US3875624A

US3875624A - Edge drive control means for tubular fabric calendering systems

Info

Publication number: US3875624A
Application number: US348068A
Authority: US
Inventors: Robert Frezza
Original assignee: Samcoe Holding Corp
Current assignee: Samcoe Holding Corp
Priority date: 1973-04-05
Filing date: 1973-04-05
Publication date: 1975-04-08
Anticipated expiration: 1992-04-08
Also published as: DE2407801B2; CH583327A5; JPS5243278B2; DE2407801A1; BE812189A; FR2224582A1; CA975147A; JPS49126992A; GB1455897A; AU6493574A; NL7402631A; IT1011687B; DE2462304A1

Abstract

The disclosure relates to apparatus for the finishing of tubular knitted fabric. The finishing treatment involves the usual spreading to width and steaming of the fabric, with or without calendering, and gathering of the treated fabric. In its general aspects, the equipment of the invention performs well known and conventional operations. In its specifics, however, the equipment incorporates significant improvements.

Description

United States Patent 1 [Ill 3,875,624

Frezza Apr. 8, 1975 [54] EDGE DRIVE CONTROL MEANS FOR 2.727.378 l2/I955 Cook 226/44 2.880,] [4 3/!959 Cohn et al 26/55 R UX TUBULAR FABRIC CALENDERING 3.257.735 6/1966 Catalio 26/56 X SYSTEMS [75] Inventor: Robert Frezza, Carle Place, NY. FOREIGN PATENTS OR APPLICATIONS 1.536.604 7/1968 France 226/44 [73] Asslgnee: Samcoe Holdmg Corporation, 2|2,369 3/1924 United Kingdom............t.... 26/55 R Woodside, NY. i,|54,7l2 6/I969 United Kingdom 26/55 R [22] Filed: I973 Primary Examiner-Robert R. Mackey [2i Appl. No.2 348,068 Attorney, Agent, or Firm-Mandeville and Schweitzer 52 us. Cl 26/56; 226/44 ABSTRACT [5 l] Int. Cl. D06c 5/00 The disclosure Mates apparatus for the finishing of [53] Fi ld f Search 2 /55 55 C. 22 /4 tubular knitted fabric. The finishing treatment in- 3 43 volves the usual spreading to width and steaming of the fabric, with or without calendering, and gathering 5 References cu of the treated fabric. In its general aspects, the equip- UMTED STATES PATENTS ment of the invention performs well known and conventional operations. In its specifics, however, the

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EDGE DRIVE CONTROL MEANS FOR TUBULAR FABRIC CALENDERING SYSTEMS Although the disclosure is directed to a plurality of inventive features, the claims of this application are limited to improvements in means for controlling and positioning edge drive rolls for a tubular fabric spreader. In a finishing machine, as contemplated by the invention, tubular knitted fabric is caused to be passed over a spreading frame, which functions to distend the fabric laterally, typically while effecting longitudinal relaxation of the fabric. While the fabric is thus laterally distended and longitudinally relaxed, it is steamed, in accordance with well known practices. To propel the fabric over the spreader frame, it is known to provide opposed, driven edge drive rolls which engage opposite edges of the spreading frame through the interposed layer of fabric.

Because excessive mechanical pressure on the fabric can result in undesirable marking of the fabric, and possibly even damage to its structure, the present invention provides a new and advantageous system for positioning the edge drive rolls, and accurately controlling the force applied by such rolls to the fabric wall. The edge drive rolls are mounted on controllably moveable carriages, which are moveable toward or away from the center line of the apparatus, typically by means of threaded shafts. The carriages are driven by the threaded shafts through nuts, which threadedly en gage the shafts, and compressible spring means, which are interposed between the nuts and the carriages.

The apparatus of the invention advantageously utilizes pressure controlled air motor means for driving the threaded shafts. This permits the system to be adjusted by air pressure control to cause stalling of the air motor in response to a predetermined contact pressure by the edge drive rolls. Resilient mounting of the roll carriages provides for convenient visual indication of the amount of the applied pressure and also accommodates passage of lumps or other enlargements without unduly increasing the pressure applied to the fabric.

Resilient mounting of the edge drive rolls additionally provides a highly simplified yet reliable arrange ment for effecting instant shut-down of the equipment in the event of a malfunction in the feeding of fabric onto the spreader frame. If the spreader frame is dislodged from its normal position between the edge drive rolls, the rolls are urged inwardly by their resilient mountings, and such movement is utilized to advantage to actuate a safety control device to shut down the equipment.

BACKGROUND AND SUMMARY OF INVENTION In the processing and finishing treatment of tubular knitted fabric, it is conventional practice to direct the tubular fabric over an internal spreading device. This distends the fabric laterally to a predetermined uniform width. While the fabric is held in this condition, it is steamed to relax the fibers and enable the fabric to readjust to the laterally distended, geometrically uniform condition. The fabric then tends to retain this condition as it is delivered off of the spreading device. The thus treated fabric may then be passed between a pair of calender rolls, and subsequently gathered in a convenient manner, as by folding or gathering into a roll.

In general, the procedures outlined in the foregoing paragraph are well known. The present invention thus is not directed to the finishing procedure in a general sense, but is directed to more specific structural and procedural aspects calculated to achieve increased production rates along with a superior quality of production.

Where tubular knitted fabric is directed over an internal spreading apparatus, it is of course desirable to provide facilities for positioning and supporting the spreader from the exterior. This means that the spread ing apparatus is to be engaged and held in position by external supporting means acting through the interposed fabric. In addition, it is usually advantageous to utilize fabricengaging drive belts in connection with the internal spreading apparatus, to assist in the forwarding conveyance of the fabric over the spreader frame. The driving of such belts, and the supporting of the spreading frame, typically may be accomplished by the use of edge drive rolls, engaging the frame at its edges and acting through the contacted edges of fabric to position the frame and frictionally drive the propeller belts.

As will be understood, supporting of the spreader frame and driving of the belts through the interposed fabric walls requires pressure to be placed upon the fabric, and this gives rise to a pressure-marking problem, especially in so-called sensitive fabrics. By way of minimizing such pressure-marking problems, the apparatus of the invention includes a new and advantageous control arrangement for automatically providing an optimum degree of edge pressure at the edge drive rolls, to afford adequate spreader frame support and propeller belt driving, without at the same time causing excessive pressure marking of the fabric. In conjunction therewith, the apparatus includes a simplified yet reliable and effective safety control, operative to shut down the entire line if there is a dislodgement of the spreader frame, indicating snagging of the fabric at the entry end of the frame, or other serious malfunction.

To advantage, the processing system of the invention includes a motor-driven, substantially tension-free feeding system for delivering tubular knitted fabric to the upstream or the entry end of the spreader frame. By providing greater uniformity of conditions in the fabric directed onto the spreader frame, improved uniformity in the processed fabric delivered therefrom is achieved.

At the discharge end, the system of the invention may include a folder or roll-up batcher. in part, the invention relates to an improved form of roll-up batcher, which minimizes shut-down or slow-down intervals when a completed roll is removed and a new roll is started. To this end, the roll-up batcher mechanism of the invention provides an increased degree of automation in the cut-off and restarting procedures. The ar rangement is such that an operator, stationed at the discharge end of the machine, need merely initiate a roll removal operation, after which fabric cut-off and the re-startin g of another batch roll takes place rapidly and without further operator intervention. This has desirable safety aspects, as well as providing for higher production by shortening the change-over interval.

RELATED APPLICATIONS An integral part of the present apparatus, contributing to its ability to achieve higher production rates without comprising quality, is an improved steaming apparatus for applying steam to the laterally distended tubular knitted fabric as it passes over the spreader frame. The specific structural features of this steamer, by itself. form the subject matter of my related copending application Ser. No. 355,401. filed Apr. 30, 1973. entitled High Production Steamer."

For a better understanding of the above and other features of the invention, reference should be made to the following detailed description of a preferred embodiment and to the accompanying drawings.

DESCRIPTION OF THE DRAWINGS FIG. IA and IB. taken together, constitute a side elevational view of the apparatus of the invention.

FIG. 2 is a back elevational view of a fabric infeed stand utilized in the apparatus of FIG, lA-IB. as viewed generally at line 22 of FIG. 18.

FIG. 3 is a top plan view of a portion of the apparatus of FIG. 1A and 1B, illustrating details of the spreader frame and edge drive arrangements therefor.

FIGS. 4 and 5 are enlarged. fragmentary top plan views illustrating details of edge drive pressure control means utilized in the apparatus of the invention.

FIG. 6 is an enlarged, fragmentary cross-sectional view taken generally on line 6-6 of FIG. 3.

FIG. 7 is an enlarged, fragmentary view, partly in section. illustrating structural details of the discharge end of the apparatus of FIG. lA-lB.

FIG. 8 is a fragmentary back elevational view of the apparatus of FIG. lA-lB, as viewed generally at line 8-8 on FIG. 7.

DESCRIPTION OF A PREFERRED EMBODIMENT Referring now to the drawings and initially to FIGS. lA-IB, the reference numeral 10 applies generally to a fabricfeeding stage, which supports a supply 11 of unfinished, tubular knitted fabric 12. In the illustration. the supply 11 is in the form of a roll. although it could as well be a truck or other supply container. The fabric I2 is delivered by the supply section to a spreading or distending section 13, where the fabric is initially distended to a predetermined uniform width and arranged in a flat. two-layered form. The fabric then. passes through a steaming section 14, while still in its distended condition. and it is there subjected to the action of jets of steam to warm and moisten the fibers of the fabric.

In the illustrated system. the fabric being discharged from the spreading section 13 passes through a calendering section 15 comprising essentially a pair of nip rolls, which may be in pressure-bearing relation or not, depending on the desired finishing procedure. The thus-finished fabric advances to a gathering section 16, where it is accumulated in a convenient manner and in batches of convenient size and weight. In the illustrated arrangement. the gathering section comprises a roll-up batcher, arranged to collect the fabric in the form of a roll. and to sever the fabric and deliver a roll of finished material of predetermined length or weight and of uniform width.

Referring more particularly to FIG. 1B, the supply section 10 of the apparatus includes an appropriate frame structure 17 arranged to rotatably support a supply roll 11 by means of arms 18. The arms 18, which normally are supported in operative positions by latch arms 20, are arranged to be folded in close to the frame 17, about pivots 19, to accommodate other forms of fabric supplies, such as containers.

Supply fabric 12 leaving the roll 11 advantageously is first directed upwardly about an idler roll 21, and then downwardly underneath and around a second idler roller 22. This provides a broad expanse of cloth conveniently accessible for visual inspection by the machine operator.

In the illustrated system. the supply fabric 12, after passing the idler roller 22, is guided over and around a driven feed roller 23. In accordance with well known principles, the feed roller 23 may be provided with a high friction surface so as to have a suitable frictional engagement on the fabric surface. After passing around the feed roller, the fabric travels downwardly, under and around a floating control roller 24 and thence upwardly and around an idler roll 25. As will be observed. the geometric relationship of the several rollers 22-24 provides for the fabric to be in contact with the feed roller 23 over a substantial arc of its circumference for good feeding contact.

In the illustrated apparatus, the feed roller 23 is driven by a chain 26 from a variable speed electric motor 27. The operating speed of the motor 27 is controlled by a rotary control device 28, which senses the vertical position of the floating roller 24 to effect an increase in motor speed, as the floating roller tends to rise, and to effect a slow-down of the motor if the floating roller tends to move to a lower position. This provides a constantly modulating speed control over the infeeding of the fabric.

With reference to FIG. 2, the floating roller 24 is shown to be supported at its opposite end by chains 29 trained over sprockets 29a affixed to opposite ends of an equalizer shaft 30. The chains 29 also support counterweights 31, which are intended to provide a substantially neutral counterbalance to the entire floating roll mechanism. The end extremities of the shaft 32 of the floating roll are guided in a vertical slot 33 (FIG. 1B) which confines the movement of the floating roll and guides it in a vertical plane.

To provide a controlled downward weight bias on the floating roll 24, a rod 34 is pivoted at 35, at one side of the supply stand, and is connected at the other end to one side of the floating roll shaft 32 by means of a pivoted connecting link 35a. The rod 34 carries one or more slidably adjustable control weights 36, which may be moved toward and away from the pivot point 35 to adjust the effective weight applied to the floating roll.

In this connection, although the adjustable weight is ap-.

plied at one side only, its effect is balanced because of the equalizer shaft 30. A suitable chain and sprocket.

arrangement, generally designated by the numeral 37, connects the equalizer shaft 30 to the rotary control device 28, so that a positive relationship is maintained between the vertical position of the floating roll and the.

rotary position of the control device 28. The rotary control device does not significantly alter the forces balancing the floating control roller 24, so that the fabric supplied from the feeding device of FIG. 1B is at all times under a substantially uniform tension, which is maintained at the lowest practicable amount.

Suitable limit switch means (not shown) may be provided to shut down the entire line in the event that the floating roller 24 would move to either the upper or lower limit of travel provided by the slot 33, reflecting a malfunction of the system at some stage. In addition, it is desirable to support the initial idler roll 21 to accommodate a limited downward movement in response to excessive tension in the fabric leading from the supply. Such movement is utilized to trip a safety switch 21a, to shut down the entire line.

Referring now to FIGS. 1A and 3, the numeral 40 designates a frame structure for the processing section of the system of the invention which supports the edge drive rolls, the steamer and the calender rolls. At the upstream or entry side of frame 40 there are provided brackets 41, which support a pair of

guide rods

42, 43 extending traversely across the machine frame. The guide rods support a pair of edge

drive roll carriages

44, 45, on which are supported, for rotation about vertical axes, a pair of edge drive rolls 46, 47.

A square or splined shaft 48 is journalled in the brackets 41, extends through the

carriages

44, 45, and mounts a sprocket 49 at one end. The square shaft 48 is driven by a chain 50 from an adjustable speed motor 51. To advantage, the speed of the motor 51 is controlled by the machine operator, using conventional controls (not specifically illustrated) such that adjusted speed of the edge drive rolls constitutes the basic machine speed of the system, and all other speed functions are appropriately related thereto. By way of example, the operational speed of the infeed station automatically is relatedto the adjusted speed of the edge drive rolls by means of the modulating control of the floating roller 24, which continually senses the rate at which the fabric is being demanded by the edge drive rolls 46, 47.

Positioned between the edge drive rolls 46, 47 is a spreading frame designated by the reference numeral 52. This spreading frame typically includes a pair of

frame sections

53, 54 extending longitudinally in spaced relation, and an adjusting bar 55; which connects the two frame sections, advantageously in the region of the edge drive rolls, and holds them at a predetermined width dictated by the fabric processing requirements.

When the equipment is to be operated as a tensionless calender (see Cohn et al., US. Pat. Nos. 2,589,344 and No. 2,589,345, for example), the spreader frame 52 includes a pair of upstream propeller belts 56, and a pair of downstream propeller belts 57, guided by a plurality of rollers 58, so as to have longitudinally extending portions exposed at the outer edge extremities of the spreader frame for engagement with the internal edges of the length of tubular knitted fabric distended over the frame.

The respective pairs of

belts

56, 57 are trained over drive pulleys 59, 60 located in the mid-region of the spreader frame. The drive pulleys are arranged to be positioned in straddling relation to the edge drive rolls 46, 47 and to contact the rolls through an interposed wall of fabric. Thus, when the edge drive rolls are rotated, by the square drive shaft 48, the

respective propeller belts

56, 47 are driven by the

pulleys

59, 60. By appropriate design of the

pulleys

59, 60, the upstream belts 56 are caused to operate at a slightly higher rate of speed than the downstream belts 57, so that the tubular knitted fabric is slightly overfed onto the downstream belts. This accommodates lengthwise relaxation of the fabric.

The two-stage spreader can also be arranged to underfeed the fabric from the first to the second stage, if desired. Where the equipment is to be operated so as a so-called straight line calender, the spreader frame may employ a single pair of belts arranged to convey the fabric at constant speed over the full length of the spreader.

Proper entry of the unprocessed tubular knitted fabric 12 onto the spreader frame is promoted by an entry end guide bar assembly 61. The guide bar assembly includes at each side a rod section 62 which is received in a pivotable socket 63 carried at the upstream extremity of the spreader frame. The rod sections 62 are connected to second rod sections 64 by short springs 65, which accommodate bending action between the first and second rod sections. The respective rod sections 64 are in turn connected together by a spring 66, which likewise accommodates bending action between those rod sections. The entire assembly is covered by a section of plastic tubing 67, so that the incoming fabric freely slides over the guide bar and is advanced to the propeller belt sections of the spreading frame. The described construction of the entry guide bar assembly is advantageous in that it accommodates substantial variation in the spacing of the

spreader frame sections

53, 54 by the bending action of the

springs

65, 66 and the pivoting movement of the sockets 63.

In accordance with one aspect of the invention, transverse adjustment of the edge

drive roll carriages

44, 45 is effected by means of a threaded shaft 70, which is reversely threaded at opposite ends so as to effect simultaneous and equal inward or outward movement of the

respective carriages

44, 45 upon rotation. In accordance with the invention, the threaded shaft 70 is not directly threadedly connected to the

carriages

44, 45. Rather, there are provided drive nuts 7!, 72 which have threaded engagement with the shaft 70 and which are connected to the

respective carriages

44, 45 through a plurality of bolts 73 and compression springs 74. The springs 74 normally are precompressed so as to urge the carriages away from the drive nuts, in a transversely inward direction, until the bolt heads 75 are seated against the outer surfaces of the drive nuts.

For driving the threaded shaft 70, there is advantageously provided a stallable drive motor, such as a stalltorque electric motor or, more preferably, a low torque air motor 76. The air motor 76 is actuated by means of a reversing valve 77 and a variable pressure regulator valve 78. Thus, when the valve 77 is actuated to advance the edge

drive roll carriages

44, 45 in a closing direction, it will continue to operate until the edge drive rolls have engaged the spreader frame 52 through the fabric walls, and the threaded shaft 70 has met with sufficient resistance to further rotation to cause the air motor 76 to stall out. The amount of torque resistance required to effect such stalling is controlled by the variable pressure regulator 78.

A substantial advantage is realized in actuating the

carriages

44 or 45 through the compressible springs 74 rather than directly from the threaded shaft 70, in that inertia effects of the closing movement can be to large extent absorbed by a slight amount of compression in the springs. Likewise, minor irregularities in the fabric can be accommodated between the spreader frame and the edge drive roll by slight compression of the springs, without significantly increasing the momentary edge pressure of the fabric. To even greater advantage, it is feasible to provide a great degree of operator control over fabric edge pressure by providing a calibrated indicating device to reflect the amount of compression in the springs 74. Thus, as shown in FIG. 5, the drive nut 71 may be provided with a series of calibrating marks 79 associated with a fixed mark 80 carried by an indicator bracket 81 extending from the carriage 44. When the edge drive rolls are advanced into position, the spring 74 will be compressed a predetermined amount before the motor 76 stalls out. The extent of the spring compression will be reflected by the relationship of the calibration marks 79, 80 and this will accurately reflect the amount of the edge pressure on the fabric. The machine operator may then easily adjust the pressure regulating valve 78 to achieve a desired degree of edge pressure as reflected by the calibrating marks.

On occasion, the incoming fabric 12 may tend to jam at the upper extremity of the spreader frame (as, for example, if the fabric were badly twisted or torn In such cases, the driving forces on the fabric may dislodge the spreading frame with the potential of casing damage to the equipment. In accordance with the present invention, this eventuality is effectively prevented by providing a safety limit switch 82, mounted on one of the carriages 45 (FIG. 4) by means of a suitable bracket 83. The safety switch 82 cooperates with an actuating arm 84 carried by the associated drive nut 72. One or both of the switch and

actuating lever

82, 83 are positioned to provide for the switch to be in a dc-actuated" condition during normal operations of the equipment. However, should the fabric 12 snag at the entry end of the spreader frame, dislodging the spreader frame, the edge roll cases will be moved quickly inward by the springs 74, causing the switch 82 to be actuated. By appropriate circuit arrangement (not shown but readily providable by persons skilled in the art) actuating of the safety switch 82 immediately shuts down the entire line for correction of the malfunction.

As will be appreciated, when the edge drive rolls 46 and 47 are withdrawn from the spreader frame, the frame will drop downward unless independently supported. Normally, the downstream extremity 85 of the spreader frame extends at least slightly between the

rolls

86, 87 of the calendering stage. so that some support is provided for this end of the frame. For support of the upstream end of the frame, it is advantageous to provide a support bar 88 which is pivotally mounted on the machine frame by swing arms 89. Normally, the bar 88 rests in a position spaced below the spreader frame, to be out of contact with the fabric passing thereover. However, in preparation for separating the edge drive rolls and releasing the frame, the support bar 88 is swung to its upward position, shown in phantom lines in FIG. IA, and secured by a latch 90.

To great advantage, the system of the present invention incorporates a new and improved steaming facility which is the subject of copending application Ser. No. 355,40l, filed Apr. 30, I973, entitled High Production Steamer." This steamer, generally designated by the numeral 14 in FIG. 1A, is described in detail in said copending application and reference thereto may be made for supplemental information. In general, the steaming apparatus 14 includes a pair of

dripless steam boxes

91, 92 extending transversely across the width of the fabric above and below the plane of the spreader 52. The construction of these steam boxes may be substantially in accordance with the S. Cohn et al., U.S. Pat. No. 2,602,314, granted July 8, 1952.

As reflected in FIG. 6, the

steam boxes

91, 92 may be of similar construction, although reversely oriented, to provide pairs of transversely extending steam discharge slots 93. Perforated steam inlet pipes 94 extend across the width of the steam boxes are arranged to discharge steam toward the closed side of a U-shaped channel 95. Flanged lips 96 of the channel extend toward the steam pipes and provide for the egress of steam into the main chamber of the steam box formed by an outer casing 97. In the case of the upper steam box 91, condensate is collected in the bottom of the channel 95, draining through an end opening 98 and eventually being extracted through an outlet pipe 99. In the case of the lower steam box, condensate is collected in troughs formed by the flange lips 96, enabling the condensate to be drained towards the ends of the steam box and eventually to be extracted through an outlet pipe 100. The outer housing 97 has flanged lips 101 which extend alongside the outer walls of the interior channel 95, to provide narrow, vertically extending slots 93 for the discharge of steam to the outside. The configuration of these slots 93 is such that steam condensate in the outer casing 97 of the upper box is collected in troughs 102 and eventually drained through outlet pipe 99.

The arrangement of the steam boxes is such as to enable steam to be discharged in full width jets across the width of the fabric both from above and from below the plane of the fabric. At the same time, condensate formed internally of the steam boxes is trapped and prevented from dripping on the fabric to cause spotting or staining. Desirably, at least the upper steam box 91 is provided with thermal insulation 103.

Although the steam boxes constructed in accordance with the beforementioned S. Cohn, et al. patent are highly effecient and effective in operation, the steaming operation has constituted a bottleneck" of the finishing stage operations performed on tubular knitted fabric. In this respect, it is desirable to impart predetermined amounts of moisture to the fabric to enable the necessary fiber relaxation and readjustment to occur. With equipment heretofore utilized, efforts to increase the rate of production or increasing the rate of steam application beyond a predetermined level have been relatively ineffective, resulting either in non-uniform application of the steam, or in excessive problems from condensation and spotting, or both. In the system of the present invention, however, the fabric steaming facilities include significant improvements enabling the effective rate of steam to be greatly increased and production rates to be correspondingly increased, up to as much as two to four times the rate of production using conventional equipment.

In accordance with the present invention, the steam.

boxes

91, 92 are surrounded and substantially enclosed by a steam chamber 104. The chamber 104 includes an insulated upper wall 105 extending over the top of the upper steam box 91, and insulated upper side walls 106, I07 extending downward at an angle and terminating approximately at the level of the bottom of the steam box 91. The chamber also includes a bottom wall 108 disposed below the lower steam box 92,

bottom side walls

109 and 110 extending upward at an angle from the bottom wall, and side wall extensions 111, I12 extending more or less vertically upward from the upper extremities of the bottom side walls and terminating approximately at the level of the top of the lower steam box 92. End walls 113 connect the upper wall structure with the lower wall structure and form therewith a substantially totally enclosed steam chamber having narrow transverse openings 1 14, 115 to accommodate the spreader frame and the distended fabric being conveyed by the frame. Desirably,

flexible seals

116, 117 are provided at the openings arranged to conform to the operatively positioned spreader frame to substantially close off the

openings

114, 115 while permitting the free passage of the tubular knitted fabric through the chamber. Typically, the flexible seals may take the form of soft brushes or the like. In this respect. highly effective sealing is not a requirement of the

elements

116, 117, but some closure facility is preferred to guide and confine the flow of steam and air within and about the chamber.

As will be readily apparent in FIGS. 1A and 3, the width dimension of the steam chamber 104--that is, in the longitudinal direction of fabric movement--is substantially less than the length of the spreader frame 52. In the illustrated system, the upstream'todownstream dimension of the steam chamber is considerably less than the length of the second or downstream stage of the spreading frame, and is also considerably less than the transverse dimension or length of the chamber.

As reflected in FIG. 6, the steam chamber 104 includes a baffle plate 120, having a portion extending underneath the lower steam box 92, and flanges 121 extending upwardly and outwardly from the bottom portion. The baffle plate 120 is mounted by means of spacer posts 122 in spaced relation with the bottom wall 108 and

bottom side walls

109, 110 of the steam chamber. The baffle plate 120 extends substantially to the end walls 113 of the steam chamber, but its flanges 121 are spaced away from the vertical side walls 111, 112 of the chamber so as to form large, transversely elongated passage openings 123 on opposite sides of the lower steam box 92.

An exhaust duct 124 is connected to the bottom wall 108 of the steam chamber so as to be in communication with the flow passage formed between the baffle 120 and the adjacent walls of the chamber. The exhaust duct is connected by suitable tubing 125 to the intake of an exhaust fan 126 arranged to direct the exhaust materials to an appropriate discharge point.

As will be understood from the illustration of FIG. 6, the exhaust duct 124 provides for a downdraft exhaust flow of the steam atmosphere contained in the chamber 104. Thus, steam issued in high velocity jets from the narrow openings 93 is impinged directly on the fabric passing through the chamber, disperses into the chamber at large, and then is quickly drawn downwardly through the passages 123 and exhausted through the duct 124. This arrangement of conventional steam boxes, closely confined within a steam chamber of limited volume in relation to the steam boxes and provided with a highly effective exhaust facility, enables the rate of application of steam from the steam boxes to be greatly increased without undesirably affecting the processing operation. More importantly, it significantly increases the rate at which the fabric may be effectively processed to a desired moisture content. Thus, high quality processing may be achieved at up to four times the rates possible with conventional apparatus.

Most advantageously, the capacity of the exhaust blower 126 is so related to the rate of input of steam into the chamber 104 as to maintain a substantially neutral to slightly positive pressure condition within the chamber, thereby preventing the escape of excessive amounts of steam from the chamber, while also preventing the inflow of undesirable amounts of fresh air. After passing through the steam chamber 104, the

fabric is directed through calendering rolls 86, 87,

which may or may not be closed, depending upon the 5 desired treatment to be imparted to the fabric. Where the fabric is to be calendered, the

rolls

86, 87 are brought into closed, pressure-bearing relationship. To this end, the lower roll 87 may be journalled on a fixed axis in a bearing block 130, while the upper roll 86 may be journalled in a bearing block 131 arranged for vertically guided movement in a guide frame 132. To advantage, appropriate spring means (not shown) are provided for biasing the movable bearings [31 and the upper calender roll 86 to an upward or open position. The calender roll may be moved downwardly, in opposition to the biasing springs, by means of fluid actuators 133 at each side, controlled by a pressure regulator 134. Thus, any degree of operating pressure may be applied to the nip of

rolls

86, 87 by appropriate adjustment of the pressure regulator 134. In the illustrated arrangement, the lower calendering roll 87 is driven directly by an electric drive motor 135, through a chain 136. The upper calendering roll 86 is driven in synchronism with the lower roller by means of idler pinions 137, 138 mounted on suitable linkages (not shown) or otherwise arranged to maintain a constantly meshing relationship while accommodating limited vertical movements of the upper roll 86.

The drive motor 135 for the calender rolls is speed adjustable relative to the main drive motor 51 for the edge drive rolls. Thus, any change in the speed of the edge drive rolls automatically will be reflected in the calender rolls, although the latter may be separately adjusted, typically to run at a controllably lower rate of speed than the edge drive rolls, to accommodate the overfeeding of the fabric where desired.

At the discharge end of the equipment there is provided a batching stand 140, which includes a roll-up batcher for the processed fabric, as well as fabric cutoff means and means for automatically or semiautomatically commencing the start of a new roll batch after fabric cut-off. To advantage, the batching stand may also include means for weighing the completed roll or batch, and also yardage counting means for recording the lengths of material in the successive batches.

Referring now to FIGS. 1A, 7 and 8, the batching stage includes a driven windup roller 141, which is journalled in the frame and is driven by a variable speed electric motor 142 by means of a chain 143 and suitable sprockets. To advantage, the variable speed motor 142 is controllable in relation to the drive motor 135 for the calender rolls. Thus, any variation in calender roll speed automatically will be reflected by a corresponding speed change in the windup roll motor 142. In addition, however, the motor 142 may be adjusted to operate at a certain percentage of speed above or below the speed of the calender drive motor 135. The arrangement typically is such that the fabric 145 extending between the calendering stage and the windup stage 16 is maintained under a very slight tension, sufficient to maintain the fabric under complete control without, however, introducing an excessive degree of longitudinal tension.

Pivotally mounted on the batching stand 140 is a support bracket 146, comprising a pair of support arms at each side of the machine, pivoted by a shaft 147 and secured together by suitable bracing (not shown) for movement in unison. The bracket 146 is operatively connected to a fluid actuator 152 for pivoting movement about an angle of almost 90, from the position shown in full lines in IA and 7, to the position shown in phantom lines in FIG. 7.

Secured to the bracket 146 are opposed pairs of

mandrel guiding channels

148 and 149. The channels 148 constitute the principal mandrel guides, while the channels 149 form a reservoir for a new mandrel, being provided with an upwardly opening slot 150 in which a new mandrel may be placed during the winding ofa roll of fabric on a previous mandrel. In operation, a mandrel 151 of appropriate length and diameter is received in the main guide channel 148 and arranged to bear against fabric resting on the driven winding roll 141. After starting of the windup operations, by means to be described, the accumulating roll forces the mandrel 151 radially away from the windup roll, urging it upward in the guide channels 148, until the desired roll size has been reached, as reflected in FIG. 1A. At that point, the actuator 152 can be energized and extended to pivot the bracket 146 in a counterclockwise direction, to a position in which the guide channels 148 are tilted slightly downward. The completed roll of fabric then is readily rolled downhill, while still supported by the end of the mandrel 151, until the mandrel ends drop into V-shaped receiving troughs 153 at the end of the windup stand 140. When this pivoting action take place, a new mandrel, held in the feeder channel 149, rolls down and enters the main guide channel 148 behind the fully wound fabric roll and rests there, are reflected at 151a in FIG. 7. When the bracket 146 subsequently is pivoted clockwise back to its normal position, the new mandrel 151a slides down the main guide channel 148, to rest directly on the fabric passing over the winding roll 141.

In the apparatus of the invention, a cut-off facility is provided on the downstream side of the winding station. This comprises a pair of transversely extending, opposed guide channels 160, 161 (FIG. 8) which serve to support and guide for transverse movement a cutter carriage 162. The carriage mounts a rotary cutting knife 163 driven by an electric motor 164. The cutter carriage has a plurality of guide rollers 165 arranged to engage the

channels

160, 161 internally and accommodate the high speed travel of the cutter carriage across the full width of the machine. A drive cable 166 is connected to the carriage 162 by means of a bracket 167. The drive cable passes around pulleys 168 at each side of the machine and is connected to a moving piston element 169 within an elongated air actuator 170. When air is introduced into the left hand end of the actuator, as illustrated in FIG. 8, the cutter carriage is rapidly driven toward the left across the machine. When the cutter carriage engages a traverse limit switch (not shown), at the extremity of its movement, it energizes a carriage traverse timer. At the end of an adjustable delay period. the air supply to the actuator 170 is reversed, and the cutter automatically returns to its starting position. Typically, the cutter motor 164 is electrically driven and, for this purpose, a retractable power cord 172 extends from an automatic rewind device 173 secured at the side of the windup frame 140.

In typical operation of the equipment, when a fabric roll has achieved the desired size, the machine operator stations himself at the discharge end of the machine (left hand end, as viewed in FIG. 1A) to prepare for the cut-off and restarting operations. When he desires to remove the completed roll, the operator actuates a foot switch 180, which is accessible from his station at the end of the machine. This causes the entire line to be stopped or at least slowed down to a very low speed. At the same time, the fluid actuators 152 are energized to pivot the roll support brackets 146 in a counterclockwise direction to the position shown in phantom lines in FIG. 7. The fabric roll will then tend to travel down the path formed by the downwardly inclined guide channels 148, but typically this movement is expedited by the operator manually gripping the exposed ends of the mandrel 151 (see FIG. 8) and drawing the completed roll toward the end of the machine. As the mandrel 151 reaches the end of the guide channel 148, it drops into the V-shaped receiving sockets 153 initiating further operations. When the mandrel ends are in their receiving sockets, a switch 181 associated with one of the sockets is actuated. The fluid actuator 152 is thereby reversed to swing the brackets 146 and guide channels 148 clockwise back to their normal operating positions. After the guide channels 148 have returned, and thus cleared the path of the cutter assembly 162-165, a timing switch (not specifically illustrated) functions to energize the traverse cylinder and initiate a rapid cutting traverse of the cutter carriage. The tubular fabric will at this time be draped over the

guide channels

160, 161, and the fabric thus will be severed by the cutter as it proceeds through its traverse, freeing the completed roll from the remainder of the fabric supply.

When the carriage reaches the end of its cutting stroke, it remains there until the traverse timer times out and initiates a return movement. During the short dwell of the carriage between cutting and return strokes, the cut end of the fabric is flipped over and restarted as a new roll, as will appear.

In accordance with one aspect of the invention, the entire cutter apparatus, including the carriage 162, its

guide channels

160, 161, and the related mechanisms is mounted on the arms of the pivotable bracket 146. As a result, when the bracket 146 is pivoted to discharge a wound roll, the entire cutter assembly pivots with the bracket to its is thus temporarily retracted out of the way of the discharged roll. After the wound roll has been received in the sockets 153, the bracket 146 is pivoted back toits upright position, returning the cutter assembly to its operative position and orientation,

By providing for the momentary pivotal retraction of to locate the cutting system and the cutting line much higher and much closer to the winding roll 14] than otherwise. This has the important advantage of reducing to a practical minimum the length of the tail of fabric which is to be flipped back over the new mandrel to start a new roll. By keeping this tall very short, greater reliability and uniformity is achieved in the restarting of rolls. In addition, the improved arrangement better accommodates the winding and handling of rolls of relatively large diameter.

Upon return of the guide channels 148 to their upright position, the new mandrel 151a, having previously rolled into the channel 148, now rolls down onto the winding roller 141, where it engages the layer of fabric extending over the winding roller in preparation for winding a new roll. In the following moments, the cutter carriage 162, as it completes its cutting traverse,

trips a limit switch (not shown) initiating the flow of air under pressure to a manifold pipe 190, extending transversely across the machine in the region between the driven windup roller 141 and the

cutter traverse channels

160, 161. The manifold 190 has an elongated discharge slot 191 extending therealong, which is directed upwardly and slightly rearwardly. When air is supplied to this manifold 190 the free cut end of the fabric is blown upwardly and rearwardly around the newly positioned mandrel 151, coming to rest on the upper surface of the fabric, on the upstream side of the mandrel 151 as reflected at 192 in FIG. 7. The duration of air supply to the pipe 190 advantageously is controlled by a timer.

When the cutter carriage reaches the end of its stroke, a rotary actuator 193 is energized to pivot, in a counterclockwise direction, a pair of tuck-in arms 194. These arms, which are of L-shaped configuration, carry positioning rollers 195 at their free ends, which are arranged to engage the end extremities of the newly positioned mandrel, to both serve as a position stop for the tuck-in arms 194 and momentarily to apply a controlled amount of pressure to the mandrel. Such momentary pressure helps to avoid slippage of the fabric on the driven winding roller 141 during the startup of a winding sequence when there is little or no inherent to the newly started roll.

Secured to the tuck-in arms 194, and extending across the width of the machine, is a tuck-in bar 196. The tuck-in bar has a plurality of resilient tucking fingers 197 so positioned that, when the arms 194 are actuated to their counterclockwise limit positions, the fingers engage the loose upper flap of the fabric 192, in the region of the bight between the mandrel 151 and the winding roller 141, and cause a portion of the fabric to be tucked into this bight. The combination of this tucking, in cooperation with the controlled momentary pressure applied by the positioning rollers 195, provides for controllably reliable restarting of the winding operation, after cut-off and doffing of a completed batch. The flip-over and tuck-in operations are normally initiated while the processing line remains in a stopped or slow speed condition. However, by appropriately located limit switch means (not shown) the counterclockwise movement of the tuck-in arms 194 to operative positions serves to reactuate the processing line to resume its normal forward speed.

To advantage, the clockwise or return movement of the tuck-in arms is under the control of an appropriate time delay means, coinciding with timed return of the cutter carriage, enabling the tuck-in operation to be reliably and effectively carried out, while at the same time withdrawing the tuck-in bar 196 before the newly winding roll undergoes a significant increase in diameter.

The completed roll batch, now resting in the sockets 153, may be removed and carried away during the interval of the winding of the next successive roll, as will be appreciated. When the filled mandrel 151 is received in the socket 153, it is also automatically weighed. The specific facility for registering the weight is not critical. To advantage, however, it may be an appropriate strain gauge or transducers element (not shown) which will sense the weight of the ends of the mandrel 151 when resting in the sockets 153.

The apparatus of the invention provides a highly improved form of apparatus for carrying out calendering and finishing operations on tubular knitted fabrics. While the finishing operations themselves are essentially conventional in a general sense, involving lateral distending, overfeeding (if desired) for lengthwise relaxation, steaming, calendering and batching, the man ner in which these operations are accomplished with the apparatus of the invention results in important advantages including significantly increased production speeds. ln particular, the processing speed of conventional steam finishing equipment has been inherently limited by the ability to carry out the steaming operation effectively. Thus, in the steaming operation a desired amount of moisture must be imparted to the fabric without causing water spotting or other blemishes on the fabric. Heretofore, efforts to increase production speeds by increasing the volume and/or velocity of steam application have not met with success, partly because the ability to impart moisture to the fabric does not appear to be simply a function of velocity of steam and partly because of severe spotting problems from condensing moisture. With the system of the present invention, however, by effecting the application of steam to the fabric with steam jet means located within a confining chamber closely embracing and surrounding the steam outlet means, and continuously extractly excess steam from the enclosed chamben'the effective production rate of the steaming operation can be greatly increased relative to conventional speeds without compromising production quality standards.

The upstream" portions of the new system may be utilized with various batching means, including folders. Nevertheless, the system of the invention incorporates to advantage improved yet simplified semi-automatic facilities for windup batching and doffing of the fabric. with a minimum of operator attention and with a minimum of discontinuity in the operation of the equipment. Thus, when the batch roll has reached the desired size, the operator initiates the doffing sequence by means of a simple foot switch control, after which roll removal, fabric cut-off, and restarting operations are carried out in a rapid, automatic sequence without further operator intervention. To this end, a novel mechanism is provided for tucking in the cut-off fabric end and for applying momentary starting pressure to the new mandrel for effectively reliable restarting of the windup. Once a few turns of fabric have been made upon the new mandrel, the rewinding will continue unaided, and the tuck-in element and the axiliary pressure means may be quickly retracted.

At the entry end of the machine, greatly improved arrangements are provided for the lateral positioning and control of the edge drive rolls, to simplify the operators task and to enable him to exercise greater control over the operating procedures. in this respect, the edge drive roll lateral adjustment is carried out through drive nuts engaging a threading positioning shaft and acting upon the edge drive roll carriages through compressible spring means. A desired level of edge drive roll pressure is achieved by a desired degree of spring compression, affording a much more delicate control over edge pressure on the fabric than if the edge drive carriages were themselves connected directly to the threaded positioning shaft. Initial movement of the edge drive rolls into gripping relation with the propeller frame is achieved by actuation of a stallable motor, advantageously an air motor controlled by a pressure regulator to stall out at a desired level of torque resistance on the threaded shaft. The amount of edge pressure is reflected by the extent of spring compression, and this in turn can be readily and accurately reflected by a calibrated indicator extending from one or both of the edge drive roll carriages to the associated drive nut therefore.

The system of the invention also incorporates an improved fabric supply system which is uniquely advantageous in the finishing operation. Thus, the supply stand illustrated in F105. 1B and 2 is independently speed controlled by the floating roller 24, which maintains a predetermined running reserve of fabric substantially without varying the longitudinal tension of the incoming fabric. With this arrangement, greater uniformity in the relaxation and stabilization of the fabric can be realized than would be the case where movement of the floating roller was accompanied by a change in the force imparted thereby to the fabric.

It should be understood, of course, that the specific form of the invention herein illustrated and described is intended to be representative only, and any changes may be made therein without departing from the clear teachings of the disclosure. Accordingly, reference should be made to the following appended claims in determining the full scope of the invention.

1 claim:

1. A system for the treatment of tubular knitted fabric and including driver means for spreading the fabric to predetermined width, means for steaming the spread fabric, and means for gathering the spread and steamed fabric after discharge from the spreading means, characterized by a. edge drive rolls mounted at opposite sides of the spreading means for engaging and driving the spreading means through the edge walls of the fabric,

b. power means for moving the edge drive rolls toward each other for effecting pressure engagement between the edge drive rolls and the fabric edge walls, including threaded shaft means for moving the edge drive rolls, and drive means for rotating said shaft means,

c. adjustable control means for automatically limiting the pressure of engagement between the edge drive rolls and the fabric by disabling the drive means when a predetermined pressure is established between the edge drive rolls and the fabric,

d. said drive means comprising an air driven motor,

and

e. said adjustable control means comprising a controllable pressure regulator associated with said air driven motor and effective to cause said motor to stall when a predetermined edge pressure is achieved.

2. A system for the treatment of tubular knitted fabric and including driver means for spreading the fabric to predetermined width, means for steaming the spread fabric, and means for gathering the spread and steamed fabric after discharge from the spreading means, characterized by a. edge drive rolls mounted on carriages at opposite sides of the spreading means for engaging and driving the spreading means through the edge walls of the fabric,

b. means for moving the edge drive roll carriages toward each other for effecting pressure engagement between the edge drive rolls and the fabric edge walls,

c. said means for moving further including a controllably driven threaded shaft,

d. a pair of drive nuts arranged in threaded engagement with said shaft and associated with the respective edge drive roll carriages,

e. spring means interposed between the associated drive nuts and edge drive roll carriages, whereby rotation of said shaft effects movement of said drive nuts and, through the interposed spring means, also of said edge drive roll carriages, and

f. edge drive pressure indicator means comprising an indicator device carried by one element of an associated edge drive roll carriage and drive nut pair, and

g. calibration scale carried by the other element of the associated pair,

h. the position of said indicator in relation to said scale reflecting the magnitude of the edge drive roll pressure.

3. A system for the treatment of tubular knitted fabric and including driver means for spreading the fabric to predetermined width, means for steaming the spread fabric, and means for gathering the spread and steamed fabric after discharge from the spreading means, characterized by a. edge drive rolls mounted on carriages at opposite sides of the spreading means for engaging and driving the spreading means through the edge walls of the fabric,

(1. a pair of drive nuts arranged in threaded engagement with said shaft and associated with the respective edge drive roll cariages,

e. spring means interposed between the associated drive nuts and edge drive roll carriages, whereby rotation of said shaft effects movement of said drive nuts and, through the interposed spring means, also of said edge drive roll carriages,

f. a safety limit switch operatively associated with a drive nut and its associated edge drive roll carriage,

g. said safety limit switch being operative in response to a predetermined condition of compression of said spring means to stop operation of the treating system.

Claims

1. A system for the treatment of tubular knitted fabric and including driver means for spreading the fabric to predetermined width, means for steaming the spread fabric, and means for gathering the spread and steamed fabric after discharge from the spreading means, characterized by a. edge drive rolls mounted at opposite sides of the spreading means for engaging and driving the spreading means through the edge walls of the fabric, b. power means for moving the edge drive rolls toward each other for effecting pressure engagement between the edge drive rolls and the fabric edge walls, including threaded shaft means for moving the edge drive rolls, and drive means for rotating said shaft means, c. adjustable control means for automatically limiting the pressure of engagement between the edge drive rolls and the fabric by disabling the drive means when a predetermined pressure is established between the edge drive rolls and the fabric, d. said drive means comprising an air driven motor, and e. said adjustable control means comprising a controllable pressure regulator associated with said air driven motor and effective to cause said motor to stall when a predetermined edge pressure is achieved.

2. A system for the treatment of tubular knitted fabric and including driver means for spreading the fabric to predetermined width, means for steaming the spread fabric, and means for gathering the spread and steamed fabric after discharge from the spreading means, characterized by a. edge drive rolls mounted on carriages at opposite sides of the spreading means for engaging and driving the spreading means through the edge walls of the fabric, b. means for moving the edge drive roll carriages toward each other for effecting pressure engagement between the edge drive rolls and the fabric edge walls, c. said means for moving further including a controllably driven threaded shaft, d. a pair of drive nuts arranged in threaded engagement with said shaft and associated with the respective edge drive roll carriages, e. spring means interposed between the associated drive nuts and edge drive roll carriages, whereby rotation of said shaft effects movement of said drive nuts and, through the interposed spring means, also of said edge drive roll carriages, and f. edge drive pressure indicator means comprising an indicator device carried by one element of an associated edge drive roll carriage and drive nut pair, and g. calibration scale carried by the other element of the associated pair, h. the position of said indicator in relation to said scale reflecting the magnitude of the edge drive roll pressure.

3. A system for the treatment of tubular knitted fabric and including driver means for spreading the fabric to predetermined width, means for steaming the spread fabric, and means for gathering the spread and steamed fabric after discharge from the spreading means, characterized by a. edge drive rolls mounted on carriages at opposite sides of the spreading means for engaging and driving the spreading means through the edge walls of the fabric, b. means for moving the edge drive roll carriages toward each other for effecting pressure engagement between the edge drive rolls and the fabric edge walls, c. said means for moving further including a controllably driven threaded shaft, d. a pair of drive nuts arranged in threaded engagement with said shaft and associated with the respective edge drive roll cariages, e. spring means interposed between the associated drive nuts and edge drive roll carriages, whereby rotation of said shaft effects movement of said drive nuts and, through the interposed spring means, also of said edge drive roll carriages, f. a safety limit switch operatively associated with a drive nut and its associated edge drive roll carriage, g. said safety limit switch being operative in response to a predetermined condition of compression of said spring means to stop operation of the treating system.