will therefore be used to identify corresponding features and will not be described in detail.

The load plate 22 shown in Figure 6 differs from the load plate 22 shown in Figures 3 and 4 in that the fence element 30 extending from the second opposing face 32 of the plate element 24 does not include any windows or openings 38.

The load plate 22 shown in Figure 6 also differs from the load plate 22 shown in Figures 3 and 4 in that the load element 40 is provided in the form of an elongate element 52 that is secured to the fence element 30 along a first elongate edge thereof so as to extend from the fence element 30 towards the side walls 34,36 of the respective yarn storage tube 12 (not shown).

The load element 40 includes a pair of wheels 54,56 mounted on the elongate element 52 so as to protrude from a second, opposite elongate edge 58 of the elongate element 52.

The wheels 54,56 in use contact the side walls 34,36 of the yarn storage tube l2so as to is allow rolling movement of the wheels 54,56 along the side walls 34,36 of the yarn storage tube 12 and in turn allow movement of the elongate element 52 along the length of the yarn storage tube 12, either during insertion of windings of yarn 18 into the hollow interior of the yarn storage tube 12 or during dispensing of yarn from the yarn storage tube 12.

Claims

CLAIMS1. A yarn storage apparatus to supply yarn to a yarn consuming apparatus comprising a plurality of yarn storage tubes that are arranged in an inclined position so that a first end of each yarn storage tube is higher than a second end of the yarn storage tube, each yarn storage tube defining a hollow interior to store windings of yarn and including a yarn outlet at or towards the first end to dispense yarn from the yarn storage tube, each yarn storage tube further including a load plate arranged in use for sliding movement along the length of the hollow interior of the yarn storage tube, the load plate including a plate element having a first face to rest against windings of yarn stored in the yarn storage tube and an opening provided in the plate element to allow yarn to pass through the plate element towards the yarn outlet, the load plate further including a fence element arranged to extend from a second opposing face of the plate element and towards the yarn outlet, the fence element dividing the hollow interior of the yarn storage tube so as to form a passage on one side of the fence element for yarn passing from the opening in the plate element towards the yarn outlet and form a cage with one or more side walls of the yarn storage tube on the other side of the fence element to receive at least one load element, the or each load element being received in use in the cage so as to apply a load to the second face of the plate element and urge the first face of the plate element against windings of yarn stored in the yarn storage tube.
2. A yarn storage apparatus according to Claim 1 wherein the fence element is a planar structure extending essentially perpendicularly from the second opposing face of the plate element.
3. A yarn storage apparatus according to Claim 1 or Claim 2 wherein the centre of the opening in the plate element of each load plate and the fence element extending from the second face of the plate element are offset in opposite directions relative to a centrally located longitudinal axis of the respective yarn storage tube.
4. A yarn storage apparatus according to Claim 3 wherein the fence element is arranged relative to the centrally located longitudinal axis of the respective yarn storage tube so that a maximum circle inscribed within the cage defined between the fence element and the one or more side walls of the yarn storage tube has a diameter that is equal to or less than 48% of the diameter of a maximum circle inscribed within the cross-section of the yarn storage tube.
A yarn storage apparatus according to any one of the preceding claims wherein two or more load elements are received, in use, in the cage defined between the fence element and the one or more side walls of the respective yarn storage tube, the load elements being arranged to rest one on top of the other against the second face of the plate element so as to urge the first face of the plate element against windings of yam stored in the yarn storage tube.
6. A yarn storage apparatus according to any one of the preceding claims wherein the or each load plate is spherical in shape.
7. A yarn storage apparatus according to Claim 6 wherein the or each load element is chosen from the group consisting of a steel ball and a glass marble.
8. A yarn storage apparatus according to any one of Claims I to 4 wherein the load is element is provided in the form of an elongate element have one or more wheels mounted thereon so as to protrude from an elongate edge thereof so that when the load element is received in use within the cage the elongate element is secured or otherwise held in position so as to extend from the fence element towards the one or more side walls so that the or each wheel contacts the or a side wall of the respective yarn storage tube.
9. A yarn storage apparatus according to any one of the preceding claims further comprising an insertion tool, the insertion tool including an elongate insertion element having a handle at a first end and a gripper at a second end for insertion into each of the yarn storage tubes to retrieve a yarn end through the opening in the plate element of the respective load plate.
10. A yarn storage apparatus according to Claim 9 wherein the insertion tool further includes a guide mounted on the elongate insertion element, the guide being shaped to contact each yarn storage tube on opposite sides of the hollow interior when the elongate insertion element is inserted into the yarn storage tube so as to align the elongate insertion element with the opening in the plate element of the respective load plate and guide further movement of the elongate insertion element into the yarn storage tube so that gripper at the second end of the elongate insertion element is directed through the opening in the plate element.
11. A yarn storage apparatus according to Claim 10 wherein the elongate insertion element is rotatable relative to the guide.
12. A yarn storage apparatus according to any one of Claims 9 to 11 wherein the gripper includes a piece of fabric attached to the second end of the elongate insertion element so as to prevent a plurality of burrs formed on its surface.
13. A yarn storage apparatus according to any one of Claims 9 to 11 wherein the gripper includes a pair of jaw elements, at least one of the jaw element being pivotably mounted for movement relative to the other jaw element at the second end of the elongate insertion element to open and close jaws defined by the jaw elements.
14. A yarn storage apparatus according to any one of Claims 9 to 11 wherein the gripper includes at least one yarn.
15. A yarn storage apparatus according to any one of the preceding claims wherein each yarn storage tube includes a yarn inlet at or towards the second end to load yarn into the yarn storage tube and the yarn storage apparatus further includes at least one yarn loader operably associated with each yarn storage tube to insert yarn into the hollow interior of the yarn storage tube.
16. A yarn storage apparatus according to any one of the preceding claims wherein each yarn storage tube is square, hexagonal or octagonal in cross-section.
17. A yarn storage apparatus generally as herein described with reference to and/or as illustrated in the accompanying drawings.