GB2599675A

GB2599675A - Improvements in or relating to yarn storage

Info

Publication number: GB2599675A
Application number: GB2015957.0A
Authority: GB
Inventors: Turnbull Philip; Watson David
Original assignee: Griffith Textile Machines Ltd
Current assignee: Griffith Textile Machines Ltd
Priority date: 2020-10-08
Filing date: 2020-10-08
Publication date: 2022-04-13
Anticipated expiration: 2040-10-08
Also published as: GB202015957D0; GB2599675B

Abstract

A yarn storage apparatus 20 for supplying yarn 34 to a plurality of yarn consuming locations spaced across the width of a yarn consuming apparatus 22 comprising a plurality of creel rows 24 spaced from and arranged to extend substantially parallel to each other, each creel row 24 including pegs (26, fig. 6) configured to support yarn windings (30, fig. 6), where yarns 34 from yarn windings (30) are drawn along a feed path 36 from pegs 26 to corresponding yarn supply locations 21. The yarn supply locations 21 spaced along an axis parallel to each creel row 24 for presentation to the yarn consuming locations 23 of the yarn consuming apparatus 22. The creel rows may be located on a level that is higher than the level the yarn consuming apparatus is located. The creel rows may be arranged over more than one level each higher than the level the yarn consuming apparatus is positioned. Also claimed is a monitoring system and method for monitoring the restocking of a yarn storage apparatus.

Description

IMPROVEMENTS IN OR RELATING TO YARN STORAGE

This invention relates to a yarn storage apparatus for supplying yarn to a plurality of yarn consuming locations spaced across the width of a yarn consuming apparatus. The invention also relates to a monitoring system for monitoring the restocking of such a yarn storage apparatus and to a method of monitoring restocking of such a yarn storage apparatus.

Examples of yarn consuming apparatus 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 is 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.

In a conventional jacquard Axminster loom, grippers are provided across the width of the loom to present tufts for insertion into a carpet being woven on the loom. Supplies of tuft yarn are inserted into yarn carriers, which also extend across the width of the loom in correspondence with the grippers. Each yarn carrier includes a yarn end for each colour required by the pattern of the carpet. A jacquard controls movement of the yarn carriers so as to present a selected yarn end to each gripper for each row of the carpet. The grippers draw a predetermined length of the presented yarns ends, which are cut by a series of knives. The grippers then insert the resultant tufts between warp threads, the tufts being held in position in the resultant carpet by each pass of the weft yarn.

In a typical 4 yard wide loom with a pitch of 7 tufts per inch, 1008 tufts are inserted into a carpet across its width in each row. This means that setting up the loom to weave a carpet including 8 different colours results in a creel including 8 bobbins of yarn per tuft insertion point, namely 8064 bobbins of yarn.

A spool gripper loom employs a smaller number of bobbins to supply an off-line spool winding process. Each spool in the complete set has a pre-selected set of colours appropriate to a particular row in the carpet, and thus allows more yarn colours to be used. The need to pre-wind spools however means that a greater quantity of yarn is used than would be the case on a gripper loom. Spool gripper looms are therefore more suitable for use in larger batch quantities. A further disadvantage with the spool gripper loom is that the pattern repeat length is limited to the number of spools in the supply system.

WO 95/31594 describes a tuft carrier loading apparatus for a gripper loom that greatly reduces the number of bobbins required in the creel of a gripper loom. The tuft carrier loading apparatus includes an elongate tuft carrier having a plurality of tuft retention sites into which tufts of yarn are fed in a sequential manner. Following the insertion of a complete row of tufts into the tuft carrier, the tuft carrier presents the tufts to the grippers of the loom for insertion into a carpet as a complete row.

EP 1 386027 and WO 2012/046056 describe an improved tuft feeding mechanisms that further reduce the number of bobbins required.

Regardless of the type of yarn consuming apparatus, a large number of yarn windings of different colours may be required in order to produce a product having a pattern involving a number of different colours.

Problems may arise in the management of such a large number of yarn windings. In particular, it can be difficult for an operator to know which spool or bobbin requires replacing at any particular time. It can thus be difficult for the operator to prioritise the replacement of spools or bobbins in an appropriate manner.

Moreover, access to the spools or bobbins may be severely restricted due to each colour of yarn having to be presented at intervals along the width of the loom, thus resulting in lots of yarns extending between the creels and the loom at one end of the creels.

According to a first aspect of the present invention there is provided a yarn storage apparatus for supplying yarn to a plurality of yarn consuming locations spaced across the width of a yarn consuming apparatus, the yarn storage apparatus comprising a plurality of creel rows spaced from and arranged to extend substantially parallel to each other, each creel row including a plurality of pegs configured to support a corresponding number of yarn windings, wherein, in use, yarns from yarn windings supported on the pegs of each creel row are drawn along a feed path from a respective peg to a corresponding one of a plurality of yarn supply locations, the plurality of yarn supply locations being spaced along an axis that is substantially parallel to each creel row for presentation to the yarn consuming locations of the yarn consuming apparatus.

Throughout the specification yarn may be described as being wound onto a cone, i.e. a type of "yarn winding" as recited above. However, it is to be understood that the yarn could be wound onto other structures such as bobbins and spools, for example.

The invention is applicable to any type of yarn consuming apparatus, but in embodiments of the invention the yarn consuming apparatus comprises a textile forming machine such as Axminister loom, for example an Axminister gripper loom. The term "loom" is used throughout the specification in reference to the yarn consuming apparatus.

Where the term "operator' is used throughout the specification it will be understood that this could be a human operator or a robotic operator.

As mentioned above, it can be necessary to manage a large number of cones of yarn in order to create an Axminister carpet having several different colours.

Typically, the yarn is wound onto cones, and the cones are stored on creels. Typically, a creel comprises a bar having pegs positioned at spaced apart intervals along the bar. A cone on which yarn has been wound is positioned on a peg.

In known loom arrangements, the creels necessary to store an appropriate number of cones of yarn are arranged so that they are positioned substantially perpendicular to the axis of the loom. This is so that yarns of a particular colour can be positioned at intervals along the creels, with each creel housing cones carrying yarn of several different colours.

Specifically, for a loom that is to create a carpet having a pattern made from ten colours, cones carrying yarn of each of the ten colours will be positioned sequentially along a creel in an order that corresponds to the pattern that is to be formed in the carpet. Typically, the sequence of cones carrying the different colours of yarn will extend down a first creel in a first direction and then will continue up an adjacent creel in an opposite direction, down a third creel in the first direction and up a fourth creel etc. Yarn will be taken in order initially from a first creel and then proceeding through the number of creels used to store the yarn.

A disadvantage with this arrangement is that it is not easy to determine when a particular cone is about to run out of yarn and thus needs replacing Because of the looping round arrangement of the sequence of coloured yarns in the known system, access to points along the creel can only be gained from one end of the creels.

This further hampers the maintenance and changeover of the cones.

However, in the yarn storage apparatus of the invention, the yarn supply locations (at which yarn from yarn windings supported on the pegs of each creel row are drawn to) extend substantially parallel to the yarn consuming locations that are spaced across the width of the loom.

As a result, cones carrying a single colour of yarn can be grouped together in the creel rows. This is because the yarn supply locations extend along the same axis as that of the yarn consuming locations, thus making it possible to present yarn of one colour at intervals along the whole width of the yarn consuming apparatus from each creel row.

This arrangement means that it is readily identifiable when a cone of a particular colour will need to be replaced or restocked. Moreover, once it is known which colour needs restocked, e.g. because the fabric pattern includes a large amount of one particular colour, it is easy for an operator to identify where that colour is in the yarn storage apparatus.

The yarn storage apparatus arrangement of the claimed invention also means that there is a shorter distance from a creel row to the point of use at the loom. This is because since the yarn supply locations are arranged substantially parallel to the yarn consuming locations, all points along the creel row are substantially the same distance from the loom. This arrangement reduces the tension in the yarn and improves the loom output.

Preferably, the plurality of creel rows is located on a level that is higher than the level on which the yarn consuming apparatus is located. Optionally, the plurality of creel rows is arranged over more than one level, each of which level is higher than the level at which the yarn consuming apparatus is positioned.

Positioning the creel rows above the loom means that the yarn is pulled downwards to the loom, thus utilising gravity to help maintain the desired tension of the yarn being presented to the loom.

Moreover, an increased number of creel rows can be utilised for the same footprint of land since the yarn storage apparatus is effectively being built vertically.

In embodiments of the invention, the yarn storage apparatus comprises a yarn guide assembly positioned between the pegs and the yarn supply locations and being configured to guide yarn, in use, from each peg towards a corresponding yarn supply location. In such embodiments, the yarn guide assembly may be configured to guide yarn, in use, from each peg to above the associated creel row and then downwards towards a corresponding yarn supply location. For example, the yarn guide assembly may include a plurality of conduits through each of which a yarn, in use, is guided from a respective peg to a corresponding yarn supply location, each conduit extending upwards to a position above the associated creel row and then downwards towards the yarn supply locations.

Such an arrangement helps to guide the yarn along the feed path so as to prevent tangling of the yarn and to maintain tension in the yarn. Moreover, the guide assembly being configured to guide yarn, in use, from each peg to above the associated creel row and then downwards towards a corresponding yarn supply location means that each end of the plurality of creel rows is free of extending yarns being presented towards the loom. Instead, the yarns are directed out the top of the associated creel row, i.e. above head height, and then pulled, e.g. centrally, downwards towards the loom. Therefore, an operator can easily access the pegs to, for example, restock a cone of yarn or carry out other forms of maintenance on the creel row. Moreover, greater space can be created between adjacent creel rows to allow easier access by an operator and allow access to the pegs by a trolley (either being pushed by an operator or automated).

Optionally, each creel row includes a plurality of pegs in a first row and a plurality of pegs in a second row, the first and second rows being laterally adjacent to one another to define a plurality of laterally adjacent peg pairs spaced along the length of the creel row.

Such a side-by-side arrangement of peg pairs spaced along the length of each creel row means that more yarn windings can be stored in each creel row without substantially increasing the overall size of the yarn storage apparatus. In particular, an operator can preload a yarn winding onto one of the peg pairs in readiness for that yarn colour running out or in readiness for the next pattern to be run through the loom. An operator can also tie on the yarn from the preloaded yarn winding to the yarn of the loaded yarn winding so that the yarn runs continuously from the loaded yarn winding to the preloaded yarn winding.

Each creel row may include more than one creel row level spaced along the height of the creel row, each creel row level including a plurality of pegs spaced along the length of the creel row.

The inclusion of such creel row levels utilises the height of creel row to store and present more yarn to the yarn supply locations while maintaining the same floor footprint of the yarn storage apparatus.

Optionally the yarn storage apparatus includes an indicator located on each creel row to identify the physical location of one or more pegs.

Having such an indicator means that an operator can readily identify where a peg, or a group of pegs, are located within the yarn storage apparatus when walking up and down the creel rows. For example, the peg(s) may be colour coded such that when the operator needs to locate a particular peg or group of pegs e.g. for the purpose of maintenance or yarn replacement, it is easy to spot where that physical location is. The indicator may also have some form a signature that can be read by an electronic reader to indicate the physical location of a peg.

The indicator may be any suitable indicator and may for example provide a visual indication identifying the location of one or more pegs.

The indicator may be in operative communication with a controller which sends an indicator signal, and the indicator is configured to activate up receiving the indicator signal. For example, the indicator may provide an audible alarm upon receiving the indictor signal so as to identify to an operator the physical location of the peg(s) within the yarn storage apparatus.

The indicator may indicate the position of a group of pegs, e.g. where the group includes pegs having yarn windings of one colour. The yarn storage apparatus may instead include an indicator located at each peg of each creel row to identify the physical location of each individual peg.

The indicator may include a label encoded with a location identifier, the label being configured to be readable by an electronic reader.

The label may take any suitable form such as a radio frequency identification (RFID) tag or a barcode.

Providing such a label means that an operator (either human or robotic) can "read" the label (i.e. by using an electronic reader such as an RFID or barcode scanner) to therefore determine the correct physical location of a desired peg. This would be used, for example, if the operator has been instructed to replace a yarn winding and so needs to locate the correct peg for that yarn winding. The label could also contain technical information about the yarn so that the operator can ascertain what yarn is at a particular location.

According to a second aspect of the invention there is provided a textile manufacturing apparatus comprising a yarn storage apparatus as described hereinabove and a yarn consuming apparatus. The textile manufacturing apparatus may further include a plurality of yarn windings having yarn wound thereon, each yarn winding being supported by one of the pegs of the creel rows, wherein the yarn from the yarn windings is drawn along a feed path from a respective peg to a corresponding one of the plurality of yarn supply locations.

The advantages of the apparatus of the first aspect of the invention and its embodiments applies mutatis mutandis to the assembly of the second aspect of the invention and its embodiments.

According to a third aspect of the invention there is provided a monitoring system for monitoring the restocking of a yarn storage apparatus as described hereinabove, the monitoring system comprising a controller programmed to calculate the rate of consumption of yarn of each colour for a fabric pattern, the controller being configured to output data from the calculation to a re-stocker, wherein the output data includes a location indicator corresponding to the physical location of a peg of one of the creel rows within the yarn storage apparatus.

Having a controller programmed in such a way means that the appropriate yarn windings can be replaced in readiness for the colour of that yarn running out, thus resulting in less downtime of the loom. It is the parallel arrangement of the creel rows and yarn supply locations relative to yarn consuming location (which, as mentioned above, means that yarn windings carrying the same coloured yarn can be grouped together within the creel rows) which makes the calculation and location signal output possible to do in a straightforward manner.

A re-stocker may be human or robotic According to fourth aspect of the invention there is provided a method of monitoring restocking of a yarn storage apparatus as described hereinabove, the method comprising the steps of: i) calculating the rate of consumption of yarn of each colour for a fabric pattern; H) outputting data calculated in step i) to a re-stocker, wherein the data includes a location indicator corresponding to the physical location of a peg of one of the creel rows within the yarn storage apparatus; iii) restocking one or more yarn windings in response to the output data so as to restock the yarn storage apparatus.

The advantages of the system of the third aspect of the invention and its embodiments applies mutafis mutandis to the method of the fourth aspect of the invention and its embodiments.

Preferably, step Hi) includes entering the yarn storage apparatus from either end of a creel row.

Again, it is the parallel arrangement of the creel rows and yarn supply locations relative to the yarn consuming locations which permits an operator to enter the yarn storage apparatus from either side of the creel rows because both sides of the creel row are free from yarn extensions. Moreover, since the yarn windings can be grouped within the creel rows by colour, the operator can walk up and down the creel rows to restock yarn windings of each colour more efficiently.

A preferred embodiment of the invention will now be described, by way of a non-limiting example, with reference to the accompanying drawings in which: Figure 1 is a schematic representation of a known yarn management system for an Axminister loom; Figure 2 is a schematic representation of a yarn storage apparatus viewed from one side according to an embodiment of the invention; Figure 3 is a schematic representation of yarn supply locations being presented to a yarn consuming apparatus; Figure 4 is a schematic representation of the yarn storage apparatus of Figure 2 showing how yarn of a particular colour are grouped together; Figure 5 is the same schematic representation of Figure 4 shown from above; Figure 6 shows a creel row of the yarn storage apparatus of Figure 2; Figure 7 shows pegs of the creel row of Figure 5; and Figure 8 shows a portion of a yarn guide assembly of the creel row of Figure 5.

Referring first to Figure 1, a known yarn storage apparatus 2 for use with an Axminister loom 4 is illustrated schematically.

An Axminister carpet is created by the loom 4 having a pattern comprising ten colours.

Yarn of each of the ten colours is wound onto cones and the cones are stored in creels 6 which are arranged in creel columns 6a-6g, each of which extends substantially perpendicular to the axis X of the loom 4. Cones having yarn of a particular colour are arranged sequentially in an order appropriate to the pattern to be made in the carpet formed by the loom.

The cones are therefore arranged so that the ten colours are arranged in a predetermined sequence starting from the first creel column 6a as indicated by arrow 8. The sequence is repeated along the second creel column but in an opposite direction indicated by arrow 10. This continues along all of the creel columns as shown by the arrows.

Yarn of a particular colour is provided to the loom starting with yarn from a first cone 12 of that colour and proceeding sequentially according to the arrows to a last cone 14 of that colour.

Such an arrangement has the disadvantages mentioned above. In addition, it can be difficult for an operator to determine where to position cones having a particular colour of yarn because the sequence in a first creel is the mirror image of the sequence in an adjacent creel.

Turning to Figure 2 to 7, a yarn storage apparatus according to an embodiment of the invention is designated generally by the reference numeral 20. The yarn storage apparatus 20 is adapted to present yarn of suitable colours to a yarn consuming apparatus 22 (e.g. an Axminister loom) which extends along a first axis, i.e. the lengthwise axis X as shown in Figure 5. As also shown in Figure 5, the yarn storage apparatus 20 includes a plurality of creel rows 24, each of which extends substantially parallel to the first axis X. More specifically, the yarn storage apparatus 20 is arranged to present yarns 32, that have been drawn along a feed path 36 from a respective peg location 28, to a corresponding one of a plurality of yarn supply locations 21. The yarn supply locations 21 are spaced along an axis that is substantially parallel to each creel row 24 for presentation of the yarn 34 to yarn consuming locations 23 which are spaced across the width of the loom 22. As shown in Figure 2, the yarn supply locations 21 are positioned just above the loom 22.

In the embodiment shown, there are twenty creel rows 24, but in other embodiments there may be more or fewer than twenty, e.g. there may be sixteen creel rows 24.

As shown more clearly in Figures 6 to 8, each of the creel rows 24 includes a plurality of pegs 26 that are spaced along the length of the creel row 24 to define a plurality of peg locations 28. The pegs 26 in this embodiment are equally spaced along the length of the creel row 24, although in other embodiments this may not be the case.

The pegs 26 are configured to support a yarn winding 30 (i.e. a cone) which itself has yarn 32 wound thereon. Since the yarn storage apparatus 20 shown in the figures is operatively set up with the loom 22, some of the pegs 26 are shown are supporting such yarn windings 30. The peg locations 28 therefore define the location from which the yarn 32 of the cone 30 is taken from the yarn storage apparatus 20 and eventually presented to the loom 22.

As shown in Figure 7, each peg 26 includes first and second peg portions 27a, 27b that are concentrically arranged with one another. The second peg portion 27b extends from the first peg portion 27a and has a smaller surface area than the first peg portion 27a. In this embodiment, the peg portions 27a, 27b are cylindrical in shape and the second peg portion 27b has a smaller diameter than the first peg portion 27a. The dimensions of the peg portions 27a, 27b are chosen such that they match those of the cone 30 so that the cone 30 can receive either the first or second peg portions 27a, 27b. Having first and second peg portions 27a, 27b allows for two different sized cones 30 to fit onto the peg 26. For example, the size of the cones 30 that wool is wound around for dying differs from the "standard" size of the cones 30 that yarn is supplied on, and the peg portions 27a, 27b are dimensioned to be received by both. This also eliminates the need for the dyed wool to be re-wound onto another ("standard") cone 30 to fit onto the peg. Moreover, due to the concentric arrangement of the peg portions 27a, 27b, the yarn is taken from the same position regardless of the size of the cone 30 that it is wound around.

Turning now to Figures 2 to 4, the loom 22 is positioned at a first floor level FLi and there is a plurality of creel rows 24 positioned at a second floor level FL2 which is higher than the first floor level FLi. Moreover, there is a further plurality of creel rows 24 positioned on a third floor level FL3 which is higher than the second floor level FL2. Therefore, the yarn storage apparatus 20 extends over two floor levels FL2, FL3, both of which are above the first floor level FLi of the loom 22. In the embodiment shown, the creel rows 24 on the second the third floor levels FL2, FL3 are positioned directly above the loom 22 with creel rows 24 located at either side (i.e. in front of and behind) the loom 22. Typically, the first floor level FLi would be the ground floor of a factory or warehouse.

In other embodiments of the invention, the yarn storage apparatus 20 may include creel rows 24 on one level (i.e. the second floor level FL2as shown in the figures), or may instead include creel rows 24 one more than two floor levels (e.g. a fourth floor level which is higher than the third floor level L3 as shown in the figures).

As more clearly shown in Figure 2, the yarn storage apparatus 20 further includes a yarn guide assembly 34 which is positioned between each of the pegs 26 and the loom 22. The yarn guide assembly 34 is configured to guide the yarn 32 from each peg location 28 upwards above the associated creel row 24 and then downwards towards the loom 22. The yarn 32 from each yarn location 28 therefore follows a feed path 36 which is up and over the creel rows 24 and then down to the loom 22. The feed path 36 from each peg location 28 in each creel row 24 at one side of the loom 22 and on one creel row level meets at the same height above the creel row 24 and follows the same feed path 36 towards a centralised area 38 above the loom 22. The feed path 36 from each peg location 28 in each creel row 24 at the other side of the loom 22 and on one creel row level meets at the same height above the creel row 24 and follows the same feed path 36 towards the centralised area 38. The yarns from either side of the loom 22 meet at the centralised where they follow the feed path 36 downwards towards the loom 22. Thus, all the yarn 32 is presented to the loom 22 from a single area 38.

At such centralised area 38, on each floor level L2, L3 of the creel rows 24, there is a centralised guide member 40 (forming part of the yarn guide assembly 34) into which all the yarns 32 from the creel rows 24 on that floor level L2, L3 are pulled into and guided downwards towards the loom 22. The centralised guide member 40 in this embodiment is a conduit, e.g. a tube.

Turning to Figures 6 to 8, each creel row 24 includes more than one creel row level CLi, CL2, CL3. Each creel row level CLi. CL2, CL3 includes a plurality of pegs 26 spaced along the length of the creel row 24 to define a plurality of peg locations 28 at each creel row level CLi, CL2, CL3. As such, there are rows of pegs 26 at different heights of the creel row 24. In the embodiment shown, there are three creel row levels CLi, CL2, CL3. but in other embodiments there may be fewer or more creel row levels As also shown in Figures 6 to 8, the yarn guide assembly 34 also includes yarn guide members 42, in the form of conduits, e.g. tubes, through which a yarn 32 of a respective cone 30 is guided from the upwards from a respective peg location 28 to follow the feed path 36.

As can be seen, for the cones 30 on the first creel row level CL,, there are first yarn guide members 42a that are positioned at the second creel row level CL2 and which extend substantially vertically. The first yarn guide members 42a, i.e. a first set of vertical guide tubes, are supported by a plate 44 that extends laterally from the bar 45 onto which the pegs 26 of the second creel row level CL2 are located. This means that the yarn 32 is pulled off the cones 30 at an angle towards the first set of vertical guide tubes 42a, and is then pulled substantially vertically through the tubes 42a.

The first set of vertical guide tubes 42a extends upwards through the third creel row level CL3 in a substantially vertical manner so that the end of the first set of vertical guide tubes 42a is at or above the creel row 24.

For the cones 30 on the second creel row level CL2, there are further first yarn guide members 42a that are positioned at the third creel row level CL3 and which extend substantially vertically. The further first yarn guide members 42a, i.e. a second set of vertical guide tubes, are supported by a plate 44 that extends laterally from the bar 45 onto which the pegs 26 of the third creel row level CL3 are located. Again, the yarn 32 is pulled off the cones 30 at an angle towards the second set of vertical guide tubes 42a, and is then pulled substantially vertically through the tubes 42.

The second set of vertical guide tubes 42a extends upwards in a substantially vertical manner so that the end of the second set of vertical guide tubes 42a is at or above the creel row 24.

The yarn guide assembly 34 further includes a set of second yarn guide members 42b which cooperate with the first yarn guide members 42a to guide the yarn 32 over the height of the creel row 24 and towards the centralised guide member 40, thus following the feed path 36 as illustrated in Figure 2. The second yarn guide members 42b are in the form of conduits, e.g. tubes, which extend from a respective first yarn guide member 42a such that they form a set of bent tubes. Although the first and second yarn guide members 42a, 42b are described as being separate sets of tubes, they may be integrally formed.

The tubes of the first and second yarn guide members 42a, 42b int his embodiment have a diameter of 10 mm. The inventors found that this diameter minimises friction and thus helps to maintain the correct tension of the yarn 32.

Returning to Figure 7, each creel row level CLi. CL2, CL3 has first and second rows 46a, 46b of pegs 26 which are laterally adjacent to one another to define a plurality of laterally to adjacent peg pairs 48 that are spaced along the length of the creel row 24. In other words, each creel row level CLi.CL2, CL3 has side-by-side peg pairs 48.

The peg pairs 48 at the second and third creel row level CL2, CL3 are joined by the laterally extending plate 44 mentioned above. Thus, the sets of vertically extending tubes 42a pass between the peg pairs 48, preferably through the middle of the peg pairs 48.

As illustrated in Figure 4, in this embodiment each creel row 24 stores yarns 32 of one colour such that there is a single colour A-J of yarn 32 present on each creel row 24. In other embodiments, the yarn colours may still be grouped together but a creel row 24 may include more than one colour of yarn 32.

The yarn storage apparatus 20 further includes a plurality of indicators 50 located on each creel row at each cone 30 to indicate the position of each yarn location 28. Only one such indicator 50 is shown in Figure 2 for clarity purposes. In the embodiment shown, the indicator 50 is includes a label in the form of a radio frequency identification (RFID) tag which is encoded with a location identifier and which is readable by an electronic reader. In other embodiments, the label may be any suitable form which is readable by an electronic reader, such as a barcode.

The indicators 50 may each include (instead of or in addition to the RFID tags) a non-electronic label which simply indicates the position of each peg location 28 to a human operative, e.g. via a colour coding scheme, numbers or other means. Moreover, the indicators 50 may each include (instead or in addition to the RFID tags) an active label which can be activated, e.g. upon receipt of an electronic signal, to indicate the position of each peg location 28. For example, the active label may make a noise or flash a light to indicate to a human operative the position of a particular peg location 28.

In use, the yarn 32 of each colour is presented to the loom 22 across the whole width of the loom 22, i.e. at each yarn consuming location 23, so that each colour is available to weave into the fabric, e.g. a carpet, at each point across the width of the fabric. As described above, the yarn 32 is guided along a feed path 36 to corresponding yarn supply locations 21 that are just above the loom 22. The yarn 32 is guided along at least a majority of the feed path 36 via the yarn guide assembly 34 (which is made up of various tubes). The feed path 36 extends up and over the creel rows to a centralised area 38 and then down to the loom 22. As also described above, the cones 30 are grouped together by yarn colour.

As the loom 22 is operating, the rate of consumption of yarn 32 of each colour for that fabric pattern can be calculated (e.g. by a controller running an algorithm). The factors that would be used in such a calculation would be how much yarn of each colour is required for that fabric pattern and the amount of yarn of each colour that has been loaded onto the creel rows 24. Other factors may include: running time to product the fabric pattern, the speed of the loom.

The data from the calculation can then be output to a re-stocker and the data can include a location indicator that corresponds to the physical position of a peg location 28 within the yarn storage apparatus 20. The re-stocker can then use this information to restock one or more cones 30 in the yarn storage apparatus 20.

The robotic re-stocker may have a trolley of coloured yarns and so each yarn may also include an indicator that is readable by an electronic reader. Therefore, the robotic re-stocker can scan each reader until the colour signature of that indicator matches a colour signal that has been received by the robotic re-stocker.

In a first example, the data from the calculation is output to a robotic re-stocker which receives the location indicator in the form of a location signal. The robotic re-stocker may be able to process this location signal against a preloaded "map" of the yarn storage apparatus 20 to then move directly to the desired peg location 28. Alternatively, the robotic re-stocker may methodically move up and down the creel rows 24 and use an electronic reader to "read" each indicator 50 until the location signature of that indicator 50 matches the location signal it received.

In a second example, the data from the calculation is output to a human re-stocker. This may be implemented by outputting a map of the yarn storage apparatus 20 which indicates where the desired peg location 28 is. The map may be displayed on a screen, such as a tablet screen, which the human re-stocker can read. The output may instead be implemented by outputting a number or colour which matches that of a label located on the creel rows 24.

In addition to, or instead of, the second example the data may be output to the indicator 50 which activates a noise or visual identifier (such as a flashing light) which indicates to the human re-stocker where the peg location 28 is.

In either case, the robotic or human re-stocker is then able to either replace the desired cone 30 or pre-load a new cone 30 onto the spare peg 26 in the peg pair 48 at that peg location 28. In the latter regard, the yarn of the spare cone 30 can be tied onto the end of the yarn of the adjacent cone 30 in a top and tail arrangement so that the pre-loaded cone 30 is ready to be pulled into the loom 22. In practice this means that when the yarn from a first cone 30 in a pair runs out, the yarn of the second cone 30 in that pair will be automatically used due to the fact that the yarn of the second cone 30 has been tied to the yarn of the first cone 30. The re-stocker may then remove the empty cone 30 and replace it with a full cone 30. The yarn from the full cone 30 may then be tied to the yarn of deployed cone 30 so that when the deployed cone 30 is depleted, the supply of yarn will continue from the new cone 30. This may be repeated whilst the carpet is being produced so that there is no downtime of the loom 22 when changing cones 30.

Due to the parallel arrangement of the creel rows 24 and yarn supply locations 21 relative to the yarn consuming locations 23, and the yarns being guided above the height of the creel rows 24, both ends of the creel rows 24 are clear of any extending yarns. Therefore, the re-stocker is free to move around the creel rows 24 without restriction.

Moreover, since the cones 30 can be grouped by yarn colour in the creel rows 24, the restocking is made much more efficient than the traditional yarn storage apparatus. If, for example, a fabric pattern is very heavy on blue, then the blue yarn cones can be pre-loaded and/or replaced at one section of the yarn storage apparatus (rather than the re-stocker having to replace/pre-load one cone at one position of the apparatus and then walk up each creel column 6a to find the next cone of that colour). It also means that extra cones 30 of one colour can be stocked at the side of the creel rows 24 which are storing that colour. Thus, the cones are nearby for the re-stocker to collect and replace/pre-load as necessary.

Claims

CLAIMS: 1. A yarn storage apparatus for supplying yarn to a plurality of yarn consuming locations spaced across the width of a yarn consuming apparatus, the yarn storage apparatus comprising a plurality of creel rows spaced from and arranged to extend substantially parallel to each other, each creel row including a plurality of pegs configured to support a corresponding number of yarn windings, wherein, in use, yarns from yarn windings supported on the pegs of each creel row are drawn along a feed path from a respective peg to a corresponding one of a plurality of yarn supply locations, the plurality of yarn supply locations being spaced along an axis that is substantially parallel to each creel row for presentation to the yarn consuming locations of the yarn consuming apparatus.
2. A yarn storage apparatus according to Claim 1 wherein the plurality of creel rows are located on a level that is higher than the level on which the yarn consuming apparatus is located.
3. A yarn storage apparatus according to Claim 2 wherein the plurality of creel rows are arranged over more than one level, each of which level is higher than the level at which the yarn consuming apparatus is positioned.
4. A yarn storage apparatus according to any one of Claims 1 to 3 comprising a yarn guide assembly positioned between the pegs and the yarn supply locations and being configured to guide yarn, in use, from each peg towards a corresponding yarn supply location.
5. A yarn storage apparatus according to Claim 4 wherein the yarn guide assembly is configured to guide yarn, in use, from each peg to above the associated creel row and then downwards towards a corresponding yarn supply location.
6. A yarn storage apparatus according to Claim 5 wherein the yarn guide assembly includes a plurality of conduits through each of which a yarn, in use, is guided from a respective peg to a corresponding yarn supply location, each conduit extending upwards to a position above the associated creel row and then downwards towards the yarn supply locations.
7. A yarn storage apparatus according to any preceding claim wherein each creel row includes a plurality of pegs in a first row and a plurality of pegs in a second row, the first and second rows being laterally adjacent to one another to define a plurality of laterally adjacent peg pairs spaced along the length of the creel row.
8. A yarn storage apparatus according to any preceding claim wherein each creel row includes more than one creel row level spaced along the height of the creel row, each creel row level including a plurality of pegs spaced along the length of the creel row.
9. A yarn storage apparatus according to any preceding claim comprising an indicator located on each creel row to identify the physical location of one or more pegs.
10. A yarn storage apparatus according to Claim 9 wherein the indicator includes a label encoded with a location identifier, the label being configured to be readable by an electronic reader.
11. A textile manufacturing apparatus comprising a yarn storage apparatus according to any one of Claims 1 to 10 and a yarn consuming apparatus.
12. A textile manufacturing apparatus according to Claim 11 further including a plurality of yarn windings having yarn wound thereon, each yarn winding being supported by one of the pegs of the creel rows, wherein the yarn from the yarn windings is drawn along a feed path from a respective peg to a corresponding one of the plurality of yarn supply locations.
13. A monitoring system for monitoring the restocking of a yarn storage apparatus according to any one of Claims 1 to 10, the monitoring system comprising a controller programmed to calculate the rate of consumption of yarn of each colour for a fabric pattern, the controller being configured to output data from the calculation to a re-stocker, wherein the output data includes a location indicator corresponding to the physical location of a peg of one of the creel rows within the yarn storage apparatus.
14. A method of monitoring restocking of a yarn storage apparatus according to any one of Claims 1 to 10, the method comprising the steps of: i) calculating the rate of consumption of yarn of each colour for a fabric pattern; H) outputting data calculated in step i) to a re-stocker, wherein the data includes a location indicator corresponding to the physical location of a peg of one of the creel rows within the yarn storage apparatus; Hi) restocking one or more yarn windings in response to the output data so as to restock the yarn storage apparatus.
15. A method according to Claim 14 wherein step iii) includes entering the yarn storage apparatus from either end of a creel row. i) restocking one or more yarn windings in response to the output data so as to restock the yarn storage apparatus.
16. A method according to Claim 14 wherein step iii) includes entering the yarn storage apparatus from either end of a creel row.