US20230331511A1 - Yarn handling system - Google Patents
Yarn handling system Download PDFInfo
- Publication number
- US20230331511A1 US20230331511A1 US18/025,091 US202118025091A US2023331511A1 US 20230331511 A1 US20230331511 A1 US 20230331511A1 US 202118025091 A US202118025091 A US 202118025091A US 2023331511 A1 US2023331511 A1 US 2023331511A1
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- US
- United States
- Prior art keywords
- yarn
- fluid
- creel
- package
- control device
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H67/00—Replacing or removing cores, receptacles, or completed packages at paying-out, winding, or depositing stations
- B65H67/04—Arrangements for removing completed take-up packages and or replacing by cores, formers, or empty receptacles at winding or depositing stations; Transferring material between adjacent full and empty take-up elements
- B65H67/0405—Arrangements for removing completed take-up packages or for loading an empty core
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H67/00—Replacing or removing cores, receptacles, or completed packages at paying-out, winding, or depositing stations
- B65H67/02—Arrangements for removing spent cores or receptacles and replacing by supply packages at paying-out stations
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H51/00—Forwarding filamentary material
- B65H51/16—Devices for entraining material by flow of liquids or gases, e.g. air-blast devices
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H54/00—Winding, coiling, or depositing filamentary material
- B65H54/02—Winding and traversing material on to reels, bobbins, tubes, or like package cores or formers
- B65H54/28—Traversing devices; Package-shaping arrangements
- B65H54/34—Traversing devices; Package-shaping arrangements for laying subsidiary winding, e.g. transfer tails
- B65H54/346—Traversing devices; Package-shaping arrangements for laying subsidiary winding, e.g. transfer tails on or outwardly of the fully wound yarn package
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H54/00—Winding, coiling, or depositing filamentary material
- B65H54/70—Other constructional features of yarn-winding machines
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H57/00—Guides for filamentary materials; Supports therefor
- B65H57/003—Arrangements for threading or unthreading the guide
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H61/00—Applications of devices for metering predetermined lengths of running material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H67/00—Replacing or removing cores, receptacles, or completed packages at paying-out, winding, or depositing stations
- B65H67/04—Arrangements for removing completed take-up packages and or replacing by cores, formers, or empty receptacles at winding or depositing stations; Transferring material between adjacent full and empty take-up elements
- B65H67/0405—Arrangements for removing completed take-up packages or for loading an empty core
- B65H67/0411—Arrangements for removing completed take-up packages or for loading an empty core for removing completed take-up packages
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H67/00—Replacing or removing cores, receptacles, or completed packages at paying-out, winding, or depositing stations
- B65H67/04—Arrangements for removing completed take-up packages and or replacing by cores, formers, or empty receptacles at winding or depositing stations; Transferring material between adjacent full and empty take-up elements
- B65H67/0405—Arrangements for removing completed take-up packages or for loading an empty core
- B65H67/0417—Arrangements for removing completed take-up packages or for loading an empty core for loading an empty core
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H67/00—Replacing or removing cores, receptacles, or completed packages at paying-out, winding, or depositing stations
- B65H67/06—Supplying cores, receptacles, or packages to, or transporting from, winding or depositing stations
- B65H67/064—Supplying or transporting cross-wound packages, also combined with transporting the empty core
- B65H67/065—Manipulators with gripping or holding means for transferring the packages from one station to another, e.g. from a conveyor to a creel trolley
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H67/00—Replacing or removing cores, receptacles, or completed packages at paying-out, winding, or depositing stations
- B65H67/08—Automatic end-finding and material-interconnecting arrangements
- B65H67/081—Automatic end-finding and material-interconnecting arrangements acting after interruption of the winding process, e.g. yarn breakage, yarn cut or package replacement
- B65H67/083—Automatic end-finding and material-interconnecting arrangements acting after interruption of the winding process, e.g. yarn breakage, yarn cut or package replacement handling the yarn-end of the new supply package
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- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02H—WARPING, BEAMING OR LEASING
- D02H1/00—Creels, i.e. apparatus for supplying a multiplicity of individual threads
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H2701/00—Handled material; Storage means
- B65H2701/30—Handled filamentary material
- B65H2701/31—Textiles threads or artificial strands of filaments
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H49/00—Unwinding or paying-out filamentary material; Supporting, storing or transporting packages from which filamentary material is to be withdrawn or paid-out
- B65H49/02—Methods or apparatus in which packages do not rotate
- B65H49/04—Package-supporting devices
- B65H49/14—Package-supporting devices for several operative packages
- B65H49/16—Stands or frameworks
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H54/00—Winding, coiling, or depositing filamentary material
- B65H54/02—Winding and traversing material on to reels, bobbins, tubes, or like package cores or formers
- B65H54/22—Automatic winding machines, i.e. machines with servicing units for automatically performing end-finding, interconnecting of successive lengths of material, controlling and fault-detecting of the running material and replacing or removing of full or empty cores
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H54/00—Winding, coiling, or depositing filamentary material
- B65H54/70—Other constructional features of yarn-winding machines
- B65H54/71—Arrangements for severing filamentary materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H57/00—Guides for filamentary materials; Supports therefor
- B65H57/12—Tubes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H57/00—Guides for filamentary materials; Supports therefor
- B65H57/16—Guides for filamentary materials; Supports therefor formed to maintain a plurality of filaments in spaced relation
Definitions
- Carpet making machines are used to manufacture rugs and carpets. Broadly, there are two types of carpet making machine, namely weaving machines and tufting machines.
- small tufting machines utilise a single needle being mounted to a moving needle assemble that translates across the width of the carpet. Accordingly, such machines require only a single supply of yarn. Such smaller tufting machines are particularly suitable for the manufacturer of smaller products and samples.
- new yarn packages are supplied to the locations within the creel manually by a worker who manually restrains a free end or “yarn tail” of the yarn, and delivers this to the creel, where it is threaded through an eye or conduit to the header, where it is typically joined or “spliced” to the previous length of yarn fed therethrough.
- the creel arrangement may provide for two yarn positions for each operation point of the carpet making machine, in which case the new yarn may be connected to the existing yarn within the creel.
- the creel comprises a first side and a second side.
- the first side may comprise a first array of creel positions.
- the second side may comprise a second array of creel positions.
- at least one winder is located adjacent to the first side of the creel and at least one winder is located adjacent to the second side of the creel.
- at least one winder is located adjacent to the first side in an initial orientation and the creel is configured to be rotated such that the first side can be serviced by the winder in the initial orientation and the creel may be rotated such that the second side may be serviced by the winder in a rotated configuration.
- the winder comprises a plurality of winding areas. Each winding area may be adapted to wind a predetermined length of yarn onto a respective empty core. The winder may wind a predetermined length of yarn onto a plurality of empty cores simultaneously.
- the winder may comprise a plurality of heads which can each wind yarn onto an empty core.
- the winder comprises a plurality of magazines adapted to receive empty cores. Each head of the winder or winding area may comprise a respective magazine.
- the magazine may be configured to receive at least one empty core at a time.
- the magazine may be configured to receive a plurality of empty cores simultaneously.
- the winder may comprise a storage buffer adapted to receive a single empty core. Where the winder has a plurality of winding areas, the winder may comprise a plurality of storage buffers each adapted to receive a single empty core.
- the system further comprises a gantry onto which the gripper assembly is connected.
- the gripper assembly may be moveable horizontally and vertically between the creel and the winder on the gantry.
- the gripper assembly is rotatable between a first orientation where the gripping jaw is aligned towards the creel and a second orientation where the gripping jaw is aligned towards winder.
- the gripping jaw is moveable along a longitudinal direction of the gripper assembly towards and away from a creel position when in the first orientation or towards and away from the winder when in the second orientation.
- the gripper assembly and gripping jaw may be moveable and actuated by air pressure and/or may comprise a pneumatic control system.
- each creel position comprises a package holder into which the core of the yarn package is placed.
- the package holder is preferably positioned and sized such that it will not interfere with the gripping jaw of the gripper assembly when the gripper assembly delivers a yarn package to said creel position or when the gripper assembly removes an empty core from said creel position.
- the system further comprises a sensing means.
- the sensing means may comprise a feature recognition camera or sensor.
- the system may comprise a controller.
- the feature recognition camera or sensor may be adapted to recognise and locate each creel position and to send signals to the controller.
- the controller may control the gripper assembly into alignment with a respective creel position when delivering a yarn package or removing an empty core.
- the feature recognition camera or sensor and controller may also control the gripper assembly to align with a magazine or a port of the winder when delivering an empty core to the winder.
- the feature recognition camera or sensor and controller may control the gripper assembly to align the gripper to a wound package on the winder.
- the sensing means may utilise a LiDAR ((light detection and ranging) for accurate positioning of the jaw.
- the sensor may utilise LiDAR.
- Another aspect of the present invention provides a method for handling yarn packages and empty cores, comprising: providing a creel having an array of creel positions, where each creel position is adapted to receive a yarn package; providing a winder configured to receive an empty core, wherein the winder is configured to wind a predetermined length of yarn onto an empty core to create a yarn package, wherein the winder is positioned adjacent to the creel; providing a gripper assembly which is configured to be moveable between the creel and the winder, the gripper assembly having a gripping jaw adapted to grip a yarn package or an empty core; locating an empty core at a creel position; maneuvering the gripper assembly to said creel position and gripping said empty core with the gripping jaw of the gripper assembly; moving the gripper assembly between the creel and the winder; delivering the empty core to the winder; maneuvering the gripper assembly such that the gripping jaw collects a yarn package from the winder; and delivering the yarn package to the creel
- the method further comprises providing a gantry onto which the gripper assembly is connected and adapted to move horizontally and vertically between the creel and the winder.
- the gripper assembly is rotatable on the gantry between a first orientation where the gripping jaws face the creel and a second orientation where the gripping jaws face the winder.
- the gripper assembly moves on the gantry to the creel position corresponding to the empty core.
- the gripping jaw in a closed position may move in a longitudinal direction of the gripper assembly towards the empty core, the gripper jaw may actuate to an open position and engage the inner surface of the empty core.
- the empty core may be removed from its respective creel position, once gripped by the gripping jaw, by moving the gripping jaw in a direction opposite to said longitudinal direction, in other words away from the respective creel position.
- the gripping jaw in a closed position may move in a longitudinal direction of the gripper assembly towards the yarn package, the gripper jaw may actuate to an open position and engage the inner surface of the yarn package.
- the invention is directed to a yarn control system for delivering a yarn tail of a yarn to a receiver, comprising: a moveable body configured to capture the yarn and guide the yarn to an operative region of the body; an inlet for introducing a first fluid into the body; a first fluid outlet located in proximity to the operative region of the body, and oriented to expel the first fluid in a first fluid flow; and a moveable member within the body that moves between an operative configuration and an inoperative configuration; and a nozzle having a second fluid outlet that expels a second fluid in a second fluid flow towards the receiver; wherein in the operative configuration the yarn is clamped in the operative region of the body such that the first fluid flow captures the yarn tail and orients the yarn tail coaxially with the first fluid flow, and in moving the movable body the first fluid flow is reoriented to intersect the second fluid flow, such that the second fluid flow expels the entrained yarn tail from the first fluid flow thereby delivering the yarn tail to the receiver.
- a gripper assembly is configured to be moveable between the creel and the winder, the gripper assembly comprising a gripping jaw adapted to grip the package or empty core, the gripper assembly configured to: (i) remove an empty core from a designated creel position and deliver the empty core to the winder; and (ii) remove a yarn package from the winder and deliver the package to a designated creel position.
- the yarn is removed from the yarn package by being fed from the designated creel position to a header plate or header.
- the yarn is fed to the receiver in the form of a conduit or tube in the centre of the designated creel position and fed therethrough to the header.
- each designated creel position comprises a housing or package holder into which the yarn spool is located and supported.
- the housing is preferably positioned and sized such that it will not interfere with the loading members of the gripper assembly when the gripper assembly delivers the yarn package to the designated creel position or when the gripper assembly removes an empty core from the designated creel position.
- the housing may be a loading tube.
- the creel may comprise an array of loading tubes each of which encircle a designated creel position and receive and support the yarn package or empty core at the designated creel position.
- the housing may further comprise a locating boss or bracket for supporting and retaining the yarn package thereon.
- the housing may house the conduit or tube.
- the conduit may be centrally located in the housing to support the yarn spool and to allow the yarn to be fed from the loading face of the creel to an opposing face thereof.
- the gripper assembly is moveable horizontally and vertically between the creel and winder such that gripper assembly may remove an empty core from any creel position in the array or deliver a yarn package to any creel position in the array.
- the system further comprises a gantry onto which the gripper assembly is mounted.
- the gripper assembly may be moveable horizontally and vertically between the creel and the winder on the gantry.
- the gripper assembly may have telescoping movement to allow the gripper assembly to extend and retract.
- the gripper assembly may be configured to operate in three degrees of freedom.
- the gripper assembly may be mounted to allow rotation thereof. The rotation may be in a horizontal plane. The rotation may be in a vertical plane.
- the gripper assembly is rotatable between a first orientation where the gripping jaw is aligned towards the creel and a second orientation where the gripping jaw is aligned towards the winder.
- the gripper assembly may be moveable along a longitudinal direction of the gripper assembly towards and away from a designated creel position, when in a first orientation, or towards and away from the winder, when in a second orientation.
- the gripper assembly may be moveable and actuated by air pressure and/or may comprise a pneumatic control system or may be electronically actuated.
- a method for loading yarn packages into a creel comprising: winding a length of yarn onto an empty core in a winder to create a yarn package; capturing the yarn package with a gripper assembly configured to move between the creel and the winder, the gripper assembly adapted to grip the yarn package and comprising a yarn control device, wherein the yarn control device captures and retains a yarn tail of the yarn package; moving the gripper assembly adjacent to the creel and delivering the yarn package to an empty creel position; and activating the yarn control device to urge the yarn tail toward the receiver.
- Yet another aspect of the present invention provides a method for loading yarn packages into a creel and threading the yarn tail through the creel, comprising: winding a length of yarn onto an empty core in a winder to create a yarn package; capturing the yarn package with a gripper assembly configured to move between the creel and the winder, the gripper assembly adapted to grip the yarn package and comprising a yarn control system, wherein the yarn control system captures and retains a yarn tail of the yarn package; moving the gripper assembly adjacent to the creel and delivering the yarn package to a designated creel position; and activating the yarn control system to direct the yarn tail toward the receiver of the designated creel position and threading the yarn tail through the receiver of the designated creel position.
- the receiver may be a conduit of the creel.
- the conduit may be a central tube.
- a plurality of central tubes may be dispersed across the creel, each central tube defining a designated creel position.
- the central tube of each creel position may be bounded by a housing or loading tube for protecting the yarn package therein.
- the yarn package may be coaxially located on the central tube, to facilitate feeding of the yarn from the spool through the central tube to a working face of the creel.
- the conduit may direct the yarn tail through the yarn package to a working face of the creel.
- the yarn package is loaded from a loading face of the creel.
- the loading face may oppose the working face of the creel. In some embodiments the loading face or the creel is also the working face.
- the receiver may be an eye or eyelet for receiving the yarn tail.
- the receiver may be a header or header box, for storing a plurality of yarn tails of a loaded creel.
- the invention provides a method of controlling a feed of yarn from a yarn package to an outlet, comprising: determining a length of a yarn feed path extending between a package holder to which the yarn package is attached during production of a yarn product and the outlet; winding a first span of yarn onto an empty core with a winding machine to form a wound core; winding a second span of yarn onto the wound core to form the yarn package, the second span having a length equal to or slightly greater than the length of the yarn feed path; and selectively feeding a tail end of the yarn package along the yarn feed path to the outlet, such that only the second span of yarn is dispensed from the yarn package.
- the winding of the first span of yarn may be an angled winding, the first span of yarn traversing along the empty core from a first end of the empty core to a second end of the empty core.
- the angled winding may be a helical winding, the first span of yarn repeatedly traversing between the first and second ends of the empty core.
- the winding of the second span of yarn may be a straight winding, the second span of yarn concentrating within a portion of the wound core.
- the straight winding may be concentrated within a substantially central portion of the wound core.
- the package holder may be one of a plurality of package holders, each of the plurality of package holders having a different yarn feed path, the method further comprising the step of defining a designated package holder to which the yarn package is to be attached, prior to determining the length of the yarn feed path.
- the plurality of package holders may be provided within a creel.
- the method may further comprise the step of transporting the yarn package from the winding machine to the designated package holder.
- the transporting of the yarn package may involve the use of an automated gripper, the automated gripper picking up the yarn package from the winding machine and attaching the yarn package to the designated package holder.
- the feeding of yarn from the yarn package may comprise applying a tension force to the tail end of the yarn package and feeding the tail end along the yarn feed path to the outlet.
- the feeding of yarn may comprise applying a frictional force to the first span of yarn with a yarn brake, to thereby inhibit dispensing of the first span of yarn from the yarn package.
- the yarn brake may be attached to a or the automated gripper, the automated gripper transporting the yarn package from the winding machine to the package holder.
- the yarn brake provides a simple mechanism for restricting the feeding of yarn from the yarn package.
- the method may further comprise the step of defining the total length of yarn required to produce the product and calculating the first span of yarn such that the first and second spans of yarn together provide the total length of yarn.
- the invention provides a yarn brake for controlling a feed of yarn from a yarn package to an outlet, the yarn package being attached to a package holder and comprising a core around which first and second spans of yarn are wound, the yarn brake including a frictional element moveable between a disengaged position, in which the frictional element does not contact the yarn package, and an engaged position, in which the frictional element engages with the first span of yarn, such that with the yarn brake in the engaged position, application of a tension force to a tail end of the yarn package results in only the second span of yarn being dispensed from the yarn package, the second span of yarn having a predetermined length calculated to feed the tail end along a yarn feed path extending from the package holder to the outlet.
- the length of the second span of yarn is of a predetermined length related to the yarn feed path, the amount of excess yarn wound onto the yarn package can be reduced. Furthermore, by feeding out only the measured second span of yarn, yarn protruding beyond the outlet is reduced, thereby reducing the risk of entanglement with neighbouring yarns or other objects.
- the frictional element may be engageable with the core when the first and second spans of yarn have been dispensed from the yarn package.
- the yarn brake is configured to interact with yarn packages having varied external diameters, resulting from different amounts of yarn being wound thereon.
- the frictional element may engage with the first span of yarn towards an opposite end of the yarn package with respect to an end of the yarn package from where the yarn is being dispensed.
- the frictional element may be pivotably moveable between the disengaged position and the engaged position.
- the frictional element may be removably insertable into a slot of a housing of the package holder.
- the package holder is one of a plurality of package holders provided within a creel, the yarn brake being moveable between each of the package holders.
- the yarn brake may be incorporated within or attachable to an automated gripper, the automated gripper being adapted to load the yarn package into the creel. By attaching the yarn brake to the automated gripper, the yarn brake is easily implemented into existing automated yarn handling systems.
- the invention provides a system for controlling a feed of yarn from a yarn package to an outlet, comprising: a winding machine configured to wind a first span of yarn and a second span of yarn onto an empty core to form a yarn package; a package holder configured to hold the yarn package during production of a yarn product; and a yarn brake configured to selectively engage with the yarn package; wherein the second span of yarn has a predetermined length calculated to feed a tail end of the yarn package along a yarn feed path extending from the package holder to the outlet, such that when the yarn brake engages with the first span of yarn, application of a tension force to the tail end results in only the second span of yarn being dispensed from the yarn package.
- the system may further comprise an automated gripper to transport the yarn package between the winding machine and the package holder.
- the yarn brake may be incorporated within or attached to the automated gripper.
- the package holder may be one of a plurality of package holders provided within a creel.
- the creel may be a mobile creel.
- the outlet may be one of a plurality of outlets provided within a header, each outlet being associated with a corresponding package holder.
- FIG. 1 A shows a perspective view of a creel, winder, winder supply store and gantry assembly according to an embodiment
- FIG. 1 B shows a side view of a creel, winder, winder supply store and gantry assembly according to an embodiment
- FIG. 1 C shows a top view of a creel, winder, winder supply store and gantry assembly according to an embodiment
- FIG. 1 D shows an end view of a creel, winder, winder supply store and gantry assembly according to an embodiment
- FIG. 2 A is a front perspective view of the creel of the yarn feeding system of FIG. 1 , showing a plurality of package holders;
- FIG. 2 B is a rear perspective view of the creel of FIG. 2 A ; showing a flexible conduit extending from a rear aperture of a package holder to an outlet within a header;
- FIG. 3 A is a perspective view of a package housing, having a conduit centrally located therein;
- FIG. 3 B is an end view of the package housing of FIG. 3 A , illustrating a central boss or mounting bracket for mounting the core of the package, such that the core is coaxially located on the mounting bracket within the housing;
- FIG. 4 A shows a perspective view of a package gripper according to an embodiment
- FIG. 4 B shows a front view of the package gripper with the jaw closed according to an embodiment
- FIG. 4 C is a front view of the gripper assembly of FIG. 4 A , showing the jaw in a closed configuration
- FIG. 4 D is a front view of the gripper assembly of FIG. 4 B , showing the jaw in an open configuration
- FIG. 5 A is a perspective view of a yarn control device according to a first embodiment, illustrating a body of the device having three supply ports supplying fluid thereto;
- FIG. 5 B is a sideview of the yarn control device of FIG. 5 A , illustrating a sectional view of the operative region of the body in a first “open” mode;
- FIG. 5 C is a sideview of the yarn control device of FIG. 5 A , illustrating a sectional view of the operative region of the body in a second “clamped” mode of operation;
- FIG. 6 A is a perspective view of the yarn control device of FIG. 5 A , illustrating a yarn tail extending through an operative region of the body when no fluid is flowing through the body;
- FIG. 6 C is a perspective view of the yarn control device of FIG. 5 A , illustrating a yarn tail extended through an operative region of the body;
- FIG. 7 A is a sideview of a yarn control device according to a second embodiment, illustrating a first fluid outlet in proximity to the operative region of the body;
- FIG. 7 B is a side view of the yarn control device of FIG. 7 A , illustrating a moveable member traversing the operative region of the body for restraining a yarn to the body;
- FIG. 8 A is a cross-sectional front view of the yarn control device of FIG. 7 A , illustrating the first fluid outlet in fluid communication with an internal bore of the body;
- FIG. 8 B is a cross-sectional side view of the yarn control device of FIG. 7 A , illustrating a first and a second moveable member located within a respective chamber of the body to reciprocate back and forth towards the operative region of the body, both moveable members are illustrated in an inoperative configuration;
- FIG. 8 C is a cross-sectional side view of the yarn control device of FIG. 7 A , illustrating the first moveable in an operative configuration whereby a head of the first moveable member is urged into contact with a head of the second moveable member to form an aperture for restraining the yarn therein;
- FIG. 8 D is a cross-sectional side view of the yarn control device of FIG. 7 A , illustrating the first moveable in an inoperative configuration and the second moveable member in an operative configuration, whereby a head of the second moveable member is urged into the operative region of the body to clamp the yarn thereto;
- FIG. 9 A is a schematic view of the body and yarn being brought into proximity with each other;
- FIG. 9 B is a schematic view of a pair of angled jaws that direct the yarn towards an operative region of the body, entrapping the yarn therein;
- FIG. 9 C is a schematic view of the yarn restrained within the operative region of the body, such that the yarn can traverse the operative region;
- FIG. 9 D is a schematic view of the yarn clamped against the operative region of the body, such that the yarn cannot move;
- FIG. 10 is a schematic view of a lance head having a nozzle adapted to propel a second fluid flow, illustrating a yarn tail crossing into the second fluid flow and becoming entrained therewith;
- FIG. 11 A illustrates is a cross-sectional side view initial stage of a yarn feeding process, showing a yarn brake in a disengaged position
- FIG. 11 B illustrates the yarn brake of FIG. 11 A in an engaged position
- FIG. 11 C Is a perspective view illustrating the yarn brake of FIG. 11 A in the disengaged position and coupled to the gripper assembly of FIG. 4 A ;
- FIGS. 12 A to 12 D show a side view of the package gripper removing an empty core from a package holder of a creel
- FIGS. 13 A to 13 C show a side view of the package gripper transferring the empty core to the winder
- FIG. 14 A is a perspective view of a core, to be wound by the winding machine of FIG. 1 ;
- FIG. 14 B is a perspective view of a wound core, the core of FIG. 14 A having been wound with a first span of yarn;
- FIG. 14 C is a perspective view of a yarn package, the wound core of FIG. 14 B having been wound with a second span of yarn;
- FIG. 15 A is a rear view of the creel of FIG. 2 A , showing a first yarn feed path from a first package holder to a first outlet within the header, and a second yarn feed path from a second package holder to a second outlet within the header;
- FIG. 15 B is a side view of the creel of FIG. 2 A , showing first and second portions of the first and second yarn feed paths;
- FIGS. 16 A to 16 F show an end view of the package gripper removing a yarn package from the winder
- FIG. 17 A is an enlarged view of the winding machine or winder doffing the yarn tail
- FIG. 17 B is a view of a wound yarn spool with the yarn control device gripping the yarn tail of the yarn on the package;
- FIG. 18 is a perspective view of the gripper assembly of FIG. 4 A , illustrating the yarn control device mounted thereon;
- FIGS. 19 A- 19 E are side views of the gripper assembly loading a yarn package into a housing of the creel and threading the yarn tail through the conduit of the housing, wherein:
- FIG. 19 A illustrates the gripper assembly approaching the package housing, with the yarn grasped by the yarn control device
- FIG. 19 B illustrates the yarn package being moved towards the support boss within the housing, with the yarn still held by the jaws of the yarn control device;
- FIG. 19 C illustrates the yarn package being mounted on the support boss within the housing, with the yarn still constrained by the yarn control device
- FIG. 19 D illustrates the body of the yarn control device having rotated 180 degrees to direct the yarn tail across the inlet of the conduit to intersect the second fluid flow from the lance;
- FIG. 19 E illustrates the yarn threaded through the conduit of the housing, such that the yarn tail protrudes from the housing as the yarn control device is rotated back 180 degrees and the gripper assembly is retracted to retrieve either of: a new yarn package from the winder; and an empty core from the creel;
- FIG. 20 A is a side view of the conduit within the housing and a second fluid outlet mounted on a lance, illustrating the second fluid outlet aligned with an opening of the conduit;
- FIG. 20 B is a sectional view of the conduit aligned with the lance of FIG. 20 A ;
- FIG. 20 C is an enlarged view of a conduit opening aligned with the second fluid outlet to receive the yarn tail;
- FIG. 21 A illustrates the yarn control device holding the yarn tail in proximity to the package housing of the creel, and a lance of the gripper assembly aligned with an inlet of the conduit;
- FIG. 21 B illustrates the yarn tail fed into the inlet and through the conduit by a second fluid flow expelled from the lance towards the conduit inlet;
- FIG. 21 C is a schematic view of the yarn travelling through a conduit of the housing on a creel, the yarn tail being captured by a covered header plate;
- FIG. 22 A illustrates an initial stage of a yarn feeding process, showing the yarn brake of FIG. 11 A in the disengaged position proximate a yarn package;
- FIG. 22 B illustrates a subsequent stage of the yarn feeding process, showing the yarn brake in an engaged position, with yarn being fed from the yarn package under tension;
- FIG. 22 C illustrates a further stage of the yarn feeding process, showing the yarn brake in an engaged position, inhibiting further feeding of yarn
- FIG. 22 D illustrates a final stage of the yarn feeding process, illustrating the yarn brake moving to an inoperable position, after the feeding of yarn has been completed.
- the term “yarn” is understood to be a continuous strand composed of either natural or man-made fibres or filaments and used in weaving, tufting, sewing and knitting.
- the term is intended to be synonymous with the term, thread, fibre, string, filament, twine, strand, ply, cord, line, wool or cotton and the like.
- yarn package is understood to mean a core that is would with a known, predetermined amount of yarn that is used to supply a machine for producing yarn-based products including textiles, for example soft floor coverings such as carpet and rugs.
- the term is intended to be synonymous with the terms: spool, bobbin, cone and the like.
- axis and movements in the X, Y and Z directions are to be understood generally as horizontal, longitudinal and vertical movements respectively.
- some of the accompanying Figures include an indicator to mark the respective orientations.
- FIGS. 1 A to 1 D show a yarn handling system 1 comprising a creel 10 and a winder 40 .
- the yarn handling system 1 further comprises a gripper assembly 70 , that is used to transfer yarn packages 30 between the winder 40 and creel 10 , to facilitate loading and unloading of the creel 10 .
- the gripper assembly 70 is connected to a gantry 50 , so as to be moveable between the creel 10 and winder 40 .
- the yarn packages 30 comprise a core 31 around which a quantity of yarn 32 is wound. The yarn packages 30 are discussed in detail below with reference to FIGS. 14 A to 14 C .
- the creel 10 shown in the Figures is a mobile creel comprising a creel frame 11 and wheels 12 .
- the frame 11 holds the elements of the creel 10 together.
- the creel 10 is a double-sided creel, having two sides, a first side 13 and a second side 14 , each side comprising an array of creel positions.
- Each side 13 , 14 of the creel 10 has an outwardly facing loading face 13 a , 14 a , respectively, and an inwardly facing non-loading face 13 b , 14 b , respectively.
- the loading and non-loading faces are indicated in FIG. 1 C .
- Each loading face 13 a , 14 a comprises an array of package holders 20 for receiving a designated yarn package 30 therein.
- the creel 10 could, alternatively, be a single sided creel, as shown in FIGS. 2 A and 2 B , with the creel positions each being disposed on a first side 13 thereof.
- the second side 14 is considered to be a non-loading side of the creel 10 .
- Each creel position comprises a package holder 20 , for receiving and supporting a yarn package 30 .
- the package holders 20 are arranged in a hexagonal array.
- Each package holder 20 comprises a mounting bracket 21 sized and shaped to receive a core 31 of the yarn package 30 , and a housing 22 .
- the housing 22 comprises a tube that at least partially encircles the mounting bracket 21 .
- the housing 22 is open at one end, extending to a closed end disposed on a non-loading face of the creel 10 .
- the housing 22 serves as a protective shield for the yarn package 30 contained therein, reducing the possibility of debris from falling thereon, and preventing yarn tails 33 of the yarn package 30 from dropping into an adjacent package holder 20 below and becoming entangled with an adjacent yarn package 30 .
- Such entanglements take time to clear and would otherwise cause the carpet making machine to be shut off while the problem is assessed, and the entangled yarn is cleared, reducing the productivity of the system 1 as a whole.
- each housing 22 extends circumferentially around a respective package holder 20 . It is noted, however, that housings 22 only need to partially surround each package holder 20 , in order to catch the yarn tail 33 from the yarn package 30 therein falling under gravity towards an adjacent package holder 20 .
- the mounting bracket 21 is configured to receive and support the yarn package 30 thereon.
- the mounting bracket 21 is located centrally within the housing 22 and towards a closed end thereof.
- the mounting bracket 21 comprises a central plinth 21 a configured to contact an inner surface 31 a of the core 31 of the yarn package 30 (see, for example, FIGS. 11 A and 11 B ), and may include a resilient member 21 b to engage the yarn package 30 and removably hold it in place.
- the mounting bracket 21 is sized such that it does not contact a full length of the yarn package 30 .
- each package holder 20 further comprises a yarn conduit 24 through which a respective yarn tail 33 travels towards an outlet 60 .
- the outlet 60 receives the respective yarn tail 33 from the yarn package 30 , and supplies the yarn to the production machine.
- the yarn conduit 24 includes a rigid conduit 24 a that extends from a central opening 25 through which the yarn is drawn to a terminal aperture 23 disposed within a non-loading face of the creel 10 .
- the opening 25 protrudes outwardly from the open end of the housing 22 , such that the yarn conduit 24 extends therefrom, when viewed in a side profile.
- the yarn conduit 24 passes through the central plinth 21 a of the mounting bracket 21 .
- the rigid conduit 24 a can be a plastic material or a metal such as steel or aluminium.
- the rigid conduit 24 a preferably has an internal diameter of between 2 mm and 6 mm, and preferably about 4.8 mm
- the rigid conduit 24 a guides the yarn tail 33 through the housing 22 to exit the housing 22 at an aperture 26 , where the yarn tail 33 enters the flexible conduit 24 b which guides the yarn tail 23 to the outlet 60 .
- the flexible conduit 24 b is a tube or a hose and can be made from plastic and other resilient materials synthetic or otherwise.
- the flexible conduit 24 b can be transparent to allow the yarn tail 33 to be visible as it exits the rigid conduit 24 a . This can provide a visual inspection point to assess the yarn tail's 33 progress along the flexible conduit 24 b.
- bespoke conduits 24 can be individually dimensioned as rigid conduits that run through the housing 22 and up to the outlet 60 thereby replacing flexible conduits 24 b ; however, for ease of manufacture the combination of rigid 24 a and flexible 24 b portions is preferred.
- the outlet 60 is one of a plurality of outlets provided within a header 61 , with each outlet 60 being associated with a respective package holder 20 within the creel 10 .
- the Header 61 is attached to the creel 10 .
- the header 61 comprises a header plate 62 within which each of the plurality of outlets 60 are disposed.
- the header plate 62 is enclosed by a header cover 63 .
- the header cover 63 is moveable between an open position to a closed position.
- the header cover 63 is made of a perforated or screen-type material, allowing air to flow though the header cover 63 , while the yarn tails 33 remain contained therein.
- the header cover 63 is configured to capture and restrain the yarn tails 33 during, for example, transportation of the creel 10 .
- the yarn tails 33 are constrained therein preventing them from interfering with the operation of loading further packages 30 into the creel 10 .
- the header cover 63 In the open position, the header cover 63 provides access to the yarn tails 33 for connecting to the production machine via, for example, splicing of the tails 33 to the machine for use.
- the open configuration of the header cover 63 is also shown in broken line in FIG. 21 D .
- the winder 40 is located adjacent to the first side 13 of the creel 10 .
- a plurality of winders 40 may be located adjacent to the first side 13 of the creel 10 .
- one or more winders 40 may be located adjacent to the second side 14 of the creel 10 .
- the winder 40 includes three winding heads 41 .
- Each winding head 41 is the area of the winder 10 where yarn is wound onto a core 31 to form a yarn package 30 .
- the winder 40 may be controlled by a user or may be automated to select a desired length of yarn to be wound onto each core 31 .
- the length of yarn wound on a particular yarn package 30 is calculated based on the amount of yarn required at the respective package holder 20 where the yarn package 30 will be placed. Accordingly, some yarn packages 30 may comprise more yarn than other yarn packages 30 .
- a winder supply store 43 is located adjacent to the winder 40 .
- the winder supply store 43 has at least one yarn supply 44 that provides yarn to each winding head 41 , when desired.
- the yarn supply store 43 comprises a plurality of yarn supplies 44 in the form of large packages of yarn.
- Each yarn supply 44 may provide yarn in a desired colour.
- Each winding head 41 may be supplied by a distinct yarn supply 44 relative to the other winding heads 41 .
- At least one winder 40 and gantry frame 50 may be located respectively adjacent to each of the first and second sides 13 , 14 of the creel 10 respectively.
- the or each winder 40 may be located adjacent to the first side 13 of the creel 10 only, such as shown in FIGS. 1 A to 1 D .
- only one side 13 , 14 of the creel 10 may be serviced by the handling system 1 at a time.
- the first side 13 may be filled with yarn packages 20 initially.
- the entire creel 10 may be rotated such that the second side 14 is located adjacent to the winder 40 (i.e. in the position previously of the first side 13 shown in FIGS. 1 A to 1 D ).
- the second side 14 may then be filled with yarn packages 30 and/or empty cores 31 removed therefrom, where necessary.
- the creel 10 is preferably fixedly held in each position, such that the respective side 13 , 14 that is adjacent to the winder 40 is positioned in a known location relative to the winder 40 , which is also fixedly held in position.
- the winder 40 may comprise a storage buffer 42 configured to hold a single empty core 31 .
- the winder 40 may comprise three storage buffers 42 (best shown in FIG. 17 a ) which each serve one of the winding heads 41 , respectively.
- the storage buffer 42 enables an empty core to be wound while another empty core is being delivered to the winder 40 at the same time.
- Each storage buffer 42 may be provided with an empty core 31 by a port in the side wall of the winder 40 , through which an empty core 31 may be inserted.
- the empty core 31 in the storage buffer may be lifted within the winder 40 to the winding head 41 .
- the storage buffer 42 may be a magazine which is adapted to hold a plurality of empty cores 31 .
- An empty core 31 will be passed from the magazine to a winding head 41 when it is required for forming a new yarn package 30 .
- the winding heads 41 may share a common magazine or, preferably, each winding area 41 may comprise its own distinct magazine, such that, for example, where there are three winding heads 41 there may be three magazines.
- the magazine may comprise a port which is sized to receive the empty cores 31 .
- the empty cores 31 will be held in line in the magazine and sent to the winding head 41 in order when a new yarn package 30 is required.
- Brackets 54 are attached at spaced apart locations to the longitudinal members 52 .
- the brackets 54 are positioned on the inner side of the longitudinal members 52 such that each bracket 54 on one longitudinal member 52 faces towards a bracket 54 on the other longitudinal member 52 .
- an upper rail 55 is attached at either end to brackets 54 , such that the upper rail 55 extends horizontally between adjacent longitudinal members 52 .
- a lower rail 56 is located directly below the upper rail 55 , extending horizontally between longitudinal members 52 .
- the lower rail 56 is preferably rigidly held in place on the ground, such as via bolts or other appropriate fastening devices.
- FIG. 1 A there is only a single upper 55 34 located outwardly of the first side 13 of creel 10 , however it is envisaged that another upper rail 55 could be located between the brackets 54 of the longitudinal members 52 outwardly of the second side 14 of the creel 10 . Similarly, another lower rail 56 would be located beneath the second upper rail (not shown).
- a vertical rail 57 extends between the upper and lower rails 55 , 56 .
- the vertical rail 57 is moveably connected to each of the upper and lower rails 55 , 56 , such that the vertical rail 57 may move along the X-direction, as shown in the Figures.
- the upper end of the vertical rail 57 comprises an upper platform 55 a and the lower end of the vertical rail 57 comprises a lower platform 56 a .
- the upper platform 55 a comprises rollers 55 b which engage with a track 55 c in the upper rail 55 .
- the lower platform 56 a comprises rollers 56 b which engage with a track 56 c of the lower rail 56 .
- a platform 57 a is moveably connected to the vertical rail 57 .
- the vertical platform 57 a has rollers 57 b which engage with a track 57 c of the vertical rail 57 such that the vertical platform 57 a is moveable vertically along the length of the vertical rail 57 .
- a vertical motor 57 d controls the motion of the vertical platform 57 a .
- the vertical motor 57 d preferably functions in a similar manner to the upper and lower motors 55 d , 56 d . Any one or more of the motors 55 d , 56 d , 57 d may cooperate with a rack and pinion and bearing arrangement to accurately control the movement of the vertical rail 57 and/or vertical platform 57 a.
- An arm rail 58 is attached to the vertical platform 57 a .
- the arm rail 58 extends longitudinally in the Y-direction as shown in FIGS. 1 A and 10 .
- a rotatable connector 58 a is adapted to be moveable longitudinally along the arm rail 58 in the Z-direction.
- the rotatable connector 58 a may have rollers 58 b which engage with tracks 58 c on the arm rail 58 .
- the rotatable connector 58 a may comprise a connector motor 58 d which controls the movement of the rotatable connector 58 a along the arm rail 58 .
- the gripper assembly 70 is connected to the gantry frame 50 via the rotatable connector 58 a in a manner such that it is moveable vertically, horizontally, and rotatably.
- the gripper assembly 70 is preferably moveable between any of the package holders 20 of the first side 13 of the creel 10 and may provide a yarn package 30 to or retrieve an empty core 31 from a respective package holder 20 , when required to do so.
- the gripper assembly 70 may be manipulated and positioned to provide an empty core 31 to or retrieve a wound yarn package 30 from the winder 40 .
- a single gripper assembly 70 is moveable along the gantry 50 relative to the first side 13 of the creel 10 and winder 40 .
- the system 1 may include a second winder 40 ′ on the first side 13 of the creel 10 .
- the second winder 40 ′ will preferably be serviced by a second gripper assembly 70 ′, also coupled to the gantry 50 .
- a second vertical rail 57 ′ being moveable horizontally on the upper and lower rails 55 , 56 , preferably in a similar manner as already discussed in relation to the vertical rail 57 .
- each gripper assembly 70 may respectively be moveable on the gantry 50 between its respective winder 40 and half of the package holders 20 at one end of the creel 10 most proximal to the respective winder 40 .
- the gripper assembly 70 connects to a side of the rotatable connector 58 a opposite to the arm rail 58 .
- the gripper assembly 70 is rotatably connected to the rotatable connector 58 a in a manner such that the gripper assembly 70 may be rotated between a first orientation where a front end 71 of the gripper assembly 70 faces towards the creel 10 in the Y-direction and a second position where the front end 71 of the gripper assembly 70 faces towards the winder 40 in the Y-direction.
- the movement of the rotatable connector 58 a in the Y-direction may cause the gripper assembly 70 to move towards or away from the creel 10 when in the first orientation.
- the movement of the rotatable connector 58 a in the Y-direction may cause the gripper assembly 70 to move towards or away from the winder 40 in the second orientation.
- the connector motor 58 d may control the rotation of the gripper assembly 70 between the first and second orientations.
- the gripper assembly 70 may comprise a separate motor which controls the rotation between the first and second orientations.
- the rotation of the gripper assembly 70 may be pneumatically controlled and may comprise hydraulic bump stops.
- two winders 40 may be positioned on each side 13 , 14 of the creel.
- two winders 40 are positioned adjacent to the first side 13 of the creel 10 and a further two winders 40 are positioned adjacent to the second side 14 of the creel 10 .
- the winders 40 are preferably located at opposing ends of the creel 10 .
- a second upper rail and a second lower rail are located adjacent the second side 14 of the creel 10 between the creel 10 and the two winders 40 .
- the gantry 50 may comprise two vertical rails 57 , each being moveable horizontally on respective upper and lower rails 55 , 56 .
- Two gripper assemblies 70 are thus moveable vertically and horizontally and rotatably on the respective vertical rails 57 on each side of the gantry 50 , with each gripper assembly 70 being moveable on the gantry 50 between its respective winder 40 and the half of the package holders 20 of the respective side 13 , 14 located towards the end of the creel 10 most proximal to the respective winder 40 .
- the head 74 has four tabs 74 a which extend in the longitudinal direction towards the front end 71 of the gripper assembly 70 .
- the tabs 74 a are evenly spaced around the circumference of the head 74 .
- the snout 75 comprises four ribs 75 a which are parallel to the tabs 74 a and extend longitudinally along the surface of the snout 75 .
- the gripper assembly 70 further comprises four fingers 76 .
- the four articulated fingers 76 extend along the snout 75 .
- Each tab 74 a is connected to each finger 76 at the rear of the respective finger 76 via two connectors 77 , with a connector 77 located on either side of the tab 74 a .
- Each finger 76 is connected to the respective rib 75 a via two connectors 70 towards the front of the finger 76 with, one connector 77 a,b on either side of the finger.
- Each finger 76 is also coupled to the respective rib 75 a via two additional connectors 70 c , 70 d towards the rear of the finger 76 on either side of the finger 76 .
- the connectors 77 pivotally couple each of the respective fingers 76 to the respective ribs 75 a and tabs 74 b .
- the location of the pivotal connectors 77 are such that a longitudinal motion of the snout 75 relative to the head 74 will cause the fingers 76 to move radially relative to the snout 55 .
- the described arrangement of the head 74 , snout 75 , fingers 76 , ribs 74 a , tabs 75 a and connectors 70 create a gripping jaw 78 which may be utilised to grasp the inner surface 31 a of a yarn package 30 .
- the jaw assembly 78 is configurable between a closed state, in which the fingers 76 lie against the snout 75 , to an open state, in which the fingers 76 extend radially outwards and do not contact the snout 75 .
- FIG. 4 C shows the jaw assembly 78 in the closed state
- FIG. 4 D shows the jaw assembly 78 in the open state.
- the jaw of a diameter defined by the assembly 78 is indicated in dashed outline.
- the fingers 76 are positioned radially inwards adjacent to the ribs 75 a .
- the fingers 76 are positioned radially outwards away from the ribs 75 a.
- the jaw assembly 78 is configured to grasp onto the core package 30 from within the core 31 , to facilitate transport thereof. With the jaw assembly 78 in the closed state, the head 74 is driven forward and the snout 75 is inserted into the core 30 . The jaw assembly 78 is then expanded to the open state, where the fingers 76 push outwardly against the inner surface 31 a of the core 31 . With the yarn package 30 now secured to the jaw assembly 78 , the head 54 is retracted, removing the yarn package 30 from the winding machine 40 .
- the gripping action of the jaw 48 may be a reverse chuck arrangement.
- the snout 75 may be moved longitudinally relative to the head 74 .
- the connectors 70 interact with the respective tabs 74 a , ribs 75 b and fingers 76 to cause a radial motion of the fingers 76 .
- the snout 75 moves longitudinally towards the front end 71 the fingers 76 will each move radially outwards from the snout 75 .
- the snout 75 then moves longitudinally towards the rear end 72 , the fingers 76 will each move radially inwards relative to the snout 75 .
- a pressurised fluid such as pressurised air, may be utilised to cause a movement of the jaw 78 .
- the motion of the fingers 76 of the jaw 78 radially inwards or outwards may be controlled by a controller.
- the gripper assembly 70 includes a pneumatic cylinder 79 .
- the pneumatic cylinder 79 is located adjacent to the gripper body 73 and extends longitudinally from the rear 72 towards the front end 71 of the gripper assembly 70 .
- Application of compressed air may cause a piston rod 79 a to extend longitudinally outwards from the pneumatic cylinder 79 .
- the head 74 is connected to the front of the piston rod 79 a such that the head 74 and jaw 78 will move longitudinally when the piston rod 79 a extends from the pneumatic cylinder 79 .
- the jaw 78 may be placed into a desired location, such as when collecting a yarn package 30 from the winding area 41 , delivering a yarn package 30 to a package holder 20 , when collecting an empty core 31 of a yarn package 30 from a package holder 20 , or when delivering an empty core 31 to the winder 40 .
- the gripper assembly 70 or creel 10 may comprise a sensor and/or camera (not shown).
- the gripper assembly 70 or creel 10 may comprise a feature recognition camera that is configurable to align the jaw 78 .
- the camera(s) or sensor(s) used may at least identify the corners of the creel 10 in order to manoeuvre and align the jaw 78 correctly with a desired package holder 20 .
- the camera(s) or sensor(s) may be configured to identify each package holder 20 individually for accurate alignment.
- camera(s) and/or sensor(s) may be utilised to manoeuvre and position the jaw 78 relative to a or the winder 10 .
- the sensing system used may utilise LiDAR (light detection and ranging) for accurate positioning of the jaw 78 .
- a gripper assembly 70 which is operated and controlled through pneumatic actuators and the flow of pressurised gas, such as pressurised air.
- pressurised gas such as pressurised air
- liquids can be substituted for the working fluids as described herein.
- the gripper assembly 70 can be controlled and manipulated via mechanical or electrical means.
- a controller is preferably provided to control the movement and position of the gripper assembly 70 .
- the gripper assembly 70 can be automated and utilise sensors to determine when an empty core 31 is to be removed from a creel position 20 or when a yarn package 30 is to be delivered to a creel position 20 .
- Computer software is preferably provided to control the movement of the gripper assembly 70 and the processes of loading the packages 30 into the housings 22 of the creel 10 .
- the gripper assembly 70 it is preferable for the gripper assembly 70 to controllably retain the yarn tail 33 of the respective yarn package 30 . This process is facilitated by way of a yarn control device 101 . It is to be understood that the yarn control device 101 can also be used for other yarn handling applications, outside of yarn handling system 1 .
- FIGS. 5 to 9 are generally directed to a yarn control device 101 for controlling a yarn tail 23 of a yarn 32 from a spool thereof such as yarn package 30 .
- the yarn control device 101 comprises: a moveable body 102 configured to capture the yarn 32 and guide the yarn 32 to an operative region 105 of the body 102 ; an inlet 107 for introducing a first fluid into the body; a first fluid outlet 110 located in proximity to the operative region 105 of the body, and oriented to expel the first fluid in a first fluid flow F; and a first moveable member 109 within the body 102 that moves between an operative configuration to clamp the yarn 32 and an inoperative configuration to release the yarn 32 ; wherein in the operative configuration the yarn 32 is clamped in the operative region 105 of the body 102 such that the first fluid flow captures the yarn tail 33 and orients the yarn tail 33 coaxially with the first fluid flow F, whereby movement of the movable 102 2 adjusts the direction of the first fluid flow F and yarn tail
- the body 102 is configured to received and guide the yarn 32 towards the operative region 105 .
- the body 102 comprises a pair of angled jaws comprising an upper jaw 103 and a lower jaw 104 that converge at a slot 121 within the operative region 105 of the body 102 .
- the jaws 103 , 104 have bevelled edges to allow the yarn 32 to travel across the jaws 103 , 104 without catching or snagging on the jaws 103 , 104 .
- first fluid outlet 110 On a first face of the body 102 is a plurality of supply ports for introducing fluids into the body 102 , including the first fluid inlet 107 that introduces a first fluid into the body 102 to be expelled at the first fluid outlet 110 .
- the first fluid can be a gas.
- the first fluid in one embodiment is air fed to the first fluid inlet 107 as compressed air.
- the first fluid outlet 110 is configured to expel the first fluid flow from the first fluid outlet 110 away from the 102 in a direction perpendicular to a major axis X of the body.
- the first fluid flow runs parallel to a run direction of the yarn 32 as it passes across the operative region 105 of the body 102 . It is contemplated that the arrangement of the jaws 103 , 104 for receiving the yarn 32 and the first fluid outlet 110 could be configured in a number of alternative configurations within the scope of the invention.
- first fluid inlet 107 is a working fluid activation supply port 106 and a working fluid deactivation supply port 108 .
- a working fluid By introducing a working fluid into the body 102 the moveable member 109 is moved within the body 102 to contact and clamp the yarn 32 within the operative region 105 .
- the working fluid can be a gas.
- the working fluid can be compressed air.
- the working fluid can be a liquid.
- the moveable member 109 can be a piston configured to reciprocate within a bore or chamber 122 (not shown) of the body 102 . As the working fluid is introduced into the chamber 122 the moveable member 109 is urged towards the operative region 105 to clamp the yarn 32 therein see FIG. 5 C .
- the body 102 provides an upper access panel 112 and a lower access panel 113 each mounted to the body 102 by at least one retaining screw 115 . Removal of access panels 112 and 113 provides access to the internal components of the body 102 .
- the body 102 includes a plurality of mounting holes 114 for mounting the body 102 to a support arm 120 to facilitate at least one of translational and rotational movement thereof.
- the moveable member 109 has a head 111 a that traverses the operative region 105 in anticipation of receiving the yarn tail 33 , as illustrated in FIG. 5 B .
- the head 111 has a smaller cross-sectional area than a cross-sectional area of a body 111 a of the moveable member 109 that presents a bar across the slot 121 of the operative region 105 for retaining the yarn tail 33 on a shoulder 119 of the moveable member 109 .
- the moveable member 109 As the moveable member 109 is activated by the working fluid the moveable member 109 traverses the operative region 105 until the shoulder 119 of contacts an upper surface 121 a of the slot 121 . As the shoulder 119 contacts the upper surface 121 a the yarn 32 is trapped therebetween and can no longer move relative to the operative region 105 . The yarn 32 is then clamped in position relative to the body 102 , see FIG. 5 C .
- the working fluid deactivation supply port 106 is opened, allowing the working fluid to enter a secondary chamber 125 (not shown) to drive the moveable member 109 away from the operative region 105 .
- the moveable member 109 can be driven back and forth by the introduction of the working fluid alternately between the first chamber 122 and the secondary chamber 125 from the respective supply ports 106 , 108 .
- FIG. 5 B illustrates the moveable member 109 in an inoperative configuration such that the upper face of the slot 121 a and the shoulder 119 are spaced apart ready to receive the yarn 32 as it travels across at least one of the jaws 103 , 104 .
- the yarn 32 can enter the operative region 105 of the body 102 and is restrained within the slot 121 against the head 111 while seated upon the shoulder 119 .
- the moveable member 109 has been driven across the operative region 105 to trap the yarn 32 between the shoulder 119 and the upper surface of the slot 121 a . This clamps the yarn 32 in proximity to the first fluid outlet 110 .
- first fluid is introduced into the body 102 via first fluid inlet 107
- the first fluid travels through a bore 127 (not shown) within the body 102 to be expelled at the first fluid outlet 110 in the first fluid flow F.
- the yarn tail 33 becomes entrained within the first fluid flow F, and axially aligned therewith.
- the yarn tail 33 of the yarn 32 is trapped in fixed relationship with the body 102 .
- the yarn tail 33 will trail from the operative region 105 , as shown in FIGS. 6 A and 6 C .
- the yarn tail 33 When the first fluid flow F is activated, the yarn tail 33 will be caught and entrained within the first fluid flow 102 and oriented to extend from the operative region 105 away from the body 102 parallel to the first fluid flow F.
- the yarn tail 33 By moving the body 102 in at least one of translational movement and rotational movement for example in the direction indicated by arrow R in FIG. 6 B the yarn tail 33 can be moved and directed towards a target region or receiver.
- FIG. 6 C is a perspective of the yarn control device 101 operatively gripping a yarn tail 33 with the first fluid flow F not activated, such that the yarn 32 is held in the operative region 105 of the body 102 and the yarn tail 33 hangs free under gravitational force only.
- FIGS. 7 A and 7 B illustrate a second embodiment of the yarn control device 201 .
- the yarn control device 201 has the same external features are those described herein in relation to yarn control device 101 .
- similar reference numerals are used to describe analogous features.
- the moveable member 109 is replaced by a first movable member 209 and a second moveable member 239 and hence two additional fluid supply ports 240 , 241 have been added to activate and deactivate the second moveable member 239 .
- FIG. 7 A illustrates the yarn control device 201 deactivated, where FIG. 7 B is illustrated in an operative configuration where the second moveable member 239 has been activated to constrain the yarn 32 but not clamp the yarn 32 .
- the body 202 has a pair of jaws, illustrated as upper jaw 203 and lower jaw 204 with bevelled edges 203 a , 204 a respectively.
- a slot 221 is located where the two jaws 203 , 204 converge to define an operative region 205 of the body 202 .
- Upper 212 and lower 213 access panels are provided for access to a first chamber 222 and a second chamber 225 for maintenance and replacement of the first moveable member 209 and second moveable member 239 , respectively.
- first fluid inlet 207 On an opposing face of the body to the pair of jaws 203 , 204 are four supply ports, 206 , 208 , 240 , 241 and a first fluid inlet 207 .
- the first fluid inlet 207 is located centrally of the body 202 to introduce the first fluid into the body 202 in communication with a bore 227 for supplying the first fluid to a first fluid outlet 178 .
- second fluid activation supply port 240 and second fluid deactivation supply port 241 Above the first fluid inlet 207 is a first fluid activation supply port 206 and first fluid deactivation supply port 208 .
- first and second working fluids can be a gas.
- the first and second working fluids can be compressed air.
- the first and second working fluids can be sourced from the same compressed air supply or two discrete air supplies.
- the first and second working fluids can be a liquid and can be sourced from two discrete fluid supplied or a single fluid supply.
- FIG. 7 B a head 226 of the second moveable member 239 is illustrated traversing the operative region 205 to form an aperture 218 for constraining the yarn 32 therein.
- This is an operative configuration than provides a yarn tail 33 feeding mode of the yarn control device 201 .
- FIG. 7 A illustrates an inoperative configuration of the yarn control device 201 in which neither the first moveable member 209 nor the second moveable member 239 is activated.
- the body 202 of the yarn control device 201 provides similar mounting features 214 to that of body 102 for driving the body 202 in at least one of translational movement and rotational movement.
- FIGS. 8 A- 8 D are cross-sectional illustrations of the yarn control device 201 and illustrate the internal components thereof.
- FIG. 8 A is a front sectional view of the yarn control device 201 in the operative clamping mode where each of the moveable members 209 , 239 are located in their lowest positions, with the head 211 of the first movable member 209 clamping down upon the lower surface 221 n of the slot 221 .
- the head 211 is concaved and has an outer peripheral rim 211 a that clamps down over the yarn 32 holding it firmly in place against the lower surface 221 b of the slot 221 .
- FIG. 8 A also illustrates an end on view of the bore 227 that communicates the first fluid from the first fluid inlet 207 to the first fluid outlet 210 .
- FIG. 8 B illustrates the yarn control device 201 in an inoperative configuration, awaiting contact with the yarn 32 .
- the supply port arrangement shown in FIG. 8 C will be described in relation to the first activation supply port 206 .
- the supply port 206 is connected to a body port 242 of the body 202 .
- the supply port 206 can be a snap-fit or snap-lock connector that delivers compressed air or alternative second working fluid to the body port 242 .
- the first working fluid is maintained within the body 202 and as such either liquids or gases can be selected to drive the moveable members 209 , 239 .
- the body port 206 is in fluid communication with the first chamber 222 via a communication channel 243 , allowing the first working fluid to be forced into the chamber 222 on activation of fluid to the supply port 206 .
- Each of the supply ports 206 , 208 , 240 , 241 operate in the manner as described above in reference to supply port 240 .
- the first movable member 209 When the first working fluid enters the chamber 222 the first movable member 209 is driven towards the operative region 205 .
- the working fluid is driven to the first deactivation supply port 206 and the supply of first working fluid to the first activation supply port 206 is ceased. This drives the first movable member 209 away from the operative region 205 and towards the access panel 212 , as shown in FIG. 8 C .
- FIG. 8 C illustrates the yarn control device 201 in an operative configuration, in a feeding mode.
- the second working fluid is pumped into the body 202 via second activation supply port 240 wherein the second moveable member 239 is activated to drive a head 226 of the second moveable member 239 into the operative region 205 .
- the head 226 protrudes from the second moveable member 239 in the form of a spigot having a planar end 224 .
- the planar end 224 is driven upwards into contact with the head 211 of the first moveable member 209 , thereby forming aperture 218 within which the yarn 32 is captured.
- the yarn 32 is restrained within the aperture 218 in close proximity to the operative region 205 of the body 202 but is fee to slide or feed through the aperture 218 .
- the head 211 of the first moveable member is concave and has a greater diameter than a diameter of the head 226 of the second moveable member.
- the yarn 32 is trapped in the aperture 218 formed in the operative region 205 .
- the yarn control device 201 With the yarn control device 201 in the feeding mode, activating the first fluid flow F, will expel the first fluid from the first fluid outlet 210 to form the first fluid flow F.
- the first fluid outlet F is in close proximity to the operative region 205 and captures the yarn tail 33 of the restrained yarn 32 .
- the yarn tail 33 becomes captured or entrained within the first fluid flow F directing the yarn tail 33 away from the body 202 perpendicularly to the body 202 and perpendicular to the bore 227 .
- the first fluid flow captures the yarn tail 33 and draws the yarn 32 through the aperture 218 across the operative region 205 increasing a length of the yarn tail 33 .
- the first air flow F is deactivated and/or the first moveable member 209 is activated to clamp the yarn 32 and terminate the feeding mode.
- This feeding mode of FIG. 8 C is to be contrasted with the clamping mode illustrated in FIG. 8 D . While the yarn control device 201 is still in an operative configuration, the moveable members 209 , 239 are opposingly operated.
- the second movable member 239 is not activated and remains within chamber 225 in proximity to the lower access panel 213 .
- the first fluid activation supply port 206 is turned on, to drive the first working fluid into the first chamber 222 and drive the first moveable member 209 and the head 211 thereof into the operative region 205 .
- the concave head 211 is driven into contact with a lower surface 221 b of the slot 221 whereby the outer peripheral rim 211 a clamps down over the yarn 32 securely holding the yarn 32 in place against the lower surface 221 b of the slot 221 .
- the chambers 222 , 225 are cylindrical and the moveable members 209 , 239 are also cylindrical, configured as pistons.
- the pistons are dimensioned to reciprocate back and forth within the respective chambers 222 , 225 with O-rings 236 providing each piston with a sealing arrangement to manage the first and second working fluids within the body 202 .
- These seals prevent leakage of the first and second working fluids within the respective chambers 222 , 225 .
- the O-rings 236 improve operational efficiency of the yarn control device 201 and improve control over the working of the yarn control device 201 .
- the first and second working fluids can be different fluids. In some embodiments, the first and second working fluids can be the same fluid.
- FIGS. 9 A- 9 D illustrate schematically the steps taken to approach, capture, restrain, and clamp the yarn tail 33 by the yarn control device 201 . It is understood that analogous steps are contemplated to capture and clamp the yarn tail 33 with the yarn control device 101 .
- FIG. 9 A illustrates the yarn control device 201 moving towards the yarn 32 , where upon contact with the upper jaw 203 or lower jaw 204 , the yarn 32 will be guided to the operative region 205 of the body 202 . As the yarn 32 traverses the jaws 203 , 204 the yarn 32 is drawn into the slot 221 see FIG. 9 B . In different operational modes, it can be the yarn 32 that is moved towards the yarn control device 201 .
- the working fluid is then introduced into the body 202 to activate the second moveable member 239 and form the aperture 218 to constrain the yarn 32 therein illustrated in FIG. 9 C .
- the first fluid inlet valve is opened to initiate the first fluid flow F and draw the yarn tail 33 through the operative region 205 of the body 202 .
- the first fluid flow F is terminated to cease feeding of the yarn 32 and the first working fluid is activated to urge the first moveable member 209 into the operative region 205 and clamp the yarn 32 against the lower surface 221 b of the slot 221 thereby clamping the yarn 32 and terminating the extension of the yarn tail 33 as illustrated in FIG. 9 D .
- the yarn tail 33 can be shortened by moving the yarn control device 201 relative to the yarn 32 . As such, any relative movement therebetween can be used to decrease the length of the yarn tail 33 .
- the yarn control device 101 , 201 can be used as part of a yarn handling device 301 .
- the yarn handling device 301 includes the yarn control device 101 , 201 and a moveable lance 302 that is independently moveable with respect to the yarn control device 101 , 201 .
- the moveable lance is shown in FIG. 10 .
- the yarn handling device 301 comprises the yarn control device 101 .
- the yarn control device 201 can also be used as a part of the yarn handling device 301 .
- the lance 302 includes a central bore 303 that feeds a nozzle 304 .
- the nozzle 304 is adapted to discharge a second fluid flow F′ towards a target receiver.
- the target is a location to which the yarn tail 33 is to be fed.
- the central bore 303 is between 2 mm and 8 mm in diameter and preferably about 4.95 mm in diameter, and narrows to a secondary bore 303 a of between 4 mm-10 mm and preferably about 8.65 mm in length.
- the secondary bore 303 a terminates at the tip of the nozzle 304 , which is between 0.5 mm-2.5 mm in diameter and preferably about 1.5 mm in diameter.
- the step down in diameter between the central bore 303 of the lance 302 to the secondary bore 303 a increases the velocity at which the second fluid is expelled from the nozzle 304 .
- the second fluid flow F′ is about between 50-150 litres/minute and preferably 113 litres/minute.
- the second fluid flow F′ has a pressure between 3 bar and 10 bar and preferably at a pressure of 7 bar.
- the second fluid flow F′ is configured to have a higher flow rate than the first fluid flow F, such that the second fluid flow F′ can displace the entrained yarn tail 33 from the first fluid flow F to redirect the yarn tail 33 coaxially with the second fluid flow F′.
- the yarn tail 33 will be directed and urged towards which ever target location the second air flow F′ is directed at, such that the second fluid flow F′ expels the entrained yarn tail 33 from the first fluid flow F thereby delivering the yarn tail 33 to the target.
- a light weight yarn of low linear mass density referred to as deci-tex or dTex can be controlled with a low flow rate, while a heavier yarn of higher dTex can be controlled with a higher flow rate to influence and manipulate the yarn tail 33 .
- the yarn 32 in-use, with the yarn control device 101 in the operative configuration, the yarn 32 is clamped in the operative region 105 of the body 102 such that the first fluid flow F captures the yarn tail 33 and orients the yarn tail 33 coaxially with the first fluid flow F, as the body 102 is moved the first fluid flow F is reoriented to intersect the second fluid flow F′ from the nozzle 304 .
- the yarn tail 33 is therefore directed towards the target.
- the dispensing of yarn 32 from the yarn package 30 is controlled by a yarn brake 80 , which will now be described in detail in reference to FIGS. 11 A to 110 .
- the yarn brake 80 is used to control the dispensing of yarn 32 from the yarn package 30 , such that once the yarn tail 33 arrives at the header 61 further dispensing of yarn 32 from the yarn package 30 is inhibited.
- the yarn brake 80 comprises a support arm 81 and a frictional element in the form of brake finger 82 .
- a linear actuator 83 extends along the support arm 81 and is coupled to the brake finger 82 .
- the actuator 83 is shown as a pneumatic cylinder including a piston rod 83 a , however other types of actuator are also contemplated.
- FIG. 11 A shows the brake finger 82 in a disengaged position, located outside of the housing 22 of the package holder 20 .
- the brake finger 82 extends substantially parallel to the brake support arm 81 .
- the brake finger 82 pivots inwards, towards the yarn package 30 .
- the brake finger 82 is received within a slot 23 of the housing 22 .
- the yarn brake 80 is part of the gripper assembly 70 , with the support arm 81 being moveably attached to the gripper body 73 , and extending longitudinally therefrom. Because the support arm 81 is offset from the body 73 of the gripper assembly 70 , the yarn brake 80 is located entirely outside of the housing 22 during the loading process and is received in a gap between adjacent housings 22 .
- operation of the system 1 comprises the following stages:
- FIGS. 12 A to 12 D show the gripper assembly 70 collecting an empty core 31 from a package holder 20 .
- the head 74 of the gripper assembly 70 will move into alignment with that package holder 20 , as shown in the partial cross-section of FIG. 12 A .
- the head 74 then moves longitudinally in the Y-direction through the open end of the respective housing 22 and towards the empty core 31 .
- the head 74 and snout 75 each include a shaft located on a central longitudinal axis. The shaft is positioned such that the yarn conduit 24 will pass through the shaft as the head 74 moves towards the empty core 31 into the housing 22 .
- FIG. 12 B shows the snout 75 and head 74 inserted into the housing 22 with the yarn conduit 24 extending through the rear of the head 74 .
- the jaw 78 is in a closed orientation such that the snout 75 , including fingers 76 , will be located within the centre of the core 31 as the head 74 approaches.
- the snout 75 is not interfered with by the mounting bracket 21 .
- the mounting bracket 21 may only engage about half of an internal surface of the core 31 , such that the snout 75 and fingers 76 may be positioned within the other half of the core 31 .
- the jaw 78 When located in the position as shown in FIG. 12 B , the jaw 78 is activated by an application of the pressurised gas, such as pressurised air. The jaw 78 will move from the closed orientation towards the open orientation until the fingers 76 engage the inner surface 31 a of the core 31 .
- the pressurised gas such as pressurised air
- FIG. 12 C shows the gripper assembly 70 when the piston rod 79 a has been fully retracted, the empty core 31 being removed from within the housing 22 .
- the gripper assembly 70 is then moved longitudinally away from the housing 22 , as shown in FIG. 12 D .
- FIGS. 13 A to 13 C show the gripper assembly 70 delivering the empty core 31 to the winder 40 .
- the gripper assembly 70 is rotated on the rotatable connector 58 a and moved in the X and Z direction, where necessary, by moving the platform 57 a relative to the vertical rail 57 in the Z direction and moving the upper and lower platforms 55 a , 56 a relative to the upper and lower rails 55 , 56 in the X direction.
- This maneuvering of the gripper assembly 70 causes the head 74 to face the winder 40 as shown in FIG. 13 A .
- the pneumatic cylinder 79 is then activated to cause the piston rod 79 a to extend outwardly in the longitudinal Y direction towards the winder 40 , as shown in FIG. 13 B .
- the head 74 will be positioned at an empty core drop-off position adjacent to a port or other receiving section of the winder 40 , which provides access to the storage buffer 42 .
- the jaw 78 will close to release the empty core 31 to provide the empty core 31 to the port or receiving section of the winder 40 .
- the winder 40 may have a means to collect the empty core 31 and to move it to the magazine or storage buffer 42 where appropriate.
- the gripper assembly 70 may include a pushing member to push the empty core 31 through the port or receiving section of the winder 40 and into the storage buffer 42 .
- the head 74 and piston rod 79 a can then be retracted away from the winder 40 in the Y direction.
- FIGS. 14 A to 14 C Each yarn package 30 comprises the tubular core 31 around which yarn 32 is wound by the winding machine 40 .
- FIG. 14 A shows an empty core 31 , before any yarn has been wound.
- FIG. 14 B shows an intermediate stage of the forming of the yarn package 30 , in which a first span 34 of yarn has been wound, to form a partially wound yarn package 30 .
- the first span of yarn 34 is wound onto the core 31 in an angled manner.
- the helical winding of the first span 34 substantially covers the core 31 .
- FIG. 14 C shows a finished yarn package 30 , after a second span 35 of yarn has been wound onto the core 20 ′ by the winding machine 12 .
- the second span of yarn 32 ′′ is wound in a straight manner.
- the second span of yarn 32 ′′ is concentrated within a central a portion of the core 31 .
- the yarn tail 33 of the yarn package 30 is the free end of the second span 35 .
- a length of the first span 34 and second span 35 of yarn on each yarn package 30 is variable, and dependent on (i) a designated package holder 20 to which the yarn package 30 will be attached, and (ii) the amount of yarn 32 required to be consumed by the production machine at the corresponding operating point.
- the total length of yarn wound onto each yarn package 30 is equal to the amount of yarn that is to be consumed by the production machine at a corresponding active operation site. Accordingly, an advantage provided by calculating the first and second spans 34 and 35 is a reduction in yarn wastage. This is because at the completion of the production of the yarn product, there is little to no yarn remaining on the yarn package 30 . Accordingly, the now empty core 31 can be re-used by the winding machine 40 to form a new yarn package 30 . This is to be contrasted with conventional production methods, where yarn remaining on the spool after a job has completed is disposed of, so as to allow the core 31 to be rewound for a subsequent job.
- the winding machine 40 Before winding the first span of yarn 34 onto the empty core 31 , the winding machine 40 receives an input indicating the amount of yarn required by the production machine and an assigned package holder 20 where the yarn package 30 will be placed. The winding machine 40 then determines the length of the second span of yarn 35 , being equal to or slightly greater than the length of a yarn feed path P associated with the assigned package holder 20 . It is envisaged that this process utilises a look-up table, where the yarn feed path P associated with each package holder 20 is predetermined and stored within the winding machine 40 . The length of the first span of yarn 34 is then calculated by the winding machine 40 , being equal to the total amount of yarn required by the production machine less the length of the second span 35 .
- Each respective package holder 20 is associated with its own yarn feed path P.
- the yarn feed path P is the path along which the yarn tail 33 of each yarn package 30 within the creel 10 is fed to its respective outlet within the header 61 .
- the yarn feed path P comprises a first portion extending along the rigid portion 24 a of the yarn conduit 24 .
- the first portion terminates in the aperture 26 , disposed on the non-loading face of the creel 10 .
- each side 13 , 14 of the double-sided creel 10 has a non-loading face 13 b , 14 b located between the first and second sides 13 , 14 respectively. It is understood that in an embodiment where the creel 10 is a single-sided creel, the non-loading face would be the second side 14 of the creel.
- the yarn feed path P further comprises a second portion extending along the non-rigid conduit 24 b from the aperture 26 within the non-loading face to the corresponding outlet within the header 61 .
- a yarn feed path P′ associated with a first creel position 20 ′ is longer than a yarn feed path P′′ associated with a second creel position 20 ′′. Accordingly, a longer length of yarn is required to be fed from the first package holder 20 ′ to a first outlet 60 ′ compared with the length of yarn required to be fed from the second package holder 20 ′′ to the second outlet 60 ′′.
- the length of yarn feed path P′ is one of the longest on the creel 10 .
- the length of the yarn feed path P′′ is one of the shortest on the creel 10 . There can be 2 metres or more of difference in length between the shortest and longest of the yarn feed paths P depending on the dimensions of the creel 10 .
- the yarn control device 101 , 201 can be configured in conjunction with the gripper assembly 70 when retrieving the yarn package 30 from the winder 40 and delivering the package 30 to the creel 10 .
- FIGS. 16 A to 16 F show the gripper assembly 70 collecting a yarn package 30 from the winder 40 after an empty core 31 has been wound with a desired length of yarn.
- the gripper assembly 70 is linearly moveable between the creel 10 and winder 40 along the gantry 50 . As shown in FIG. 16 A , the gripper arm 70 is maneuvered such that its gripping jaw 78 faces the position of the yarn package 30 on the winder 40 . Positioning the gripper assembly 70 in this position may follow it being retracted after delivering an empty core 31 to the port or receiving section of the winder 40 as previously described.
- the rotatable connector 58 a moves longitudinally along the arm rail 58 in the Y-direction towards the winder 40 to place the gripper assembly 70 in the position shown in FIG. 16 B .
- the cylinder 79 may then be actuated to extend the piston rod 79 a towards the package 30 until the jaws 78 is located inside the inner core 31 with the head 74 located adjacent thereto.
- the jaw 78 When moved towards the yarn package 30 , the jaw 78 is in a closed orientation such that the snout 75 , including fingers 76 , will be located within the centre of the core 31 as the head 74 approaches the package 30 .
- the snout 75 and fingers 76 When located in the position as shown in FIG. 16 C , the snout 75 and fingers 76 are entirely or substantially within the core 31 , and the jaw 78 is then be activated by application of the pressurised gas, such as compressed air, or other means.
- the jaw 78 will move from the closed orientation towards the open orientation until the fingers 76 engage the inner surface 31 a of the core 31 as shown in FIG. 16 D .
- the cylinder 79 may then be actuated again to move retract the piston rod 79 a in the Y-direction, as shown in FIG. 16 E .
- the rotatable connector 58 a may be moved in the Y-direction relative to the arm rail 58 to move the gripper assembly 70 away from
- the core 31 is released or “doffed” from the winder 40 , and rests in a pick-up position, with the supply yarn 44 from the winder 40 being uncut or held in some way.
- FIG. 17 A This is to enable control of the yarn tail 33 of the wound package 30 until the gripper assembly 70 can grasp the package 30 , with the yarn control device 101 , 201 taking control of the yarn tail 33 .
- the yarn control device 101 , 201 uses V-shaped jaws to intersect and capture the yarn 33 before it is cut and still under control of the winder 40 . This is shown in FIG. 17 B .
- the yarn 32 is released or cut by the winder 40 .
- the yarn tail 33 is then solely constrained by the yarn control device 101 , 201 .
- the first fluid flow F′ can be activated, such that the yarn 33 is entrained therein, aligned coaxially with the fluid flow F′.
- the next stage is to deliver the yarn package 30 to the assigned package holder 20 .
- This stage is shown in FIGS. 18 - 19 .
- the gripper assembly 70 is moved along the gantry 50 , until the inner surface 31 a of the core 31 of the yarn package 30 attached thereto is positioned axially in-line with the core mounting bracket 21 of the assigned package holder 20 .
- the head 74 is then driven forward towards the housing 22 , such that the yarn package 30 is received onto the core mounting bracket 21 .
- the jaw 78 is returned to the closed state, such that the yarn package 30 is solely supported by the core mounting bracket 21 .
- the head 74 is then retracted, such that the gripper assembly 70 is entirely disposed outside of the housing 22 .
- the rotatable connector 58 a is rotated such that the jaw 78 of the gripper assembly 70 is in the orientation where it faces the creel 10 .
- the connector 58 a is preferably rotated in the direction opposite to that which caused the gripper assembly 70 to move from facing the creel 10 to facing the winder 40 .
- the gripper assembly 70 will also be moved in the X and Z directions, by moving the arm platform 57 a vertically along the vertical rail 57 in the Z direction and moving the upper and lower platforms 55 a , 56 a horizontally along the upper and lower rails 55 , 56 in the X direction.
- the gripper assembly 70 holding package 30 will then be in the position shown in FIG. 19 A .
- the rotatable connector 58 a is then moved in the Y-direction to cause the gripper assembly 70 holding package 30 to move towards and into the respective housing 22 , as shown in FIG. 19 B .
- the cylinder 79 is actuated to cause the piston rod 79 a to extend until the yarn package 30 is located within and at the rear of the housing 22 , as shown in FIG. 19 C .
- the inner core 31 of the package 30 will then be located on the mounting bracket 21 .
- the jaw 78 is activated once again in reverse to cause the fingers 76 to disengage from the inner surface 31 a of the core 31 until the jaw 78 is in its closed position. At this point, the yarn package 30 is supported entirely by the mounting bracket 21 .
- the gripper assembly 70 may then be partially retracted by engaging the cylinder 79 to cause the piston rod 79 a to retract, until the head 74 of the gripper assembly is outside of the housing 22 , all the while maintaining control of the yarn tail 33 within the yarn control device 101 . This is shown in FIG. 19 D .
- the first step of this process is to thread the yarn tail 33 into the conduit opening 25 , as shown in FIG. 19 E .
- delivery of the yarn tail 33 to the respective outlet 69 is facilitated by the yarn handling device 301 that incorporates the yarn control device 101 , 201 as described herein.
- the yarn handling device 301 is coupled to the gripper assembly 70 . It is contemplated, however, that the yarn handling device 301 may be moveable via other methods and mechanisms outside of the gripper assembly 60 .
- the target for the yarn handling device 301 is the conduit opening 25 of a respective package holder 20 , with the head 74 and snout 75 of the gripper assembly 70 providing the moveable lance 302 .
- the nozzle 304 is thus brought into proximity with the conduit opening 25 as the gripper assembly 70 is urged forward and the package 30 is slid over the core mounting bracket 21 .
- the nozzle 304 is located about 3 mm ⁇ 2 from the conduit opening 25 .
- This optimum distance G between the nozzle 304 and the conduit opening 25 is approximately twice the diameter of the nozzle 304 , illustrated in FIG. 20 A .
- the ratio of the diameter of the second fluid outlet provided by nozzle 304 to the diameter of the conduit opening 25 is about 1:3.
- a different ratio can be selected, from 1:2-1:5.
- the second fluid flow F′ is activated once the head 74 is brought into alignment with the conduit 24 .
- FIGS. 21 A- 21 B With the nozzle 304 of the head 74 aligned with the central opening 25 of the conduit 24 and located at an optimal distance from the conduit 24 ( FIG. 21 A ), the second fluid flow F′ is activated and directed into the opening 25 of the conduit 24 .
- the yarn control device 101 is then moved, by rotation and/or translation of the gripper assembly 70 , to direct the yarn tail 33 —entrained within the first fluid flow F—across the second fluid flow F′ ( FIG. 21 B ).
- the second fluid flow F′ has a greater fluid flow than the first fluid flow F. Accordingly, once the yarn tail 33 in the first fluid flow F crosses the second fluid flow F′, the yarn tail 33 is ejected from the first fluid flow F and fired into the conduit opening 25 and fed through both the rigid conduit 24 a and the flexible conduit 24 b to be received at the header 61 .
- the gripper assembly 60 is then fully retracted from the housing 22 to restart the process, as illustrated in FIG. 19 E .
- a tension force T is applied to the yarn tail 33 .
- the yarn 32 on the package 30 is thus drawn through the conduit 24 along the yarn feed path P.
- the tension force T is provided by the second air flow F′ from the nozzle 304 .
- the second fluid stream F′ thus propels the yarn tail 33 into the conduit opening 25 and along the yarn feed path P to the header 61 .
- the header 61 receives and stores the yarn tails 33 to prevent them being tangled or snagged if the yarn tails were to fall into the creel positions 20 beneath the header 61 .
- a second span of yarn 35 is wound onto the package 30 in a straight configuration, thereby defining a feeding yarn that continues to be unwound from the package 30 during the loading of the package 30 into the housing 22 of the creel 11 .
- a specific length of feeding yarn 35 can be tailored to the location of the package 30 on the creel 10 .
- the brake finger 82 is moved to the engaged position to make frictional contact with the first span 34 of the yarn package 30 . This is shown in FIG. 22 A .
- the brake finger 82 is dimensioned so as to be able to contact the core 31 loaded within the package holder 20 . In this manner, the brake 80 can be used for yarn packages 30 of varying diameters, having different amounts of yarn 32 wound thereupon.
- the frictional force R is applied to an end of the first span 34 , proximate to where the helical winding of the first span 34 transitions into the straight winding of the second span 35 .
- the frictional force R acts in a direction opposite to the tension force T.
- the brake finger 82 is engaged with the first span 34 of yarn only, the second span 35 of yarn is free to unwind unrestricted under the tension force T, enabling the yarn tail 33 to feed towards the header 61 . This is shown in FIG. 22 B .
- FIG. 22 C shows the configuration of the yarn brake 80 during a later stage of the yarn feed process.
- the second span 35 of yarn has completely unwound from the yarn package 30 , such that the yarn tail 33 has arrived at the header 61 .
- the frictional force F applied by the brake finger 82 is greater than the tension force T of the fluid stream F′′, further dispensing of yarn 32 from the yarn package 30 is inhibited.
- the entire first span 34 of yarn remains on the yarn package 30 .
- This is advantageous, as it reduced an overhang of the yarn tail 33 at the corresponding outlet 60 within header 61 . Accordingly, adjacent yarn tails 33 within the header 61 are less likely to entangle with one another. Further, yarn wastage arising during the splicing of each of the yarn tails 33 to the corresponding yarn supply at the production machine is reduced. This is because there is no need to cut excess overhang of the yarn tails 33 .
- the tension force T is deactivated.
- the predetermined time does not need to be accurately calculated for the yarn feed path P of each package holder 20 . Rather, the predetermined time merely needs to be sufficient to feed the yarn tail 33 from the package holder 20 having the longest yarn feed path P. Accordingly, the tension force T is applied for the same predetermined time for each package holder 20 of the creel 10 , simplifying the overall feeding process.
- the actuator 83 is deactivated, such that the brake finger 82 is returned to the disengaged position, outside of the housing 22 , as shown in FIG. 22 D .
- the yarn brake 80 is then retracted back towards the gripper head 74 , to an inoperable position. In the inoperable position, the yarn brake 85 , and the entire gripper assembly 70 , is located outside of the creel 10 . The process can then be repeated, for subsequent yarn packages 30 .
- the process includes the steps of: maneuvering the gripper assembly 70 to retrieve the package 30 from the winder 40 and capture the yarn tail 33 ; delivering the package 30 to the housing 22 on the creel 10 and activating the first fluid flow F to orient the yarn tail 33 ; moving the body 102 to draw the yarn tail 33 across the second fluid flow F′ wherein the second fluid flow F′ drives the entrained yarn tail 33 from the first fluid flow F and into the opening 25 of the conduit 24 , and delivering the yarn tail 33 to the header 61 by controllably feeding the yarn 32 along the conduit 24 with the assistance of yarn brake 80 .
Abstract
A system for handling yarn packages and empty cores. The system includes a winder, a creel and a gripper assembly. The winder is configured to receive an empty core and to wind a predetermined length of yarn onto the empty core to create a yarn package. The creel is configured to provide an array of creel positions for receiving a yarn package. The gripper assembly is configured to be moveable between the winder and the creel. The gripper assembly has a jaw adapted to grip a yarn package when delivering the yarn package from the winder to the creel and to grip an empty core when removing the empty core from the creel and delivering the empty core to the winder. Devices, systems and methods for controlling a yarn tail, loading a yarn spool into a creel, and feeding the yarn through the creel, are also disclosed.
Description
- The present application claims priority to Australian provisional application numbers AU 2020903209, AU 2020903210 and AU 2020903212, the entire disclosures of each are incorporated herein by reference.
- The present disclosure relates to systems, methods and apparatus for use in the manufacture of woven or tufted products, including textiles such as carpets and rugs.
- Carpet making machines are used to manufacture rugs and carpets. Broadly, there are two types of carpet making machine, namely weaving machines and tufting machines.
- Weaving involves the interweaving of perpendicular sets of weft and warp yarns. In the production of a woven carpet, several uniformly spaced parallel strands of yarn extend along a length of the carpet. These strands are referred to as warp strands. As the warp yarns are indexed forward by looms of the weaving machine, strands of yarns are fed perpendicularly through the set of warp yarns across the width of the carpet, being trapped therebetween to form the carpet. These strands are known as weft strands. Each of the strands of yarn making up the warp and the weft are fed by a different supply of yarn, often in the form of a yarn cone, bobbin or spool.
- Tufting involves the stitching of yarns through a net-like backing. In the production of a tufted carpet using a large tufting machine, several needles extend linearly across a width of the backing. As the backing is indexed forward through the tufting machine, the needles loop yarn through the backing. Each needle is fed by a different supply of yarn.
- Conversely, small tufting machines utilise a single needle being mounted to a moving needle assemble that translates across the width of the carpet. Accordingly, such machines require only a single supply of yarn. Such smaller tufting machines are particularly suitable for the manufacturer of smaller products and samples.
- The gauge of a woven or tufted product is a measure of the number of strands or needles per unit inch of width. Typical carpets and rugs are manufactured in 1/10 gauge, which equates to ten yarns per inch. Accordingly, a carpet or rug of a typical width can comprise one thousand or more yarns across its width, each being fed from a different supply of yarn.
- Conventionally, carpet making machines comprise multiple needles and/or “operation points”, and are provided with yarn via large, stationary creels. A creel is a rack or frame that provides a plurality of locations for accommodating spools of yarn, or “yarn packages”. Each location within the creel supplies a different operation point of the carpet making machine.
- Early carpet making machines used to produce level cut or loop carpet piles would use yarn from each package equally such that the packages would run out of yarn at approximately the same time. More modern carpet making machines, however, can produce patterned carpets or rugs which have variable height loops or cut pile, resulting in different consumption of yarn at different operation points. In addition, full width patterning capabilities of more modern carpet manufacturing machines mean that yarn consumption at each operation point, and hence for each yarn package, may be different. Furthermore, some recent machines can also show one of a number of colours at a position within a pattern to produce a variety of carpet or rug patterns, further increasing the variation of yarn usage between different packages.
- Yarn from each location within a creel is typically drawn towards a “header” device, which in turn feeds the individual supplies of yarn to the operation point of the carpet making machine. Typical creels can accommodate hundreds or even thousands of packages of yarn. Conventionally, each yarn package within the creel is wound with a uniform length of yarn, approximated to the amount of yarn required. This can result in yarn waste at the end of the job, with excess yarn remaining on the package at the completion of a job being drawn through the carpet making machine and disposed of before the next job commences.
- Typically, new yarn packages are supplied to the locations within the creel manually by a worker who manually restrains a free end or “yarn tail” of the yarn, and delivers this to the creel, where it is threaded through an eye or conduit to the header, where it is typically joined or “spliced” to the previous length of yarn fed therethrough. Given the large number of locations within the creel requiring loading and unloading, the threading of the yarn tails and feed towards the header, and manual unloading of the empty cores can be a laborious and time-consuming endeavour. Alternatively, the creel arrangement may provide for two yarn positions for each operation point of the carpet making machine, in which case the new yarn may be connected to the existing yarn within the creel. Furthermore, when several yarn packages are being loaded and spliced together at the header at the same time, there is a risk of entanglement of neighbouring yarns.
- Complete replacement or replenishment of these packages can represent many man hours of work, around 20 hours for this example. Accordingly, whilst conventional large, manually-fed creels were well suited to early carpet making machines, more modern machines, often consuming differing amounts of yarn at different operation points, are less suited, with the variability of yarn usage leading to an increase in the amount of yarn being wasted. Alternatively, partially used yarn packages may be removed from the creel and placed into storage until yarn of that colour and amount is required, which increases the amount of storage required.
- Against this backdrop, alternative systems have been recently developed which attempt to provide improvements to creels and in the supply of yarn thereto.
- One such system relies on the use of smaller, mobile creels that can be filled with yarn away from the carpet making machine. A first mobile creel is used to supply the carpet making machine while a second mobile creel is loaded with yarn packages, and when the use of yarn on the first creel is completed it can be swapped with the second creel. This system reduces down-time associated with the emptying and refilling of a conventional, stationary creel. However, such a system still requires manual refilling of the yarn packages into the locations within each mobile creel, and if the consumption of yarn at each position is unequal, the yarn packages with a substantial amount of yarn remaining must still be removed and stored.
- Another alternative system involves the use of winding machines configured to wind a precise length of yarn onto an empty core with a high degree of accuracy. Labels are then placed onto the yarn packages to identify specific positions within the creel where each package is to be uniquely placed. A batch of the uniquely wound packages is then delivered to the creel, with each package will placed manually into the designated position denoted on the label on that package. One example of such a system is the Gilbos ‘UniWinder’ machine and associated software.
- Accordingly, it would be desirable to provide an improved method of supplying yarn to a production machine that addresses some of the drawbacks of conventional creel-based systems. It would also be advantageous to provide systems and apparatus for undertaking such a method.
- The present invention was conceived with these shortcomings in mind.
- An aspect of the present invention provides a system for handling yarn packages and empty cores, comprising: a creel comprising an array of creel positions each configured to receive a yarn package, wherein removal of a yarn from the yarn package results in the yarn package becoming an empty core; a winder located adjacent to the creel, the winder being configured to receive an empty core, and wherein the winder is configured to wind a predetermined length of yarn onto the empty core to create a yarn package; and a gripper assembly configured to be moveable between the creel and the winder, the gripper assembly comprising a gripping jaw adapted to grip a yarn package or empty core, wherein the gripping jaw of the gripper assembly is adapted to grip an empty core in a creel position and remove the empty core from the creel and deliver the empty core to the winder.
- The removal of the yarn from the yarn package may be through a process of using the yarn in the formation of a rug or carpet. For example, the yarn may be removed from the yarn package by being fed from the creel position to a header plate. The yarn may be fed through a conduit in the centre of the creel position to the header plate. When the required amount of yarn has been used, there may be a small residual amount of yarn remaining on the package which is removed to result in the empty core.
- According to embodiments, the creel comprises an array of tubes which each encircle a respective creel position.
- According to embodiments, the creel comprises a first side and a second side. The first side may comprise a first array of creel positions. The second side may comprise a second array of creel positions. Optionally, at least one winder is located adjacent to the first side of the creel and at least one winder is located adjacent to the second side of the creel. Optionally, at least one winder is located adjacent to the first side in an initial orientation and the creel is configured to be rotated such that the first side can be serviced by the winder in the initial orientation and the creel may be rotated such that the second side may be serviced by the winder in a rotated configuration.
- According to embodiments, the creel is a mobile creel. The mobile creel may be filled with yarn packages at one location and moved to another location, such as a location adjacent to a tufting machine, where desired.
- According to embodiments, the winder comprises a plurality of winding areas. Each winding area may be adapted to wind a predetermined length of yarn onto a respective empty core. The winder may wind a predetermined length of yarn onto a plurality of empty cores simultaneously. The winder may comprise a plurality of heads which can each wind yarn onto an empty core. Optionally, the winder comprises a plurality of magazines adapted to receive empty cores. Each head of the winder or winding area may comprise a respective magazine. The magazine may be configured to receive at least one empty core at a time. Optionally, the magazine may be configured to receive a plurality of empty cores simultaneously. The winder may comprise a storage buffer adapted to receive a single empty core. Where the winder has a plurality of winding areas, the winder may comprise a plurality of storage buffers each adapted to receive a single empty core.
- According to embodiments, the winder comprises at least one port through which the winder receives an empty core.
- According to embodiments, the gripper assembly is moveable horizontally and vertically between the creel and winder such that gripper assembly may remove an empty core from any creel position in the array or deliver a yarn package to any creel position in the array.
- According to embodiments, the system further comprises a gantry onto which the gripper assembly is connected. The gripper assembly may be moveable horizontally and vertically between the creel and the winder on the gantry.
- According to embodiments, the gripper assembly is rotatable between a first orientation where the gripping jaw is aligned towards the creel and a second orientation where the gripping jaw is aligned towards winder.
- According to embodiments, the gripping jaw is moveable along a longitudinal direction of the gripper assembly towards and away from a creel position when in the first orientation or towards and away from the winder when in the second orientation. The gripper assembly and gripping jaw may be moveable and actuated by air pressure and/or may comprise a pneumatic control system.
- According to embodiments, each creel position comprises a package holder into which the core of the yarn package is placed. The package holder is preferably positioned and sized such that it will not interfere with the gripping jaw of the gripper assembly when the gripper assembly delivers a yarn package to said creel position or when the gripper assembly removes an empty core from said creel position.
- According to embodiments, the gripping jaw is adapted to grip an inner surface of the yarn package or empty core. Optionally, the gripping jaw comprises a plurality of fingers. The fingers may have a low radial profile in a closed position and the fingers have an increased radial profile in an open position. The fingers may be adapted to engage the inner surface of a yarn package or empty core when in the open position and may release the yarn package or empty core when transitioning from the open position to the closed position.
- According to embodiments, the system further comprises a sensing means. The sensing means may comprise a feature recognition camera or sensor. The system may comprise a controller. The feature recognition camera or sensor may be adapted to recognise and locate each creel position and to send signals to the controller. Thus, the controller may control the gripper assembly into alignment with a respective creel position when delivering a yarn package or removing an empty core. The feature recognition camera or sensor and controller may also control the gripper assembly to align with a magazine or a port of the winder when delivering an empty core to the winder. The feature recognition camera or sensor and controller may control the gripper assembly to align the gripper to a wound package on the winder. The sensing means may utilise a LiDAR ((light detection and ranging) for accurate positioning of the jaw. The sensor may utilise LiDAR.
- Another aspect of the present invention provides a method for handling yarn packages and empty cores, comprising: providing a creel having an array of creel positions, where each creel position is adapted to receive a yarn package; providing a winder configured to receive an empty core, wherein the winder is configured to wind a predetermined length of yarn onto an empty core to create a yarn package, wherein the winder is positioned adjacent to the creel; providing a gripper assembly which is configured to be moveable between the creel and the winder, the gripper assembly having a gripping jaw adapted to grip a yarn package or an empty core; locating an empty core at a creel position; maneuvering the gripper assembly to said creel position and gripping said empty core with the gripping jaw of the gripper assembly; moving the gripper assembly between the creel and the winder; delivering the empty core to the winder; maneuvering the gripper assembly such that the gripping jaw collects a yarn package from the winder; and delivering the yarn package to the creel position by maneuvering the gripper assembly.
- According to embodiments, the method further comprises providing a gantry onto which the gripper assembly is connected and adapted to move horizontally and vertically between the creel and the winder. Preferably, the gripper assembly is rotatable on the gantry between a first orientation where the gripping jaws face the creel and a second orientation where the gripping jaws face the winder.
- According to embodiments, prior to gripping said empty core, the gripper assembly moves on the gantry to the creel position corresponding to the empty core. To grip said empty core the gripping jaw in a closed position may move in a longitudinal direction of the gripper assembly towards the empty core, the gripper jaw may actuate to an open position and engage the inner surface of the empty core. The empty core may be removed from its respective creel position, once gripped by the gripping jaw, by moving the gripping jaw in a direction opposite to said longitudinal direction, in other words away from the respective creel position. Similarly, to grip said yarn package the gripping jaw in a closed position may move in a longitudinal direction of the gripper assembly towards the yarn package, the gripper jaw may actuate to an open position and engage the inner surface of the yarn package.
- It is understood that any of the individual features provided above or described below or shown in the accompanying Figures may themselves be the subject of independent or dependent claims. The features as described herein may be utilised in any combination as would provide a beneficial outcome and no single embodiment is considered on its own to be limiting to the scope of the invention.
- Another aspect of the present invention provides a yarn control device for controlling a yarn tail of a yarn, comprising: a moveable body configured to capture the yarn and guide the yarn to an operative region of the body; an inlet for introducing a first fluid into the body; a first fluid outlet located in proximity to the operative region of the body, and oriented to expel the first fluid in a first fluid flow; and a first moveable member within the body that moves between an operative configuration to clamp the yarn and an inoperative configuration to release the yarn; wherein in the operative configuration the yarn is clamped in the operative region of the body such that the first fluid flow captures the yarn tail and orients the yarn tail coaxially with the first fluid flow, whereby movement of the movable body adjusts the direction of the first fluid flow and yarn tail entrained therein to control orientation of the yarn tail.
- A further aspect, the invention is directed to a yarn control system for delivering a yarn tail of a yarn to a receiver, comprising: a moveable body configured to capture the yarn and guide the yarn to an operative region of the body; an inlet for introducing a first fluid into the body; a first fluid outlet located in proximity to the operative region of the body, and oriented to expel the first fluid in a first fluid flow; and a moveable member within the body that moves between an operative configuration and an inoperative configuration; and a nozzle having a second fluid outlet that expels a second fluid in a second fluid flow towards the receiver; wherein in the operative configuration the yarn is clamped in the operative region of the body such that the first fluid flow captures the yarn tail and orients the yarn tail coaxially with the first fluid flow, and in moving the movable body the first fluid flow is reoriented to intersect the second fluid flow, such that the second fluid flow expels the entrained yarn tail from the first fluid flow thereby delivering the yarn tail to the receiver.
- A winder is configured to receive an empty core wherein the winder is configured to wind a predetermined length of yarn onto the empty core to create a yarn package.
- A gripper assembly is configured to be moveable between the creel and the winder, the gripper assembly comprising a gripping jaw adapted to grip the package or empty core, the gripper assembly configured to: (i) remove an empty core from a designated creel position and deliver the empty core to the winder; and (ii) remove a yarn package from the winder and deliver the package to a designated creel position.
- The yarn is removed from the yarn package by being fed from the designated creel position to a header plate or header. The yarn is fed to the receiver in the form of a conduit or tube in the centre of the designated creel position and fed therethrough to the header.
- According to embodiments, each designated creel position comprises a housing or package holder into which the yarn spool is located and supported. The housing is preferably positioned and sized such that it will not interfere with the loading members of the gripper assembly when the gripper assembly delivers the yarn package to the designated creel position or when the gripper assembly removes an empty core from the designated creel position.
- The housing may be a loading tube. The creel may comprise an array of loading tubes each of which encircle a designated creel position and receive and support the yarn package or empty core at the designated creel position. The housing may further comprise a locating boss or bracket for supporting and retaining the yarn package thereon. The housing may house the conduit or tube. The conduit may be centrally located in the housing to support the yarn spool and to allow the yarn to be fed from the loading face of the creel to an opposing face thereof.
- According to embodiments, the gripper assembly is moveable horizontally and vertically between the creel and winder such that gripper assembly may remove an empty core from any creel position in the array or deliver a yarn package to any creel position in the array.
- According to embodiments, the system further comprises a gantry onto which the gripper assembly is mounted. The gripper assembly may be moveable horizontally and vertically between the creel and the winder on the gantry. The gripper assembly may have telescoping movement to allow the gripper assembly to extend and retract. The gripper assembly may be configured to operate in three degrees of freedom. The gripper assembly may be mounted to allow rotation thereof. The rotation may be in a horizontal plane. The rotation may be in a vertical plane.
- According to embodiments, the gripper assembly is rotatable between a first orientation where the gripping jaw is aligned towards the creel and a second orientation where the gripping jaw is aligned towards the winder.
- According to embodiments, the gripper assembly may be moveable along a longitudinal direction of the gripper assembly towards and away from a designated creel position, when in a first orientation, or towards and away from the winder, when in a second orientation. The gripper assembly may be moveable and actuated by air pressure and/or may comprise a pneumatic control system or may be electronically actuated.
- In Another aspect of the present invention, there is provided a method for loading yarn packages into a creel, comprising: winding a length of yarn onto an empty core in a winder to create a yarn package; capturing the yarn package with a gripper assembly configured to move between the creel and the winder, the gripper assembly adapted to grip the yarn package and comprising a yarn control device, wherein the yarn control device captures and retains a yarn tail of the yarn package; moving the gripper assembly adjacent to the creel and delivering the yarn package to an empty creel position; and activating the yarn control device to urge the yarn tail toward the receiver.
- Yet another aspect of the present invention provides a method for loading yarn packages into a creel and threading the yarn tail through the creel, comprising: winding a length of yarn onto an empty core in a winder to create a yarn package; capturing the yarn package with a gripper assembly configured to move between the creel and the winder, the gripper assembly adapted to grip the yarn package and comprising a yarn control system, wherein the yarn control system captures and retains a yarn tail of the yarn package; moving the gripper assembly adjacent to the creel and delivering the yarn package to a designated creel position; and activating the yarn control system to direct the yarn tail toward the receiver of the designated creel position and threading the yarn tail through the receiver of the designated creel position.
- In some embodiments, the receiver may be a conduit of the creel. The conduit may be a central tube. A plurality of central tubes may be dispersed across the creel, each central tube defining a designated creel position. The central tube of each creel position may be bounded by a housing or loading tube for protecting the yarn package therein. The yarn package may be coaxially located on the central tube, to facilitate feeding of the yarn from the spool through the central tube to a working face of the creel. The conduit may direct the yarn tail through the yarn package to a working face of the creel. The yarn package is loaded from a loading face of the creel. The loading face may oppose the working face of the creel. In some embodiments the loading face or the creel is also the working face.
- In some embodiments, the receiver may be an eye or eyelet for receiving the yarn tail. In some embodiments, the receiver may be a header or header box, for storing a plurality of yarn tails of a loaded creel.
- In a further aspect still, the invention provides a method of controlling a feed of yarn from a yarn package to an outlet, comprising: determining a length of a yarn feed path extending between a package holder to which the yarn package is attached during production of a yarn product and the outlet; winding a first span of yarn onto an empty core with a winding machine to form a wound core; winding a second span of yarn onto the wound core to form the yarn package, the second span having a length equal to or slightly greater than the length of the yarn feed path; and selectively feeding a tail end of the yarn package along the yarn feed path to the outlet, such that only the second span of yarn is dispensed from the yarn package. By determining the length of the yarn feed path prior to winding of the yarn package, the amount of excess yarn remaining on the yarn package at the completion of the production of the product is reduced.
- The winding of the first span of yarn may be an angled winding, the first span of yarn traversing along the empty core from a first end of the empty core to a second end of the empty core. The angled winding may be a helical winding, the first span of yarn repeatedly traversing between the first and second ends of the empty core. The winding of the second span of yarn may be a straight winding, the second span of yarn concentrating within a portion of the wound core. The straight winding may be concentrated within a substantially central portion of the wound core. By concentrating the winding of the second span within the central portion, the process of dispensing only the second span from the yarn package is simplified.
- The package holder may be one of a plurality of package holders, each of the plurality of package holders having a different yarn feed path, the method further comprising the step of defining a designated package holder to which the yarn package is to be attached, prior to determining the length of the yarn feed path. The plurality of package holders may be provided within a creel. The method may further comprise the step of transporting the yarn package from the winding machine to the designated package holder. The transporting of the yarn package may involve the use of an automated gripper, the automated gripper picking up the yarn package from the winding machine and attaching the yarn package to the designated package holder. By attaching the yarn brake to the automated gripper, a single yarn brake can be moved between several yarn packages attached to different package holders to dispense yarn therefrom.
- In some embodiments, the feeding of yarn from the yarn package may comprise applying a tension force to the tail end of the yarn package and feeding the tail end along the yarn feed path to the outlet. The feeding of yarn may comprise applying a frictional force to the first span of yarn with a yarn brake, to thereby inhibit dispensing of the first span of yarn from the yarn package. The yarn brake may be attached to a or the automated gripper, the automated gripper transporting the yarn package from the winding machine to the package holder. The yarn brake provides a simple mechanism for restricting the feeding of yarn from the yarn package.
- The method may further comprise the step of defining the total length of yarn required to produce the product and calculating the first span of yarn such that the first and second spans of yarn together provide the total length of yarn. By calculating the first and second yarn lengths prior to winding, the amount of yarn on each yarn package is limited to the amount of yarn required to be consumed at each operation point of the production machine. Accordingly, yarn wastage associated with excess yarn being left over on the yarn package at the completion of a job is further reduced.
- In yet another aspect, the invention provides a yarn brake for controlling a feed of yarn from a yarn package to an outlet, the yarn package being attached to a package holder and comprising a core around which first and second spans of yarn are wound, the yarn brake including a frictional element moveable between a disengaged position, in which the frictional element does not contact the yarn package, and an engaged position, in which the frictional element engages with the first span of yarn, such that with the yarn brake in the engaged position, application of a tension force to a tail end of the yarn package results in only the second span of yarn being dispensed from the yarn package, the second span of yarn having a predetermined length calculated to feed the tail end along a yarn feed path extending from the package holder to the outlet. As the length of the second span of yarn is of a predetermined length related to the yarn feed path, the amount of excess yarn wound onto the yarn package can be reduced. Furthermore, by feeding out only the measured second span of yarn, yarn protruding beyond the outlet is reduced, thereby reducing the risk of entanglement with neighbouring yarns or other objects.
- The frictional element may be engageable with the core when the first and second spans of yarn have been dispensed from the yarn package. As such, the yarn brake is configured to interact with yarn packages having varied external diameters, resulting from different amounts of yarn being wound thereon. The frictional element may engage with the first span of yarn towards an opposite end of the yarn package with respect to an end of the yarn package from where the yarn is being dispensed. The frictional element may be pivotably moveable between the disengaged position and the engaged position. The frictional element may be removably insertable into a slot of a housing of the package holder.
- In some embodiments, the package holder is one of a plurality of package holders provided within a creel, the yarn brake being moveable between each of the package holders. The yarn brake may be incorporated within or attachable to an automated gripper, the automated gripper being adapted to load the yarn package into the creel. By attaching the yarn brake to the automated gripper, the yarn brake is easily implemented into existing automated yarn handling systems.
- In a still further aspect, the invention provides a system for controlling a feed of yarn from a yarn package to an outlet, comprising: a winding machine configured to wind a first span of yarn and a second span of yarn onto an empty core to form a yarn package; a package holder configured to hold the yarn package during production of a yarn product; and a yarn brake configured to selectively engage with the yarn package; wherein the second span of yarn has a predetermined length calculated to feed a tail end of the yarn package along a yarn feed path extending from the package holder to the outlet, such that when the yarn brake engages with the first span of yarn, application of a tension force to the tail end results in only the second span of yarn being dispensed from the yarn package.
- The system may further comprise an automated gripper to transport the yarn package between the winding machine and the package holder. The yarn brake may be incorporated within or attached to the automated gripper.
- In some embodiments, the package holder may be one of a plurality of package holders provided within a creel. The creel may be a mobile creel. The outlet may be one of a plurality of outlets provided within a header, each outlet being associated with a corresponding package holder. By providing a plurality of package holders within a creel, the length of the yarn feed path from each package holder to a corresponding outlet of the header can be simply determined.
- It is understood that any of the individual features provided above or described below or shown in the accompanying figures may themselves be the subject of independent or dependent claims. The features as described herein may be utilised in any combination as would provide a beneficial outcome and no single embodiment is considered in its own to be limiting to the scope of the invention.
- Embodiments of the present disclosure will now be described, by way of non-limiting example, with reference to the accompanying drawings, in which:
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FIG. 1A shows a perspective view of a creel, winder, winder supply store and gantry assembly according to an embodiment; -
FIG. 1B shows a side view of a creel, winder, winder supply store and gantry assembly according to an embodiment; -
FIG. 1C shows a top view of a creel, winder, winder supply store and gantry assembly according to an embodiment; -
FIG. 1D shows an end view of a creel, winder, winder supply store and gantry assembly according to an embodiment; -
FIG. 2A is a front perspective view of the creel of the yarn feeding system ofFIG. 1 , showing a plurality of package holders; -
FIG. 2B is a rear perspective view of the creel ofFIG. 2A ; showing a flexible conduit extending from a rear aperture of a package holder to an outlet within a header; -
FIG. 3A is a perspective view of a package housing, having a conduit centrally located therein; -
FIG. 3B is an end view of the package housing ofFIG. 3A , illustrating a central boss or mounting bracket for mounting the core of the package, such that the core is coaxially located on the mounting bracket within the housing; -
FIG. 4A shows a perspective view of a package gripper according to an embodiment; -
FIG. 4B shows a front view of the package gripper with the jaw closed according to an embodiment; -
FIG. 4C is a front view of the gripper assembly ofFIG. 4A , showing the jaw in a closed configuration; -
FIG. 4D is a front view of the gripper assembly ofFIG. 4B , showing the jaw in an open configuration; -
FIG. 5A is a perspective view of a yarn control device according to a first embodiment, illustrating a body of the device having three supply ports supplying fluid thereto; -
FIG. 5B is a sideview of the yarn control device ofFIG. 5A , illustrating a sectional view of the operative region of the body in a first “open” mode; -
FIG. 5C is a sideview of the yarn control device ofFIG. 5A , illustrating a sectional view of the operative region of the body in a second “clamped” mode of operation; -
FIG. 6A is a perspective view of the yarn control device ofFIG. 5A , illustrating a yarn tail extending through an operative region of the body when no fluid is flowing through the body; -
FIG. 6B is a perspective view of the yarn control device ofFIG. 5A , illustrating a yarn tail extended through an operative region of the body when fluid is flowing through the body; -
FIG. 6C is a perspective view of the yarn control device ofFIG. 5A , illustrating a yarn tail extended through an operative region of the body; -
FIG. 7A is a sideview of a yarn control device according to a second embodiment, illustrating a first fluid outlet in proximity to the operative region of the body; -
FIG. 7B is a side view of the yarn control device ofFIG. 7A , illustrating a moveable member traversing the operative region of the body for restraining a yarn to the body; -
FIG. 8A is a cross-sectional front view of the yarn control device ofFIG. 7A , illustrating the first fluid outlet in fluid communication with an internal bore of the body; -
FIG. 8B is a cross-sectional side view of the yarn control device ofFIG. 7A , illustrating a first and a second moveable member located within a respective chamber of the body to reciprocate back and forth towards the operative region of the body, both moveable members are illustrated in an inoperative configuration; -
FIG. 8C is a cross-sectional side view of the yarn control device ofFIG. 7A , illustrating the first moveable in an operative configuration whereby a head of the first moveable member is urged into contact with a head of the second moveable member to form an aperture for restraining the yarn therein; -
FIG. 8D is a cross-sectional side view of the yarn control device ofFIG. 7A , illustrating the first moveable in an inoperative configuration and the second moveable member in an operative configuration, whereby a head of the second moveable member is urged into the operative region of the body to clamp the yarn thereto; -
FIG. 9A is a schematic view of the body and yarn being brought into proximity with each other; -
FIG. 9B is a schematic view of a pair of angled jaws that direct the yarn towards an operative region of the body, entrapping the yarn therein; -
FIG. 9C is a schematic view of the yarn restrained within the operative region of the body, such that the yarn can traverse the operative region; -
FIG. 9D is a schematic view of the yarn clamped against the operative region of the body, such that the yarn cannot move; -
FIG. 10 is a schematic view of a lance head having a nozzle adapted to propel a second fluid flow, illustrating a yarn tail crossing into the second fluid flow and becoming entrained therewith; -
FIG. 11A illustrates is a cross-sectional side view initial stage of a yarn feeding process, showing a yarn brake in a disengaged position; -
FIG. 11B illustrates the yarn brake ofFIG. 11A in an engaged position; -
FIG. 11C Is a perspective view illustrating the yarn brake ofFIG. 11A in the disengaged position and coupled to the gripper assembly ofFIG. 4A ; -
FIGS. 12A to 12D show a side view of the package gripper removing an empty core from a package holder of a creel; -
FIGS. 13A to 13C show a side view of the package gripper transferring the empty core to the winder; -
FIG. 14A is a perspective view of a core, to be wound by the winding machine ofFIG. 1 ; -
FIG. 14B is a perspective view of a wound core, the core ofFIG. 14A having been wound with a first span of yarn; -
FIG. 14C is a perspective view of a yarn package, the wound core ofFIG. 14B having been wound with a second span of yarn; -
FIG. 15A is a rear view of the creel ofFIG. 2A , showing a first yarn feed path from a first package holder to a first outlet within the header, and a second yarn feed path from a second package holder to a second outlet within the header; -
FIG. 15B is a side view of the creel ofFIG. 2A , showing first and second portions of the first and second yarn feed paths; -
FIGS. 16A to 16F show an end view of the package gripper removing a yarn package from the winder; -
FIG. 17A is an enlarged view of the winding machine or winder doffing the yarn tail; -
FIG. 17B is a view of a wound yarn spool with the yarn control device gripping the yarn tail of the yarn on the package; -
FIG. 18 is a perspective view of the gripper assembly ofFIG. 4A , illustrating the yarn control device mounted thereon; -
FIGS. 19A-19E are side views of the gripper assembly loading a yarn package into a housing of the creel and threading the yarn tail through the conduit of the housing, wherein: -
FIG. 19A illustrates the gripper assembly approaching the package housing, with the yarn grasped by the yarn control device; -
FIG. 19B illustrates the yarn package being moved towards the support boss within the housing, with the yarn still held by the jaws of the yarn control device; -
FIG. 19C illustrates the yarn package being mounted on the support boss within the housing, with the yarn still constrained by the yarn control device; -
FIG. 19D illustrates the body of the yarn control device having rotated 180 degrees to direct the yarn tail across the inlet of the conduit to intersect the second fluid flow from the lance; -
FIG. 19E illustrates the yarn threaded through the conduit of the housing, such that the yarn tail protrudes from the housing as the yarn control device is rotated back 180 degrees and the gripper assembly is retracted to retrieve either of: a new yarn package from the winder; and an empty core from the creel; -
FIG. 20A is a side view of the conduit within the housing and a second fluid outlet mounted on a lance, illustrating the second fluid outlet aligned with an opening of the conduit; -
FIG. 20B is a sectional view of the conduit aligned with the lance ofFIG. 20A ; -
FIG. 20C is an enlarged view of a conduit opening aligned with the second fluid outlet to receive the yarn tail; -
FIG. 21A illustrates the yarn control device holding the yarn tail in proximity to the package housing of the creel, and a lance of the gripper assembly aligned with an inlet of the conduit; -
FIG. 21B illustrates the yarn tail fed into the inlet and through the conduit by a second fluid flow expelled from the lance towards the conduit inlet; -
FIG. 21C is a schematic view of the yarn travelling through a conduit of the housing on a creel, the yarn tail being captured by a covered header plate; -
FIG. 22A illustrates an initial stage of a yarn feeding process, showing the yarn brake ofFIG. 11A in the disengaged position proximate a yarn package; -
FIG. 22B illustrates a subsequent stage of the yarn feeding process, showing the yarn brake in an engaged position, with yarn being fed from the yarn package under tension; -
FIG. 22C illustrates a further stage of the yarn feeding process, showing the yarn brake in an engaged position, inhibiting further feeding of yarn; and -
FIG. 22D illustrates a final stage of the yarn feeding process, illustrating the yarn brake moving to an inoperable position, after the feeding of yarn has been completed. - In this description, the term “yarn” is understood to be a continuous strand composed of either natural or man-made fibres or filaments and used in weaving, tufting, sewing and knitting. The term is intended to be synonymous with the term, thread, fibre, string, filament, twine, strand, ply, cord, line, wool or cotton and the like.
- In this description, the term “yarn package” is understood to mean a core that is would with a known, predetermined amount of yarn that is used to supply a machine for producing yarn-based products including textiles, for example soft floor coverings such as carpet and rugs. The term is intended to be synonymous with the terms: spool, bobbin, cone and the like.
- In this description, axis and movements in the X, Y and Z directions are to be understood generally as horizontal, longitudinal and vertical movements respectively. For clarity, some of the accompanying Figures include an indicator to mark the respective orientations.
- Yarn Handling System
- The following section and accompanying Figures are used to describe an automated yarn handling system for loading and unloading yarn packages into a creel. Various aspects of the handling system will then be explored in more detail, in later sections.
-
FIGS. 1A to 1D show ayarn handling system 1 comprising acreel 10 and awinder 40. Theyarn handling system 1 further comprises agripper assembly 70, that is used to transfer yarn packages 30 between thewinder 40 andcreel 10, to facilitate loading and unloading of thecreel 10. Thegripper assembly 70 is connected to agantry 50, so as to be moveable between thecreel 10 andwinder 40. The yarn packages 30 comprise acore 31 around which a quantity ofyarn 32 is wound. The yarn packages 30 are discussed in detail below with reference toFIGS. 14A to 14C . - The Creel
- The
creel 10 shown in the Figures is a mobile creel comprising acreel frame 11 andwheels 12. Theframe 11 holds the elements of thecreel 10 together. Thecreel 10 is a double-sided creel, having two sides, afirst side 13 and asecond side 14, each side comprising an array of creel positions. Eachside creel 10 has an outwardly facing loading face 13 a,14 a, respectively, and an inwardly facingnon-loading face FIG. 1C . Each loading face 13 a,14 a comprises an array ofpackage holders 20 for receiving a designatedyarn package 30 therein. - It is understood, however, that the
creel 10 could, alternatively, be a single sided creel, as shown inFIGS. 2A and 2B , with the creel positions each being disposed on afirst side 13 thereof. In a single sided creel, thesecond side 14 is considered to be a non-loading side of thecreel 10. - Each creel position comprises a
package holder 20, for receiving and supporting ayarn package 30. Thepackage holders 20 are arranged in a hexagonal array. Eachpackage holder 20 comprises a mountingbracket 21 sized and shaped to receive acore 31 of theyarn package 30, and ahousing 22. - Best shown in
FIGS. 3A and 3B , thehousing 22 comprises a tube that at least partially encircles the mountingbracket 21. Thehousing 22 is open at one end, extending to a closed end disposed on a non-loading face of thecreel 10. Thehousing 22 serves as a protective shield for theyarn package 30 contained therein, reducing the possibility of debris from falling thereon, and preventingyarn tails 33 of theyarn package 30 from dropping into anadjacent package holder 20 below and becoming entangled with anadjacent yarn package 30. Such entanglements take time to clear and would otherwise cause the carpet making machine to be shut off while the problem is assessed, and the entangled yarn is cleared, reducing the productivity of thesystem 1 as a whole. As shown, eachhousing 22 extends circumferentially around arespective package holder 20. It is noted, however, thathousings 22 only need to partially surround eachpackage holder 20, in order to catch theyarn tail 33 from theyarn package 30 therein falling under gravity towards anadjacent package holder 20. - Other methods of protecting the yarn packages 30 from entanglement with yarn of
other yarn packages 30 inother package holders 20 and from debris are also contemplated within the overall scope of the present disclosure. - With reference to
FIGS. 3A to 3B , the mountingbracket 21 is configured to receive and support theyarn package 30 thereon. The mountingbracket 21 is located centrally within thehousing 22 and towards a closed end thereof. The mountingbracket 21 comprises acentral plinth 21 a configured to contact aninner surface 31 a of thecore 31 of the yarn package 30 (see, for example,FIGS. 11A and 11B ), and may include aresilient member 21 b to engage theyarn package 30 and removably hold it in place. The mountingbracket 21 is sized such that it does not contact a full length of theyarn package 30. - Returning now to
FIGS. 2A and 2B , eachpackage holder 20 further comprises ayarn conduit 24 through which arespective yarn tail 33 travels towards anoutlet 60. Theoutlet 60 receives therespective yarn tail 33 from theyarn package 30, and supplies the yarn to the production machine. - The
yarn conduit 24 includes arigid conduit 24 a that extends from acentral opening 25 through which the yarn is drawn to aterminal aperture 23 disposed within a non-loading face of thecreel 10. Theopening 25 protrudes outwardly from the open end of thehousing 22, such that theyarn conduit 24 extends therefrom, when viewed in a side profile. In the illustrated embodiment, theyarn conduit 24 passes through thecentral plinth 21 a of the mountingbracket 21. Therigid conduit 24 a can be a plastic material or a metal such as steel or aluminium. Therigid conduit 24 a preferably has an internal diameter of between 2 mm and 6 mm, and preferably about 4.8 mm - The
rigid conduit 24 a guides theyarn tail 33 through thehousing 22 to exit thehousing 22 at anaperture 26, where theyarn tail 33 enters theflexible conduit 24 b which guides theyarn tail 23 to theoutlet 60. Theflexible conduit 24 b is a tube or a hose and can be made from plastic and other resilient materials synthetic or otherwise. Theflexible conduit 24 b can be transparent to allow theyarn tail 33 to be visible as it exits therigid conduit 24 a. This can provide a visual inspection point to assess the yarn tail's 33 progress along theflexible conduit 24 b. - In other embodiments, it is contemplated that
bespoke conduits 24 can be individually dimensioned as rigid conduits that run through thehousing 22 and up to theoutlet 60 thereby replacingflexible conduits 24 b; however, for ease of manufacture the combination of rigid 24 a and flexible 24 b portions is preferred. - The Header
- Best shown in
FIGS. 2A and 2B , theoutlet 60 is one of a plurality of outlets provided within aheader 61, with eachoutlet 60 being associated with arespective package holder 20 within thecreel 10. TheHeader 61 is attached to thecreel 10. - The
header 61 comprises aheader plate 62 within which each of the plurality ofoutlets 60 are disposed. Theheader plate 62 is enclosed by aheader cover 63. Theheader cover 63 is moveable between an open position to a closed position. Theheader cover 63 is made of a perforated or screen-type material, allowing air to flow though theheader cover 63, while theyarn tails 33 remain contained therein. - In the closed position, the
header cover 63 is configured to capture and restrain theyarn tails 33 during, for example, transportation of thecreel 10. With theheader cover 63 in the closed position, theyarn tails 33 are constrained therein preventing them from interfering with the operation of loadingfurther packages 30 into thecreel 10. - In the open position, the
header cover 63 provides access to theyarn tails 33 for connecting to the production machine via, for example, splicing of thetails 33 to the machine for use. The open configuration of theheader cover 63 is also shown in broken line inFIG. 21D . - The Winder
- Returning now to
FIGS. 1A-1D , thewinder 40 is located adjacent to thefirst side 13 of thecreel 10. According to embodiments of the invention, a plurality ofwinders 40 may be located adjacent to thefirst side 13 of thecreel 10. Similarly, one ormore winders 40 may be located adjacent to thesecond side 14 of thecreel 10. - In the embodiment shown in
FIG. 1A , thewinder 40 includes three windingheads 41. Each windinghead 41 is the area of thewinder 10 where yarn is wound onto a core 31 to form ayarn package 30. Thewinder 40 may be controlled by a user or may be automated to select a desired length of yarn to be wound onto each core 31. - The length of yarn wound on a
particular yarn package 30 is calculated based on the amount of yarn required at therespective package holder 20 where theyarn package 30 will be placed. Accordingly, someyarn packages 30 may comprise more yarn than other yarn packages 30. - A
winder supply store 43 is located adjacent to thewinder 40. Thewinder supply store 43 has at least oneyarn supply 44 that provides yarn to each windinghead 41, when desired. Preferably, theyarn supply store 43 comprises a plurality of yarn supplies 44 in the form of large packages of yarn. Eachyarn supply 44 may provide yarn in a desired colour. Each windinghead 41 may be supplied by adistinct yarn supply 44 relative to the other windingheads 41. - In order to service the
package holders 20 on each side of thecreel 10 simultaneously, at least onewinder 40 andgantry frame 50 may be located respectively adjacent to each of the first andsecond sides creel 10 respectively. - Alternatively, in some instances, the or each
winder 40 may be located adjacent to thefirst side 13 of thecreel 10 only, such as shown inFIGS. 1A to 1D . In that case, only oneside creel 10 may be serviced by thehandling system 1 at a time. For example, thefirst side 13 may be filled withyarn packages 20 initially. Once thefirst side 13 is fully loaded withpackages 30, theentire creel 10 may be rotated such that thesecond side 14 is located adjacent to the winder 40 (i.e. in the position previously of thefirst side 13 shown inFIGS. 1A to 1D ). Thesecond side 14 may then be filled withyarn packages 30 and/orempty cores 31 removed therefrom, where necessary. Thecreel 10 is preferably fixedly held in each position, such that therespective side winder 40 is positioned in a known location relative to thewinder 40, which is also fixedly held in position. - The
winder 40 may comprise astorage buffer 42 configured to hold a singleempty core 31. In the embodiment shown inFIG. 1 , thewinder 40 may comprise three storage buffers 42 (best shown inFIG. 17 a ) which each serve one of the windingheads 41, respectively. Thestorage buffer 42 enables an empty core to be wound while another empty core is being delivered to thewinder 40 at the same time. Eachstorage buffer 42 may be provided with anempty core 31 by a port in the side wall of thewinder 40, through which anempty core 31 may be inserted. When the windinghead 41 requires anempty core 31, theempty core 31 in the storage buffer may be lifted within thewinder 40 to the windinghead 41. - Alternatively, the
storage buffer 42 may be a magazine which is adapted to hold a plurality ofempty cores 31. Anempty core 31 will be passed from the magazine to a windinghead 41 when it is required for forming anew yarn package 30. The winding heads 41 may share a common magazine or, preferably, each windingarea 41 may comprise its own distinct magazine, such that, for example, where there are three windingheads 41 there may be three magazines. The magazine may comprise a port which is sized to receive theempty cores 31. Theempty cores 31 will be held in line in the magazine and sent to the windinghead 41 in order when anew yarn package 30 is required. - The Gantry Frame
- The
gantry frame 50, as shown inFIGS. 1A to 1D comprises a frame formed byvertical members 51,longitudinal members 52 and angled supports 53. Thevertical members 51 are respectively located outwardly of each corner of thecreel 10 such that thegantry frame 50 surrounds thecreel 10. Thevertical members 51 at either end of thesystem 1 are connected at their upper ends by thelongitudinal members 52, with thelongitudinal members 52 extending in the Y-direction as shown inFIG. 1 . Anangled support 53 is connected to eachvertical member 51 to provide stability to the frame arrangement of thegantry frame 50. The lower ends of thevertical members 51 and the angled supports 53 are preferably connected to the ground, such as by bolts through flange sections, to ensure thegantry frame 50 remains stable in its position. -
Brackets 54 are attached at spaced apart locations to thelongitudinal members 52. Thebrackets 54 are positioned on the inner side of thelongitudinal members 52 such that eachbracket 54 on onelongitudinal member 52 faces towards abracket 54 on the otherlongitudinal member 52. - As shown in
FIG. 1A , anupper rail 55 is attached at either end tobrackets 54, such that theupper rail 55 extends horizontally between adjacentlongitudinal members 52. Alower rail 56 is located directly below theupper rail 55, extending horizontally betweenlongitudinal members 52. Thelower rail 56 is preferably rigidly held in place on the ground, such as via bolts or other appropriate fastening devices. In the embodiment shown inFIG. 1A there is only a single upper 55 34 located outwardly of thefirst side 13 ofcreel 10, however it is envisaged that anotherupper rail 55 could be located between thebrackets 54 of thelongitudinal members 52 outwardly of thesecond side 14 of thecreel 10. Similarly, anotherlower rail 56 would be located beneath the second upper rail (not shown). - Best shown in
FIG. 1B , avertical rail 57 extends between the upper andlower rails vertical rail 57 is moveably connected to each of the upper andlower rails vertical rail 57 may move along the X-direction, as shown in the Figures. In the embodiment shown, the upper end of thevertical rail 57 comprises anupper platform 55 a and the lower end of thevertical rail 57 comprises alower platform 56 a. Theupper platform 55 a comprisesrollers 55 b which engage with atrack 55 c in theupper rail 55. Similarly, thelower platform 56 a comprisesrollers 56 b which engage with atrack 56 c of thelower rail 56. Thevertical rail 57 is therefore adapted to maintain its vertical alignment along the Z-direction when moved along the X-direction. Anupper motor 55 d is attached to theupper platform 55 a. Alower motor 56 d is attached to thelower platform 56 a. The upper andlower motors upper motor 55 d is operated to cause a movement in a first direction, thelower motor 56 d will be simultaneously operated to cause a movement in the first direction, and each motor will activate and stop at the same time. Themotors - A
platform 57 a is moveably connected to thevertical rail 57. Thevertical platform 57 a hasrollers 57 b which engage with a track 57 c of thevertical rail 57 such that thevertical platform 57 a is moveable vertically along the length of thevertical rail 57. Avertical motor 57 d controls the motion of thevertical platform 57 a. Thevertical motor 57 d preferably functions in a similar manner to the upper andlower motors motors vertical rail 57 and/orvertical platform 57 a. - An
arm rail 58 is attached to thevertical platform 57 a. Thearm rail 58 extends longitudinally in the Y-direction as shown inFIGS. 1A and 10 . Arotatable connector 58 a is adapted to be moveable longitudinally along thearm rail 58 in the Z-direction. Therotatable connector 58 a may have rollers 58 b which engage with tracks 58 c on thearm rail 58. Therotatable connector 58 a may comprise a connector motor 58 d which controls the movement of therotatable connector 58 a along thearm rail 58. - The Gripper Assembly
- The
gripper assembly 70 is connected to thegantry frame 50 via therotatable connector 58 a in a manner such that it is moveable vertically, horizontally, and rotatably. Thegripper assembly 70 is preferably moveable between any of thepackage holders 20 of thefirst side 13 of thecreel 10 and may provide ayarn package 30 to or retrieve anempty core 31 from arespective package holder 20, when required to do so. In addition, thegripper assembly 70 may be manipulated and positioned to provide anempty core 31 to or retrieve awound yarn package 30 from thewinder 40. - In the embodiment shown in
FIGS. 1A to 1D asingle gripper assembly 70 is moveable along thegantry 50 relative to thefirst side 13 of thecreel 10 andwinder 40. In other possible embodiments, thesystem 1 may include asecond winder 40′ on thefirst side 13 of thecreel 10. In such embodiments, thesecond winder 40′ will preferably be serviced by asecond gripper assembly 70′, also coupled to thegantry 50. A secondvertical rail 57′ being moveable horizontally on the upper andlower rails vertical rail 57. Accordingly, eachgripper assembly 70 may respectively be moveable on thegantry 50 between itsrespective winder 40 and half of thepackage holders 20 at one end of thecreel 10 most proximal to therespective winder 40. - The
gripper assembly 70 connects to a side of therotatable connector 58 a opposite to thearm rail 58. Thegripper assembly 70 is rotatably connected to therotatable connector 58 a in a manner such that thegripper assembly 70 may be rotated between a first orientation where afront end 71 of thegripper assembly 70 faces towards thecreel 10 in the Y-direction and a second position where thefront end 71 of thegripper assembly 70 faces towards thewinder 40 in the Y-direction. Thus, the movement of therotatable connector 58 a in the Y-direction may cause thegripper assembly 70 to move towards or away from thecreel 10 when in the first orientation. Similarly, the movement of therotatable connector 58 a in the Y-direction may cause thegripper assembly 70 to move towards or away from thewinder 40 in the second orientation. The connector motor 58 d may control the rotation of thegripper assembly 70 between the first and second orientations. Alternatively, thegripper assembly 70 may comprise a separate motor which controls the rotation between the first and second orientations. The rotation of thegripper assembly 70 may be pneumatically controlled and may comprise hydraulic bump stops. - According to yet another embodiment (not shown), two
winders 40 may be positioned on eachside winders 40 are positioned adjacent to thefirst side 13 of thecreel 10 and a further twowinders 40 are positioned adjacent to thesecond side 14 of thecreel 10. Thewinders 40 are preferably located at opposing ends of thecreel 10. In this embodiment, a second upper rail and a second lower rail are located adjacent thesecond side 14 of thecreel 10 between thecreel 10 and the twowinders 40. Further, adjacent to eachside creel 10, thegantry 50 may comprise twovertical rails 57, each being moveable horizontally on respective upper andlower rails gripper assemblies 70 are thus moveable vertically and horizontally and rotatably on the respectivevertical rails 57 on each side of thegantry 50, with eachgripper assembly 70 being moveable on thegantry 50 between itsrespective winder 40 and the half of thepackage holders 20 of therespective side creel 10 most proximal to therespective winder 40. - Referring now to
FIGS. 4A-4C . Thegripper assembly 70 has arail 73 which extends longitudinally between the front 71 and rear 72 ends of thegripper assembly 70. Therail 73 provides a body of thegripper assembly 70. Thefront end 71 includes ahead 74 which is attached to asnout 75. Thehead assembly 74 is configured to be received within the central hollow of thecore 31. Thehead 74 is in the form of a cylindrical member and thesnout 75 extends from thehead 74 towards thefront end 71 of thegripper assembly 70. Thesnout 75 is independently moveable with respect to thehead 74. Thesnout 75 is also a cylindrical member with a smaller radius that than thehead 74. Further, thesnout 75 has a length in the longitudinal direction of thegripper assembly 70 which is larger than the longitudinal length of thehead 74. - The
head 74 has fourtabs 74 a which extend in the longitudinal direction towards thefront end 71 of thegripper assembly 70. Thetabs 74 a are evenly spaced around the circumference of thehead 74. Thesnout 75 comprises fourribs 75 a which are parallel to thetabs 74 a and extend longitudinally along the surface of thesnout 75. Thegripper assembly 70 further comprises fourfingers 76. The four articulatedfingers 76 extend along thesnout 75. Eachtab 74 a is connected to eachfinger 76 at the rear of therespective finger 76 via twoconnectors 77, with aconnector 77 located on either side of thetab 74 a. Eachfinger 76 is connected to therespective rib 75 a via twoconnectors 70 towards the front of thefinger 76 with, one connector 77 a,b on either side of the finger. Eachfinger 76 is also coupled to therespective rib 75 a via two additional connectors 70 c, 70 d towards the rear of thefinger 76 on either side of thefinger 76. Together, theconnectors 77 pivotally couple each of therespective fingers 76 to therespective ribs 75 a and tabs 74 b. The location of thepivotal connectors 77 are such that a longitudinal motion of thesnout 75 relative to thehead 74 will cause thefingers 76 to move radially relative to thesnout 55. - The described arrangement of the
head 74,snout 75,fingers 76,ribs 74 a,tabs 75 a andconnectors 70 create agripping jaw 78 which may be utilised to grasp theinner surface 31 a of ayarn package 30. Thejaw assembly 78 is configurable between a closed state, in which thefingers 76 lie against thesnout 75, to an open state, in which thefingers 76 extend radially outwards and do not contact thesnout 75.FIG. 4C shows thejaw assembly 78 in the closed state, whilstFIG. 4D shows thejaw assembly 78 in the open state. InFIGS. 4C and 4D , the jaw of a diameter defined by theassembly 78 is indicated in dashed outline. In the closed formation thefingers 76 are positioned radially inwards adjacent to theribs 75 a. In the open formation thefingers 76 are positioned radially outwards away from theribs 75 a. - The
jaw assembly 78 is configured to grasp onto thecore package 30 from within thecore 31, to facilitate transport thereof. With thejaw assembly 78 in the closed state, thehead 74 is driven forward and thesnout 75 is inserted into thecore 30. Thejaw assembly 78 is then expanded to the open state, where thefingers 76 push outwardly against theinner surface 31 a of thecore 31. With theyarn package 30 now secured to thejaw assembly 78, thehead 54 is retracted, removing theyarn package 30 from the windingmachine 40. - The gripping action of the jaw 48 may be a reverse chuck arrangement. For example, the
snout 75 may be moved longitudinally relative to thehead 74. When thesnout 75 moves longitudinally, theconnectors 70 interact with therespective tabs 74 a, ribs 75 b andfingers 76 to cause a radial motion of thefingers 76. When thesnout 75 moves longitudinally towards thefront end 71 thefingers 76 will each move radially outwards from thesnout 75. Similarly, when thesnout 75 then moves longitudinally towards therear end 72, thefingers 76 will each move radially inwards relative to thesnout 75. The maximum inward radial movement of thefingers 76 will cause thefingers 76 to contact theribs 75 a. A pressurised fluid, such as pressurised air, may be utilised to cause a movement of thejaw 78. The motion of thefingers 76 of thejaw 78 radially inwards or outwards may be controlled by a controller. - As shown in
FIGS. 4A and 4B , thegripper assembly 70 includes apneumatic cylinder 79. Thepneumatic cylinder 79 is located adjacent to thegripper body 73 and extends longitudinally from the rear 72 towards thefront end 71 of thegripper assembly 70. Application of compressed air may cause apiston rod 79 a to extend longitudinally outwards from thepneumatic cylinder 79. Thehead 74 is connected to the front of thepiston rod 79 a such that thehead 74 andjaw 78 will move longitudinally when thepiston rod 79 a extends from thepneumatic cylinder 79. In this manner, thejaw 78 may be placed into a desired location, such as when collecting ayarn package 30 from the windingarea 41, delivering ayarn package 30 to apackage holder 20, when collecting anempty core 31 of ayarn package 30 from apackage holder 20, or when delivering anempty core 31 to thewinder 40. - In order to align the
jaw 78 correctly with apackage holder 20, thegripper assembly 70 orcreel 10 may comprise a sensor and/or camera (not shown). For example, thegripper assembly 70 orcreel 10 may comprise a feature recognition camera that is configurable to align thejaw 78. The camera(s) or sensor(s) used may at least identify the corners of thecreel 10 in order to manoeuvre and align thejaw 78 correctly with a desiredpackage holder 20. The camera(s) or sensor(s) may be configured to identify eachpackage holder 20 individually for accurate alignment. Similarly, camera(s) and/or sensor(s) may be utilised to manoeuvre and position thejaw 78 relative to a or thewinder 10. The sensing system used may utilise LiDAR (light detection and ranging) for accurate positioning of thejaw 78. - The above description and accompanying figures show and describe a
gripper assembly 70 which is operated and controlled through pneumatic actuators and the flow of pressurised gas, such as pressurised air. However, liquids can be substituted for the working fluids as described herein. Likewise, thegripper assembly 70 can be controlled and manipulated via mechanical or electrical means. A controller is preferably provided to control the movement and position of thegripper assembly 70. Thegripper assembly 70 can be automated and utilise sensors to determine when anempty core 31 is to be removed from acreel position 20 or when ayarn package 30 is to be delivered to acreel position 20. Computer software is preferably provided to control the movement of thegripper assembly 70 and the processes of loading thepackages 30 into thehousings 22 of thecreel 10. - Yarn Control Device
- It is preferable for the
gripper assembly 70 to controllably retain theyarn tail 33 of therespective yarn package 30. This process is facilitated by way of ayarn control device 101. It is to be understood that theyarn control device 101 can also be used for other yarn handling applications, outside ofyarn handling system 1. -
FIGS. 5 to 9 are generally directed to ayarn control device 101 for controlling ayarn tail 23 of ayarn 32 from a spool thereof such asyarn package 30. Theyarn control device 101 comprises: amoveable body 102 configured to capture theyarn 32 and guide theyarn 32 to anoperative region 105 of thebody 102; aninlet 107 for introducing a first fluid into the body; a firstfluid outlet 110 located in proximity to theoperative region 105 of the body, and oriented to expel the first fluid in a first fluid flow F; and a firstmoveable member 109 within thebody 102 that moves between an operative configuration to clamp theyarn 32 and an inoperative configuration to release theyarn 32; wherein in the operative configuration theyarn 32 is clamped in theoperative region 105 of thebody 102 such that the first fluid flow captures theyarn tail 33 and orients theyarn tail 33 coaxially with the first fluid flow F, whereby movement of the movable 102 2 adjusts the direction of the first fluid flow F andyarn tail 33 entrained therein to control orientation of theyarn tail 33. - The
body 102 is configured to received and guide theyarn 32 towards theoperative region 105. Thebody 102 comprises a pair of angled jaws comprising anupper jaw 103 and alower jaw 104 that converge at aslot 121 within theoperative region 105 of thebody 102. Thejaws yarn 32 to travel across thejaws jaws - On a first face of the
body 102 is a plurality of supply ports for introducing fluids into thebody 102, including the firstfluid inlet 107 that introduces a first fluid into thebody 102 to be expelled at the firstfluid outlet 110. The first fluid can be a gas. The first fluid in one embodiment is air fed to the firstfluid inlet 107 as compressed air. InFIG. 5 the firstfluid outlet 110 is configured to expel the first fluid flow from the firstfluid outlet 110 away from the 102 in a direction perpendicular to a major axis X of the body. The first fluid flow runs parallel to a run direction of theyarn 32 as it passes across theoperative region 105 of thebody 102. It is contemplated that the arrangement of thejaws yarn 32 and the firstfluid outlet 110 could be configured in a number of alternative configurations within the scope of the invention. - Further to the first
fluid inlet 107 is a working fluidactivation supply port 106 and a working fluiddeactivation supply port 108. By introducing a working fluid into thebody 102 themoveable member 109 is moved within thebody 102 to contact and clamp theyarn 32 within theoperative region 105. The working fluid can be a gas. The working fluid can be compressed air. The working fluid can be a liquid. - The
moveable member 109 can be a piston configured to reciprocate within a bore or chamber 122 (not shown) of thebody 102. As the working fluid is introduced into the chamber 122 themoveable member 109 is urged towards theoperative region 105 to clamp theyarn 32 therein seeFIG. 5C . - The
body 102 provides anupper access panel 112 and alower access panel 113 each mounted to thebody 102 by at least one retainingscrew 115. Removal ofaccess panels body 102. Thebody 102 includes a plurality of mountingholes 114 for mounting thebody 102 to asupport arm 120 to facilitate at least one of translational and rotational movement thereof. - The
moveable member 109 has ahead 111 a that traverses theoperative region 105 in anticipation of receiving theyarn tail 33, as illustrated inFIG. 5B . Thehead 111 has a smaller cross-sectional area than a cross-sectional area of abody 111 a of themoveable member 109 that presents a bar across theslot 121 of theoperative region 105 for retaining theyarn tail 33 on ashoulder 119 of themoveable member 109. - As the
moveable member 109 is activated by the working fluid themoveable member 109 traverses theoperative region 105 until theshoulder 119 of contacts anupper surface 121 a of theslot 121. As theshoulder 119 contacts theupper surface 121 a theyarn 32 is trapped therebetween and can no longer move relative to theoperative region 105. Theyarn 32 is then clamped in position relative to thebody 102, seeFIG. 5C . - To release the
yarn 32, the working fluiddeactivation supply port 106 is opened, allowing the working fluid to enter a secondary chamber 125 (not shown) to drive themoveable member 109 away from theoperative region 105. As each ofsupply ports moveable member 109 can be driven back and forth by the introduction of the working fluid alternately between the first chamber 122 and the secondary chamber 125 from therespective supply ports -
FIG. 5B illustrates themoveable member 109 in an inoperative configuration such that the upper face of theslot 121 a and theshoulder 119 are spaced apart ready to receive theyarn 32 as it travels across at least one of thejaws yarn 32 can enter theoperative region 105 of thebody 102 and is restrained within theslot 121 against thehead 111 while seated upon theshoulder 119. - In
FIG. 5C , themoveable member 109 has been driven across theoperative region 105 to trap theyarn 32 between theshoulder 119 and the upper surface of theslot 121 a. This clamps theyarn 32 in proximity to the firstfluid outlet 110. When the first fluid is introduced into thebody 102 viafirst fluid inlet 107, the first fluid travels through a bore 127 (not shown) within thebody 102 to be expelled at the firstfluid outlet 110 in the first fluid flow F. Theyarn tail 33 becomes entrained within the first fluid flow F, and axially aligned therewith. - Where the
yarn 32 is clamped in theoperative region 105, theyarn tail 33 of theyarn 32 is trapped in fixed relationship with thebody 102. When no fluid is directed to the firstfluid outlet 110 theyarn tail 33 will trail from theoperative region 105, as shown inFIGS. 6A and 6C . - When the first fluid flow F is activated, the
yarn tail 33 will be caught and entrained within thefirst fluid flow 102 and oriented to extend from theoperative region 105 away from thebody 102 parallel to the first fluid flow F. By moving thebody 102 in at least one of translational movement and rotational movement for example in the direction indicated by arrow R inFIG. 6B theyarn tail 33 can be moved and directed towards a target region or receiver. -
FIG. 6C is a perspective of theyarn control device 101 operatively gripping ayarn tail 33 with the first fluid flow F not activated, such that theyarn 32 is held in theoperative region 105 of thebody 102 and theyarn tail 33 hangs free under gravitational force only. -
FIGS. 7A and 7B illustrate a second embodiment of theyarn control device 201. Theyarn control device 201 has the same external features are those described herein in relation toyarn control device 101. For convenience, similar reference numerals are used to describe analogous features. However, themoveable member 109 is replaced by a firstmovable member 209 and a secondmoveable member 239 and hence two additionalfluid supply ports moveable member 239.FIG. 7A illustrates theyarn control device 201 deactivated, whereFIG. 7B is illustrated in an operative configuration where the secondmoveable member 239 has been activated to constrain theyarn 32 but not clamp theyarn 32. - The
body 202 has a pair of jaws, illustrated asupper jaw 203 andlower jaw 204 with bevellededges slot 221 is located where the twojaws operative region 205 of thebody 202. -
Upper 212 and lower 213 access panels are provided for access to afirst chamber 222 and asecond chamber 225 for maintenance and replacement of the firstmoveable member 209 and secondmoveable member 239, respectively. - On an opposing face of the body to the pair of
jaws fluid inlet 207. The firstfluid inlet 207 is located centrally of thebody 202 to introduce the first fluid into thebody 202 in communication with abore 227 for supplying the first fluid to a first fluid outlet 178. Below the firstfluid inlet 207 is second fluidactivation supply port 240 and second fluiddeactivation supply port 241. Above the firstfluid inlet 207 is a first fluidactivation supply port 206 and first fluiddeactivation supply port 208. - It is understood that the first and second working fluids can be a gas. The first and second working fluids can be compressed air. The first and second working fluids can be sourced from the same compressed air supply or two discrete air supplies. The first and second working fluids can be a liquid and can be sourced from two discrete fluid supplied or a single fluid supply.
- In
FIG. 7B ahead 226 of the secondmoveable member 239 is illustrated traversing theoperative region 205 to form anaperture 218 for constraining theyarn 32 therein. This is an operative configuration than provides ayarn tail 33 feeding mode of theyarn control device 201. This is to be contrasted withFIG. 7A which illustrates an inoperative configuration of theyarn control device 201 in which neither the firstmoveable member 209 nor the secondmoveable member 239 is activated. - The
body 202 of theyarn control device 201 provides similar mounting features 214 to that ofbody 102 for driving thebody 202 in at least one of translational movement and rotational movement. -
FIGS. 8A-8D are cross-sectional illustrations of theyarn control device 201 and illustrate the internal components thereof. -
FIG. 8A is a front sectional view of theyarn control device 201 in the operative clamping mode where each of themoveable members head 211 of the firstmovable member 209 clamping down upon the lower surface 221 n of theslot 221. Thehead 211 is concaved and has an outerperipheral rim 211 a that clamps down over theyarn 32 holding it firmly in place against thelower surface 221 b of theslot 221.FIG. 8A also illustrates an end on view of thebore 227 that communicates the first fluid from the firstfluid inlet 207 to the firstfluid outlet 210. -
FIG. 8B illustrates theyarn control device 201 in an inoperative configuration, awaiting contact with theyarn 32. - The supply port arrangement shown in
FIG. 8C will be described in relation to the firstactivation supply port 206. Thesupply port 206 is connected to abody port 242 of thebody 202. Thesupply port 206 can be a snap-fit or snap-lock connector that delivers compressed air or alternative second working fluid to thebody port 242. - The first working fluid is maintained within the
body 202 and as such either liquids or gases can be selected to drive themoveable members body port 206 is in fluid communication with thefirst chamber 222 via acommunication channel 243, allowing the first working fluid to be forced into thechamber 222 on activation of fluid to thesupply port 206. Each of thesupply ports port 240. - When the first working fluid enters the
chamber 222 the firstmovable member 209 is driven towards theoperative region 205. When the firstmovable member 209 is to be released the working fluid is driven to the firstdeactivation supply port 206 and the supply of first working fluid to the firstactivation supply port 206 is ceased. This drives the firstmovable member 209 away from theoperative region 205 and towards theaccess panel 212, as shown inFIG. 8C . -
FIG. 8C illustrates theyarn control device 201 in an operative configuration, in a feeding mode. The second working fluid is pumped into thebody 202 via secondactivation supply port 240 wherein the secondmoveable member 239 is activated to drive ahead 226 of the secondmoveable member 239 into theoperative region 205. Thehead 226 protrudes from the secondmoveable member 239 in the form of a spigot having aplanar end 224. Theplanar end 224 is driven upwards into contact with thehead 211 of the firstmoveable member 209, thereby formingaperture 218 within which theyarn 32 is captured. Theyarn 32 is restrained within theaperture 218 in close proximity to theoperative region 205 of thebody 202 but is fee to slide or feed through theaperture 218. - The
head 211 of the first moveable member is concave and has a greater diameter than a diameter of thehead 226 of the second moveable member. When thesecond head 226 is driven into thefirst head 211 theyarn 32 is trapped in theaperture 218 formed in theoperative region 205. - With the
yarn control device 201 in the feeding mode, activating the first fluid flow F, will expel the first fluid from the firstfluid outlet 210 to form the first fluid flow F. The first fluid outlet F is in close proximity to theoperative region 205 and captures theyarn tail 33 of the restrainedyarn 32. Theyarn tail 33 becomes captured or entrained within the first fluid flow F directing theyarn tail 33 away from thebody 202 perpendicularly to thebody 202 and perpendicular to thebore 227. - As the
yarn 32 is not clamped the first fluid flow captures theyarn tail 33 and draws theyarn 32 through theaperture 218 across theoperative region 205 increasing a length of theyarn tail 33. When theyarn tail 33 reaches a sufficient length for threading into thecreel 10 the first air flow F is deactivated and/or the firstmoveable member 209 is activated to clamp theyarn 32 and terminate the feeding mode. - This feeding mode of
FIG. 8C is to be contrasted with the clamping mode illustrated inFIG. 8D . While theyarn control device 201 is still in an operative configuration, themoveable members - In the clamping mode, the second
movable member 239 is not activated and remains withinchamber 225 in proximity to thelower access panel 213. Meanwhile, the first fluidactivation supply port 206 is turned on, to drive the first working fluid into thefirst chamber 222 and drive the firstmoveable member 209 and thehead 211 thereof into theoperative region 205. Theconcave head 211 is driven into contact with alower surface 221 b of theslot 221 whereby the outerperipheral rim 211 a clamps down over theyarn 32 securely holding theyarn 32 in place against thelower surface 221 b of theslot 221. - In one embodiment, the
chambers moveable members respective chambers rings 236 providing each piston with a sealing arrangement to manage the first and second working fluids within thebody 202. These seals prevent leakage of the first and second working fluids within therespective chambers rings 236 improve operational efficiency of theyarn control device 201 and improve control over the working of theyarn control device 201. The first and second working fluids can be different fluids. In some embodiments, the first and second working fluids can be the same fluid. -
FIGS. 9A-9D illustrate schematically the steps taken to approach, capture, restrain, and clamp theyarn tail 33 by theyarn control device 201. It is understood that analogous steps are contemplated to capture and clamp theyarn tail 33 with theyarn control device 101. -
FIG. 9A illustrates theyarn control device 201 moving towards theyarn 32, where upon contact with theupper jaw 203 orlower jaw 204, theyarn 32 will be guided to theoperative region 205 of thebody 202. As theyarn 32 traverses thejaws yarn 32 is drawn into theslot 221 seeFIG. 9B . In different operational modes, it can be theyarn 32 that is moved towards theyarn control device 201. - The working fluid is then introduced into the
body 202 to activate the secondmoveable member 239 and form theaperture 218 to constrain theyarn 32 therein illustrated inFIG. 9C . Where theyarn tail 33 is not of a sufficient length the first fluid inlet valve is opened to initiate the first fluid flow F and draw theyarn tail 33 through theoperative region 205 of thebody 202. When theyarn tail 33 is deemed of sufficient length, the first fluid flow F is terminated to cease feeding of theyarn 32 and the first working fluid is activated to urge the firstmoveable member 209 into theoperative region 205 and clamp theyarn 32 against thelower surface 221 b of theslot 221 thereby clamping theyarn 32 and terminating the extension of theyarn tail 33 as illustrated inFIG. 9D . - Where the
yarn tail 33 exceeds the predetermined length, theyarn tail 33 can be shortened by moving theyarn control device 201 relative to theyarn 32. As such, any relative movement therebetween can be used to decrease the length of theyarn tail 33. - In some embodiments, the
yarn control device yarn handling device 301. Theyarn handling device 301 includes theyarn control device moveable lance 302 that is independently moveable with respect to theyarn control device FIG. 10 . - In the illustrated embodiments, the
yarn handling device 301 comprises theyarn control device 101. However, it is understood that theyarn control device 201 can also be used as a part of theyarn handling device 301. - The
lance 302 includes acentral bore 303 that feeds anozzle 304. Thenozzle 304 is adapted to discharge a second fluid flow F′ towards a target receiver. The target is a location to which theyarn tail 33 is to be fed. Thecentral bore 303 is between 2 mm and 8 mm in diameter and preferably about 4.95 mm in diameter, and narrows to asecondary bore 303 a of between 4 mm-10 mm and preferably about 8.65 mm in length. - The
secondary bore 303 a terminates at the tip of thenozzle 304, which is between 0.5 mm-2.5 mm in diameter and preferably about 1.5 mm in diameter. The step down in diameter between thecentral bore 303 of thelance 302 to thesecondary bore 303 a increases the velocity at which the second fluid is expelled from thenozzle 304. - The second fluid flow F′ is about between 50-150 litres/minute and preferably 113 litres/minute. The second fluid flow F′ has a pressure between 3 bar and 10 bar and preferably at a pressure of 7 bar.
- The second fluid flow F′ is configured to have a higher flow rate than the first fluid flow F, such that the second fluid flow F′ can displace the entrained
yarn tail 33 from the first fluid flow F to redirect theyarn tail 33 coaxially with the second fluid flow F′. Theyarn tail 33 will be directed and urged towards which ever target location the second air flow F′ is directed at, such that the second fluid flow F′ expels the entrainedyarn tail 33 from the first fluid flow F thereby delivering theyarn tail 33 to the target. - The above dimensions are directed to a specific working embodiment of the invention; however, it is contemplated that these dimensions and the pressure of the second fluid can be varied to provide a desired flow rate to complement a given yarn density. For example, a light weight yarn of low linear mass density referred to as deci-tex or dTex can be controlled with a low flow rate, while a heavier yarn of higher dTex can be controlled with a higher flow rate to influence and manipulate the
yarn tail 33. - Accordingly, it is understood that in-use, with the
yarn control device 101 in the operative configuration, theyarn 32 is clamped in theoperative region 105 of thebody 102 such that the first fluid flow F captures theyarn tail 33 and orients theyarn tail 33 coaxially with the first fluid flow F, as thebody 102 is moved the first fluid flow F is reoriented to intersect the second fluid flow F′ from thenozzle 304. Theyarn tail 33 is therefore directed towards the target. - Yarn Brake
- The dispensing of
yarn 32 from theyarn package 30 is controlled by ayarn brake 80, which will now be described in detail in reference toFIGS. 11A to 110 . - The
yarn brake 80 is used to control the dispensing ofyarn 32 from theyarn package 30, such that once theyarn tail 33 arrives at theheader 61 further dispensing ofyarn 32 from theyarn package 30 is inhibited. - The
yarn brake 80 comprises asupport arm 81 and a frictional element in the form ofbrake finger 82. Alinear actuator 83 extends along thesupport arm 81 and is coupled to thebrake finger 82. Theactuator 83 is shown as a pneumatic cylinder including apiston rod 83 a, however other types of actuator are also contemplated. - Activation of the
linear actuator 83 moves thebrake finger 82 from a disengaged position to an engaged position.FIG. 11A shows thebrake finger 82 in a disengaged position, located outside of thehousing 22 of thepackage holder 20. In the disengaged position, thebrake finger 82 extends substantially parallel to thebrake support arm 81. In the engaged position, shown inFIG. 11B , however, thebrake finger 82 pivots inwards, towards theyarn package 30. Thebrake finger 82 is received within aslot 23 of thehousing 22. - In the embodiment illustrated in
FIG. 11C , theyarn brake 80 is part of thegripper assembly 70, with thesupport arm 81 being moveably attached to thegripper body 73, and extending longitudinally therefrom. Because thesupport arm 81 is offset from thebody 73 of thegripper assembly 70, theyarn brake 80 is located entirely outside of thehousing 22 during the loading process and is received in a gap betweenadjacent housings 22. - Method of Automatically Loading and Unloading the Creel
- Broadly speaking, operation of the
system 1 comprises the following stages: -
- i.
empty yarn cores 31 are retrieved from thecreel 10; - ii. the
empty cores 31 are delivered to the windingmachine 40; - iii. the winding
machine 40winds yarn 32 onto theempty cores 31 to form yarn packages 30; - iv. the yarn packages 30 are then collected from the winding
machine 40 by thegripper assembly 70; - v. the yarn packages 30 are delivered and loaded into
respective package holders 20 within thecreel 10 by thegripper assembly 60; - vi.
tails 33 of eachyarn package 30 are respectively threaded intoconduits 24 of therespective package holders 20; and - vii. the
yarn tails 33 from eachyarn package 30 within thecreel 10 are fed into to theirrespective outlet 60 within theheader 31; with theoutlets 60 supplyingyarn 32 to a respective operation point of the production machine, where theyarn 32 is consumed in the production of a yarn product, such as a carpet.
- i.
- The following sections of the disclosure relates to processes (i) to (vii) as identified above.
- Retrieving Empty Cores from the Creel
-
FIGS. 12A to 12D show thegripper assembly 70 collecting anempty core 31 from apackage holder 20. Thehead 74 of thegripper assembly 70 will move into alignment with thatpackage holder 20, as shown in the partial cross-section ofFIG. 12A . Thehead 74 then moves longitudinally in the Y-direction through the open end of therespective housing 22 and towards theempty core 31. Thehead 74 andsnout 75 each include a shaft located on a central longitudinal axis. The shaft is positioned such that theyarn conduit 24 will pass through the shaft as thehead 74 moves towards theempty core 31 into thehousing 22. -
FIG. 12B shows thesnout 75 andhead 74 inserted into thehousing 22 with theyarn conduit 24 extending through the rear of thehead 74. Thejaw 78 is in a closed orientation such that thesnout 75, includingfingers 76, will be located within the centre of the core 31 as thehead 74 approaches. Once in a location where thesnout 75 andfingers 76 are entirely or substantially within thecore 31, as shown inFIG. 12B , thesnout 75 is not interfered with by the mountingbracket 21. For example, the mountingbracket 21 may only engage about half of an internal surface of the core 31, such that thesnout 75 andfingers 76 may be positioned within the other half of thecore 31. - When located in the position as shown in
FIG. 12B , thejaw 78 is activated by an application of the pressurised gas, such as pressurised air. Thejaw 78 will move from the closed orientation towards the open orientation until thefingers 76 engage theinner surface 31 a of thecore 31. - Once the
fingers 76 have engaged theinner surface 31 a of the core 31, theempty core 31 may be removed from the mountingbracket 21. Thepiston rod 79 a is retracted and thehead 74 to move longitudinally back towards thegripper body 73. Thehead 74 andsnout 75 are thus removed from thehousing 22. Furthermore, theempty core 31 is removed from thepackage holder 20.FIG. 12C , shows thegripper assembly 70 when thepiston rod 79 a has been fully retracted, theempty core 31 being removed from within thehousing 22. Thegripper assembly 70 is then moved longitudinally away from thehousing 22, as shown inFIG. 12D . - Delivery of Empty Cores to the Winder
-
FIGS. 13A to 13C show thegripper assembly 70 delivering theempty core 31 to thewinder 40. Thegripper assembly 70 is rotated on therotatable connector 58 a and moved in the X and Z direction, where necessary, by moving theplatform 57 a relative to thevertical rail 57 in the Z direction and moving the upper andlower platforms lower rails gripper assembly 70 causes thehead 74 to face thewinder 40 as shown inFIG. 13A . - The
pneumatic cylinder 79 is then activated to cause thepiston rod 79 a to extend outwardly in the longitudinal Y direction towards thewinder 40, as shown inFIG. 13B . - The
head 74 will be positioned at an empty core drop-off position adjacent to a port or other receiving section of thewinder 40, which provides access to thestorage buffer 42. Thejaw 78 will close to release theempty core 31 to provide theempty core 31 to the port or receiving section of thewinder 40. Thewinder 40 may have a means to collect theempty core 31 and to move it to the magazine orstorage buffer 42 where appropriate. According to an embodiment, not shown in the Figures, thegripper assembly 70 may include a pushing member to push theempty core 31 through the port or receiving section of thewinder 40 and into thestorage buffer 42. - Once the
empty core 31 has been provided to the magazine orstorage buffer 42, as shown inFIG. 13C , thehead 74 andpiston rod 79 a can then be retracted away from thewinder 40 in the Y direction. - Winding of Yarn Packages
- Turning now to
FIGS. 14A to 14C . Eachyarn package 30 comprises thetubular core 31 around whichyarn 32 is wound by the windingmachine 40.FIG. 14A shows anempty core 31, before any yarn has been wound.FIG. 14B shows an intermediate stage of the forming of theyarn package 30, in which afirst span 34 of yarn has been wound, to form a partially woundyarn package 30. The first span ofyarn 34 is wound onto the core 31 in an angled manner. The helical winding of thefirst span 34 substantially covers thecore 31.FIG. 14C shows afinished yarn package 30, after asecond span 35 of yarn has been wound onto the core 20′ by the windingmachine 12. The second span ofyarn 32″ is wound in a straight manner. In contrast to thefirst span 34, the second span ofyarn 32″ is concentrated within a central a portion of thecore 31. Theyarn tail 33 of theyarn package 30 is the free end of thesecond span 35. - A length of the
first span 34 andsecond span 35 of yarn on eachyarn package 30 is variable, and dependent on (i) a designatedpackage holder 20 to which theyarn package 30 will be attached, and (ii) the amount ofyarn 32 required to be consumed by the production machine at the corresponding operating point. The total length of yarn wound onto eachyarn package 30 is equal to the amount of yarn that is to be consumed by the production machine at a corresponding active operation site. Accordingly, an advantage provided by calculating the first andsecond spans yarn package 30. Accordingly, the nowempty core 31 can be re-used by the windingmachine 40 to form anew yarn package 30. This is to be contrasted with conventional production methods, where yarn remaining on the spool after a job has completed is disposed of, so as to allow the core 31 to be rewound for a subsequent job. - Before winding the first span of
yarn 34 onto theempty core 31, the windingmachine 40 receives an input indicating the amount of yarn required by the production machine and an assignedpackage holder 20 where theyarn package 30 will be placed. The windingmachine 40 then determines the length of the second span ofyarn 35, being equal to or slightly greater than the length of a yarn feed path P associated with the assignedpackage holder 20. It is envisaged that this process utilises a look-up table, where the yarn feed path P associated with eachpackage holder 20 is predetermined and stored within the windingmachine 40. The length of the first span ofyarn 34 is then calculated by the windingmachine 40, being equal to the total amount of yarn required by the production machine less the length of thesecond span 35. - Each
respective package holder 20 is associated with its own yarn feed path P. The yarn feed path P is the path along which theyarn tail 33 of eachyarn package 30 within thecreel 10 is fed to its respective outlet within theheader 61. - With reference to
FIGS. 15A and 15B , the yarn feed path P comprises a first portion extending along therigid portion 24 a of theyarn conduit 24. The first portion terminates in theaperture 26, disposed on the non-loading face of thecreel 10. As shown in the Figures, eachside sided creel 10 has anon-loading face second sides creel 10 is a single-sided creel, the non-loading face would be thesecond side 14 of the creel. - The yarn feed path P further comprises a second portion extending along the
non-rigid conduit 24 b from theaperture 26 within the non-loading face to the corresponding outlet within theheader 61. - Shown schematically in
FIG. 15B , a yarn feed path P′ associated with afirst creel position 20′ is longer than a yarn feed path P″ associated with asecond creel position 20″. Accordingly, a longer length of yarn is required to be fed from thefirst package holder 20′ to afirst outlet 60′ compared with the length of yarn required to be fed from thesecond package holder 20″ to thesecond outlet 60″. The length of yarn feed path P′ is one of the longest on thecreel 10. By comparison the length of the yarn feed path P″ is one of the shortest on thecreel 10. There can be 2 metres or more of difference in length between the shortest and longest of the yarn feed paths P depending on the dimensions of thecreel 10. - Collection of Yarn Packages from the Winder
- After following the above steps, there will be a
package holder 20 in thecreel 10 which is absent apackage 30 orcore 31 on its mountingbracket 21. - The
yarn control device gripper assembly 70 when retrieving theyarn package 30 from thewinder 40 and delivering thepackage 30 to thecreel 10. -
FIGS. 16A to 16F show thegripper assembly 70 collecting ayarn package 30 from thewinder 40 after anempty core 31 has been wound with a desired length of yarn. - As previously described, the
gripper assembly 70 is linearly moveable between thecreel 10 andwinder 40 along thegantry 50. As shown inFIG. 16A , thegripper arm 70 is maneuvered such that itsgripping jaw 78 faces the position of theyarn package 30 on thewinder 40. Positioning thegripper assembly 70 in this position may follow it being retracted after delivering anempty core 31 to the port or receiving section of thewinder 40 as previously described. - From the position shown in
FIG. 16A , therotatable connector 58 a moves longitudinally along thearm rail 58 in the Y-direction towards thewinder 40 to place thegripper assembly 70 in the position shown inFIG. 16B . Thecylinder 79 may then be actuated to extend thepiston rod 79 a towards thepackage 30 until thejaws 78 is located inside theinner core 31 with thehead 74 located adjacent thereto. - When moved towards the
yarn package 30, thejaw 78 is in a closed orientation such that thesnout 75, includingfingers 76, will be located within the centre of the core 31 as thehead 74 approaches thepackage 30. When located in the position as shown inFIG. 16C , thesnout 75 andfingers 76 are entirely or substantially within thecore 31, and thejaw 78 is then be activated by application of the pressurised gas, such as compressed air, or other means. Thejaw 78 will move from the closed orientation towards the open orientation until thefingers 76 engage theinner surface 31 a of the core 31 as shown inFIG. 16D . Thecylinder 79 may then be actuated again to move retract thepiston rod 79 a in the Y-direction, as shown inFIG. 16E . Where necessary, therotatable connector 58 a may be moved in the Y-direction relative to thearm rail 58 to move thegripper assembly 70 away from thewinder 40, to a position as shown inFIG. 16F . - Notably, after the
winder 40 completes the winding of thepackage 20, thecore 31 is released or “doffed” from thewinder 40, and rests in a pick-up position, with thesupply yarn 44 from thewinder 40 being uncut or held in some way. This is shown inFIG. 17A . This is to enable control of theyarn tail 33 of thewound package 30 until thegripper assembly 70 can grasp thepackage 30, with theyarn control device yarn tail 33. - As previously noted, the
yarn control device yarn 33 before it is cut and still under control of thewinder 40. This is shown inFIG. 17B . Once in the control of theyarn control device yarn 32 is released or cut by thewinder 40. Theyarn tail 33 is then solely constrained by theyarn control device yarn tail 33 is constrained within theyarn control device 101, the first fluid flow F′ can be activated, such that theyarn 33 is entrained therein, aligned coaxially with the fluid flow F′. - Delivery of Yarn Packages to the Creel
- The next stage is to deliver the
yarn package 30 to the assignedpackage holder 20. This stage is shown inFIGS. 18-19 . During this stage, thegripper assembly 70 is moved along thegantry 50, until theinner surface 31 a of thecore 31 of theyarn package 30 attached thereto is positioned axially in-line with thecore mounting bracket 21 of the assignedpackage holder 20. Thehead 74 is then driven forward towards thehousing 22, such that theyarn package 30 is received onto thecore mounting bracket 21. At this point, thejaw 78 is returned to the closed state, such that theyarn package 30 is solely supported by thecore mounting bracket 21. Thehead 74 is then retracted, such that thegripper assembly 70 is entirely disposed outside of thehousing 22. Each step of this stage is now described in more detail below. - Initially, the
rotatable connector 58 a is rotated such that thejaw 78 of thegripper assembly 70 is in the orientation where it faces thecreel 10. In this step, theconnector 58 a is preferably rotated in the direction opposite to that which caused thegripper assembly 70 to move from facing thecreel 10 to facing thewinder 40. - Where necessary, the
gripper assembly 70 will also be moved in the X and Z directions, by moving thearm platform 57 a vertically along thevertical rail 57 in the Z direction and moving the upper andlower platforms lower rails gripper assembly 70 holdingpackage 30 will then be in the position shown inFIG. 19A . - The
rotatable connector 58 a is then moved in the Y-direction to cause thegripper assembly 70 holdingpackage 30 to move towards and into therespective housing 22, as shown inFIG. 19B . From here, thecylinder 79 is actuated to cause thepiston rod 79 a to extend until theyarn package 30 is located within and at the rear of thehousing 22, as shown inFIG. 19C . Theinner core 31 of thepackage 30 will then be located on the mountingbracket 21. - Once the
yarn package 30 is located on the mountingbracket 21, thejaw 78 is activated once again in reverse to cause thefingers 76 to disengage from theinner surface 31 a of the core 31 until thejaw 78 is in its closed position. At this point, theyarn package 30 is supported entirely by the mountingbracket 21. - After the
package 30 is secure, thegripper assembly 70 may then be partially retracted by engaging thecylinder 79 to cause thepiston rod 79 a to retract, until thehead 74 of the gripper assembly is outside of thehousing 22, all the while maintaining control of theyarn tail 33 within theyarn control device 101. This is shown inFIG. 19D . - Threading of the Yarn Tail into the Conduit
- Once the
yarn package 30 is supported on thecore mounting bracket 21, it is necessary for theyarn tail 33 to be fed towards itsrespective outlet 60 withinHeader 61 via theconduit 24. The first step of this process is to thread theyarn tail 33 into the conduit opening 25, as shown inFIG. 19E . In a preferred embodiment, delivery of theyarn tail 33 to the respective outlet 69 is facilitated by theyarn handling device 301 that incorporates theyarn control device yarn handling device 301 is coupled to thegripper assembly 70. It is contemplated, however, that theyarn handling device 301 may be moveable via other methods and mechanisms outside of thegripper assembly 60. - With reference to
FIGS. 20A to 20C , it is understood that the target for theyarn handling device 301 is the conduit opening 25 of arespective package holder 20, with thehead 74 andsnout 75 of thegripper assembly 70 providing themoveable lance 302. - With the
head 74 providing themoveable lance 302, thenozzle 304 is thus brought into proximity with the conduit opening 25 as thegripper assembly 70 is urged forward and thepackage 30 is slid over thecore mounting bracket 21. Preferably, in-use, thenozzle 304 is located about 3 mm±2 from theconduit opening 25. This optimum distance G between thenozzle 304 and the conduit opening 25 is approximately twice the diameter of thenozzle 304, illustrated inFIG. 20A . The ratio of the diameter of the second fluid outlet provided bynozzle 304 to the diameter of the conduit opening 25 is about 1:3. However, it is contemplated that for different yarn dTex a different ratio can be selected, from 1:2-1:5. The second fluid flow F′ is activated once thehead 74 is brought into alignment with theconduit 24. - Referring now to
FIGS. 21A-21B . With thenozzle 304 of thehead 74 aligned with thecentral opening 25 of theconduit 24 and located at an optimal distance from the conduit 24 (FIG. 21A ), the second fluid flow F′ is activated and directed into theopening 25 of theconduit 24. Theyarn control device 101 is then moved, by rotation and/or translation of thegripper assembly 70, to direct theyarn tail 33—entrained within the first fluid flow F—across the second fluid flow F′ (FIG. 21B ). - The second fluid flow F′ has a greater fluid flow than the first fluid flow F. Accordingly, once the
yarn tail 33 in the first fluid flow F crosses the second fluid flow F′, theyarn tail 33 is ejected from the first fluid flow F and fired into the conduit opening 25 and fed through both therigid conduit 24 a and theflexible conduit 24 b to be received at theheader 61. - The
gripper assembly 60 is then fully retracted from thehousing 22 to restart the process, as illustrated inFIG. 19E . - Feeding of Yarn to the Outlet
- With the
yarn package 30 now supported by thepackage holder 21 and theyarn tail 33 threaded into the conduit opening 25, a tension force T is applied to theyarn tail 33. Theyarn 32 on thepackage 30 is thus drawn through theconduit 24 along the yarn feed path P. The tension force T is provided by the second air flow F′ from thenozzle 304. The second fluid stream F′ thus propels theyarn tail 33 into the conduit opening 25 and along the yarn feed path P to theheader 61. Theheader 61 receives and stores theyarn tails 33 to prevent them being tangled or snagged if the yarn tails were to fall into the creel positions 20 beneath theheader 61. - As described herein, in some embodiments, a second span of
yarn 35 is wound onto thepackage 30 in a straight configuration, thereby defining a feeding yarn that continues to be unwound from thepackage 30 during the loading of thepackage 30 into thehousing 22 of thecreel 11. As previously noted, a specific length of feedingyarn 35 can be tailored to the location of thepackage 30 on thecreel 10. - When feeding
yarn 32 along the yarn feed path P, it is desirable to feed only the minimum length of yarn required to reach therespective outlet 60. This is to reduce the possibility of yarn fromadjacent outlets 60 within theheader 61 from becoming entangled with one another. This selective feeding is facilitated, at least in part, viayarn brake 80. Operation of theyarn brake 80 during the feeding process will now be described in reference toFIGS. 22A to 22D . - After the
yarn tail 33 has been inserted into the yarn conduit opening 25 thebrake finger 82 is moved to the engaged position to make frictional contact with thefirst span 34 of theyarn package 30. This is shown inFIG. 22A . Thebrake finger 82 is dimensioned so as to be able to contact the core 31 loaded within thepackage holder 20. In this manner, thebrake 80 can be used foryarn packages 30 of varying diameters, having different amounts ofyarn 32 wound thereupon. - Engagement between the
brake finger 82 and theyarn 32 results in a frictional force R. The frictional force R is applied to an end of thefirst span 34, proximate to where the helical winding of thefirst span 34 transitions into the straight winding of thesecond span 35. The frictional force R acts in a direction opposite to the tension force T. As thebrake finger 82 is engaged with thefirst span 34 of yarn only, thesecond span 35 of yarn is free to unwind unrestricted under the tension force T, enabling theyarn tail 33 to feed towards theheader 61. This is shown inFIG. 22B . -
FIG. 22C shows the configuration of theyarn brake 80 during a later stage of the yarn feed process. As shown, thesecond span 35 of yarn has completely unwound from theyarn package 30, such that theyarn tail 33 has arrived at theheader 61. As the frictional force F applied by thebrake finger 82 is greater than the tension force T of the fluid stream F″, further dispensing ofyarn 32 from theyarn package 30 is inhibited. Thus, only thesecond span 35 of yarn is fed along theconduit 24, whilst the entirefirst span 34 of yarn remains on theyarn package 30. This is advantageous, as it reduced an overhang of theyarn tail 33 at thecorresponding outlet 60 withinheader 61. Accordingly,adjacent yarn tails 33 within theheader 61 are less likely to entangle with one another. Further, yarn wastage arising during the splicing of each of theyarn tails 33 to the corresponding yarn supply at the production machine is reduced. This is because there is no need to cut excess overhang of theyarn tails 33. - After a predetermined duration of time, the tension force T is deactivated. Notably, as the friction force F applied by the
yarn brake 80 inhibits dispensing of thefirst span 34 of yarn even with the tension force T being active, the predetermined time does not need to be accurately calculated for the yarn feed path P of eachpackage holder 20. Rather, the predetermined time merely needs to be sufficient to feed theyarn tail 33 from thepackage holder 20 having the longest yarn feed path P. Accordingly, the tension force T is applied for the same predetermined time for eachpackage holder 20 of thecreel 10, simplifying the overall feeding process. - Once the tension force T is deactivated, the
actuator 83 is deactivated, such that thebrake finger 82 is returned to the disengaged position, outside of thehousing 22, as shown inFIG. 22D . Theyarn brake 80 is then retracted back towards thegripper head 74, to an inoperable position. In the inoperable position, the yarn brake 85, and theentire gripper assembly 70, is located outside of thecreel 10. The process can then be repeated, for subsequent yarn packages 30. - The above processes may be repeated a plurality of times. Summarily, the process includes the steps of: maneuvering the
gripper assembly 70 to retrieve thepackage 30 from thewinder 40 and capture theyarn tail 33; delivering thepackage 30 to thehousing 22 on thecreel 10 and activating the first fluid flow F to orient theyarn tail 33; moving thebody 102 to draw theyarn tail 33 across the second fluid flow F′ wherein the second fluid flow F′ drives the entrainedyarn tail 33 from the first fluid flow F and into theopening 25 of theconduit 24, and delivering theyarn tail 33 to theheader 61 by controllably feeding theyarn 32 along theconduit 24 with the assistance ofyarn brake 80. - It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country.
- In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.
-
LEGEND 1 YARN HANDLING SYSTEM 10 CREEL 11 FRAME 12 WHEELS 13 FIRST SIDE 13A LOADING FACE 13B NON-LOADING FACE 14 SECOND SIDE 14A LOADING FACE 14B NON-LOADING FACE 20 PACKAGE HOLDER 21 MOUNTING BRACKET 21A CENTRAL PLINTH 21B RESILIENT MEMBER 22 HOUSING 23 SLOT 24 YARN CONDUIT 24A RIGID CONDUIT 24B FLEXIBLE CONDUIT 25 CONDUIT OPENING 26 APERTURE 30 YARN PACKAGE 31 CORE 32 YARN 33 YARN TAIL 34 FIRST SPAN OF YARN 35 SECOND SPAN OF YARN 40 WINDER 41 WINDER HEAD/AREA 42 MAGAZINE 43 STORE 44 SUPPLY YARN 50 GANTRY 51 VERTICAL MEMBERS 52 LONGITUDINAL MEMBERS 53 ANGLED MEMBERS 54 BRACKETS 55 UPPER RAIL 55A UPPER PLATFORM 55B UPPER ROLLERS 55C UPPER TRACK 55D UPPER MOTOR 56 LOWER RAIL 56A LOWER PLATFORM 56B LOWER ROLLERS 56C LOWER TRACK 56D LOWER MOTOR 57 VERTICAL RAIL 57A VERTICAL PLATFORM 57B VERTICAL ROLLERS 57C VERTICAL TRACK 57D VERTICAL MOTOR 58 ARM RAIL 58A ROTATEABLE CONNECTOR 58B ARM ROLLERS 58C ARM TRACK 58D ARM MOTOR 60 OUTLET 61 HEADER 62 HEADER PLATE 63 HEADER COVER 70 GRIPPER ASSEMBLY 71 FRONT END 72 REAR END 73 BODY 74 HEAD 74A TABS 75 SNOUT 75A RIBS 76 FINGERS 77 CONNECTORS 78 JAW ASSEMBLY 79 CYLINDER 79A PISTON HEAD 80 YARN BRAKE 81 SUPPORT ARM 82 FINGER 83 CYLINDER 83A PISTON ROD 101 YARN CONTROL DEVICE 102 MOVEABLE BODY 103 UPPER JAW 104 LOWER JAW 105 OPERATIVE REGION 106 FLUID ACTIVATION PORT 107 FLUID INLET 108 FLUID DEACTIVATION PORT 109 MOVEABLE MEMBER PISTON 110 FIRST FLUID OUTLET 111 PLANAR HEAD 112 ACCESS PANEL UPPER 113 ACCESS PANEL LOWER 114 BODY MOUNTING POINT 115 ACCESS PANEL SCREW 118 APERTURE 119 SHOULDER 120 SUPPORT ARM 121 SLOT 121A UPPER SURFACE OF SLOT 121B UPPER SURFACE OF SLOT 122 FIRST CHAMBER 123 FIRST HEAD 124 PLANAR END 125 SECOND CHAMBER 126 CONCAVE HEAD 127 BORE 201 YARN CONTROL DEVICE 202 MOVEABLE BODY 203 UPPER JAW 204 LOWER JAW 205 OPERATIVE REGION 206 FIRST ACTIVATION PORT 207 FIRST FLUID INLET 208 FIRST DEACTIVATION PORT 209 FIRST MOVEABLE MEMBER 210 FIRST FLUID OUTLET 211 PLANAR HEAD 212 UPPER ACCESS PANEL 213 LOWER ACCESS PANEL 214 BODY MOUNTING POINT 215 ACCESS PANEL SCREW 218 APERTURE 219 SHOULDER 221 SLOT 221A UPPER SURFACE OF SLOT 221B UPPER SURFACE OF SLOT 222 FIRST CHAMBER 223 FIRST HEAD 224 PLANAR END 225 SECOND CHAMBER 226 CONCAVE HEAD 227 BORE 239 SECOND MOVEABLE MEMBER 240 SECOND ACTIVATION PORT 241 SECOND DEACTIVATION PORT 242 BODY PORT 301 YARN HANDLING DEVICE 302 LANCE 303 BORE 304 NOZZLE F FIRST FLUID FLOW F′ SECOND FLUID FLOW P YARN FEED PATH T TENSION FORCE R FRICTION FORCE
Claims (27)
1-23. (canceled)
24. A yarn control device for controlling a yarn tail of a yarn, comprising:
a moveable body configured to capture the yarn and guide the yarn to an operative region of the body;
an inlet for introducing a first fluid into the body; a first fluid outlet located in proximity to the operative region of the body, and oriented to expel the first fluid in a first fluid flow; and
a first moveable member within the body that moves between an operative configuration to clamp the yarn and an inoperative configuration to release the yarn;
wherein in the operative configuration the yarn is retained in the operative region of the body such that the first fluid flow captures the yarn tail and orients the yarn tail coaxially with the first fluid flow, whereby movement of the movable body adjusts the direction of the first fluid flow and yarn tail entrained therein to control orientation of the yarn tail.
25. The yarn control device of claim 24 , further comprising a second moveable member with the body, configured to operate in conjunction with the first moveable member to provide a feed configuration, wherein the yarn tail is retained in the operative region of the body, and drawn through the operative region by the first fluid flow thereby varying a length of the yarn tail.
26. The yarn control device of claim 25 , wherein the first and second movable members are a pair of reciprocating pistons.
27. The yarn control device of claim 26 , wherein each of the first and second pistons comprises independent operative and inoperative configurations.
28. The yarn control device of claim 24 , wherein the first moveable member has a head for clamping and securing the yarn to the body.
29. The yarn control device of claim 25 , wherein the second movable member has a head which forms an aperture when brought into contact with the operative region of the body, restraining the yarn within the operative region and allowing the yarn to be drawn through the aperture.
30. The yarn control device of claim 29 , wherein each of the first moveable member and the second moveable member comprise at least one seal respectively, to control flow of the working fluid within the respective bores.
31. (canceled)
32. The yarn control device of claim 24 , wherein a series of fluid inlet and outlet valves are located within the body to control flow of a working fluid into and out of respective first and second bores, in which the first and second moveable members are located.
33. The yarn control device of claim 24 , wherein the body has a wedge-shaped cross-section providing a pair of angled jaws for capturing a yarn and guiding the yarn towards the operative region.
34. The yarn control device of claim 24 , the first moveable member is activated to clamp the yarn once in the operative region of the body by supplying working fluid to the activation supply port to allow the working fluid to enter the bore in which the first moveable member is located.
35. The yarn control device of claim 24 , the first moveable member is deactivated to release the yarn from the operative region of the body by supplying working fluid to the deactivation supply port to allow the working fluid to escape the bore in which the first moveable member is located.
36. The yarn control device of claim 24 , wherein the first fluid outlet is located in close proximity to the operative region and directed away from the body.
37. The yarn control device of claim 24 , wherein the first fluid outlet is on a surface of the body.
38. The yarn control device of claim 24 , wherein the first fluid outlet is in fluid communication with the first fluid inlet via a bore within the body.
39. The yarn control device of claim 38 , wherein the bore is oriented to expel the first fluid flow perpendicularly to the body.
40. (canceled)
41. The yarn control device of claim 1, wherein at least one of the first fluid, the second fluid and the working fluid is air.
42. (canceled)
43. A yarn control system for delivering a yarn tail of a yarn to a receiver, comprising:
a moveable body configured to capture the yarn and guide the yarn to an operative region of the body;
an inlet for introducing a first fluid into the body; a first fluid outlet located in proximity to the operative region of the body, and oriented to expel the first fluid in a first fluid flow; and
a moveable member within the body that moves between an operative configuration and an inoperative configuration; and
a nozzle having a second fluid outlet that expels a second fluid in a second fluid flow towards the receiver;
wherein in the operative configuration the yarn is fixedly held in the operative region of the body such that the first fluid flow captures the yarn tail and orients the yarn tail coaxially with the first fluid flow as the body is moved the first fluid flow is reoriented to intersect the second fluid flow, such that the second fluid flow expels the entrained yarn tail from the first fluid flow thereby delivering the yarn tail to the receiver.
44-46. (canceled)
47. The yarn control system of claim 43 , wherein the receiver is selected from any one of the following: a conduit, a central yarn tube, an eye, an eyelet, a needle, a yarn feed tube or the like.
48. The yarn control system of claim 43 , wherein at least one of the first fluid, the second fluid and the working fluid is air.
49. (canceled)
50. A spool handling device comprising the yarn control device according to claim 24 .
51-79. (canceled)
Applications Claiming Priority (7)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2020903212A AU2020903212A0 (en) | 2020-09-08 | Yarn Feeding System | |
AU2020903209 | 2020-09-08 | ||
AU2020903212 | 2020-09-08 | ||
AU2020903210 | 2020-09-08 | ||
AU2020903209A AU2020903209A0 (en) | 2020-09-08 | Core and package handling system | |
AU2020903210A AU2020903210A0 (en) | 2020-09-08 | Yarn Control Device | |
PCT/AU2021/051038 WO2022051803A1 (en) | 2020-09-08 | 2021-09-08 | Yarn handling system |
Publications (1)
Publication Number | Publication Date |
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US20230331511A1 true US20230331511A1 (en) | 2023-10-19 |
Family
ID=80632440
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US18/025,091 Pending US20230331511A1 (en) | 2020-09-08 | 2021-09-08 | Yarn handling system |
Country Status (6)
Country | Link |
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US (1) | US20230331511A1 (en) |
EP (1) | EP4211066A1 (en) |
JP (1) | JP2023539939A (en) |
CN (1) | CN116438131A (en) |
AU (1) | AU2021340273A1 (en) |
WO (1) | WO2022051803A1 (en) |
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Publication number | Priority date | Publication date | Assignee | Title |
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CN108750791A (en) * | 2018-08-07 | 2018-11-06 | 泉州市万佳智能科技有限公司 | Efficient paying out machine |
CN115028022A (en) * | 2022-05-30 | 2022-09-09 | 新乡化纤股份有限公司 | Intelligent chemical fiber yarn tube transferring and chemical fiber paper tube transferring mechanism |
CN117512866B (en) * | 2024-01-08 | 2024-03-26 | 汕头市致盛纺织科技有限公司 | Yarn searching and supplying device for knitting equipment |
Family Cites Families (12)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2325974A (en) * | 1943-05-10 | 1943-08-03 | Peter C Pasquerello | Creel apparatus |
US3854275A (en) * | 1971-05-28 | 1974-12-17 | Celanese Corp | Mechanized bobbin handler |
DE2646873C2 (en) * | 1976-10-16 | 1978-12-14 | Palitex Project-Company Gmbh, 4150 Krefeld | Device for taking up and playing back a single predetermined length of thread without tension |
JPS6031740B2 (en) * | 1977-03-25 | 1985-07-24 | 帝人株式会社 | How to doff yarn package |
DE3229329A1 (en) * | 1982-08-06 | 1984-02-09 | W. Schlafhorst & Co, 4050 Mönchengladbach | DEVICE FOR SUCTIONING AND HOLDING A THREAD |
JPH0759460B2 (en) * | 1986-01-27 | 1995-06-28 | 村田機械株式会社 | Package supply device for clear |
DE3901770A1 (en) * | 1989-01-21 | 1990-07-26 | Palitex Project Co Gmbh | METHOD FOR TRANSPORTING A YARN BOBBIN TO A YARNING MACHINE, IN PARTICULAR A DOUBLE-WIRE TWISTING MACHINE, AND DEVICE FOR CARRYING OUT THE METHOD |
IT1231057B (en) * | 1989-09-27 | 1991-11-12 | Roy Electrotex Spa | WEFT FEEDER FOR FLUID JET WEAVING FRAMES. |
DE4433865A1 (en) * | 1993-09-29 | 1995-03-30 | Barmag Barmer Maschf | Method for changing bobbins and apparatus for carrying out the method |
DE19641756A1 (en) * | 1995-10-13 | 1997-04-17 | Barmag Barmer Maschf | Symmetrical bobbin removal assembly |
BR9915724A (en) * | 1998-11-06 | 2001-10-23 | Interface Inc | Compact harrow |
TW201211335A (en) * | 2010-06-18 | 2012-03-16 | Interface Inc | Portable creels with insertable yarn trays and improved headers and yarn handling methods |
-
2021
- 2021-09-08 CN CN202180063182.5A patent/CN116438131A/en active Pending
- 2021-09-08 AU AU2021340273A patent/AU2021340273A1/en active Pending
- 2021-09-08 US US18/025,091 patent/US20230331511A1/en active Pending
- 2021-09-08 JP JP2023515617A patent/JP2023539939A/en active Pending
- 2021-09-08 EP EP21865385.5A patent/EP4211066A1/en active Pending
- 2021-09-08 WO PCT/AU2021/051038 patent/WO2022051803A1/en unknown
Also Published As
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EP4211066A1 (en) | 2023-07-19 |
AU2021340273A1 (en) | 2023-05-18 |
AU2021340273A9 (en) | 2024-04-18 |
CN116438131A (en) | 2023-07-14 |
JP2023539939A (en) | 2023-09-20 |
WO2022051803A1 (en) | 2022-03-17 |
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