DESC:AN AUTOMATIC YARN PIECING SYSTEM

FIELD OF THE INVENTION
[0001] The present invention relates to an improved piecing robot for textile spinning machines. More particularly, the invention relates to a versatile automatic piecing robot for ring spinning machines to perform automatic piecing operation of broken yarns in multiple spinning machines.

BACKGROUND OF THE INVENTION

[0002] Currently, in a textile spinning mill, the raw fibres are opened, cleaned, and then twisted together to form yarn. Initially, the fibres are processed in a blow room with a series of machines and subsequently, the processed fibers are passed to a carding machine. The individualized fibers from the carding machine are transported to a draw frame in the form of slivers. In the draw frame, doubling and drafting of a plurality of fed slivers are performed. The drafted slivers are formed into a lap by means of a lap-forming machine. Subsequently, the obtained lap is further combed in a combing machine. The combed sliver is converted into roving in a speed frame/fly frame machine. The roving is further twisted into yarn in ring spinning machines and wound onto the ring cop. Subsequently, the yarn is wound onto a cone or cheese in a yarn-winding machine.

[0003] The yarn breakage in ring spinning machines is a major problem that requires continuous attention of skilled labour. One of the major problems faced by the spinning mills is a shortage of skilled operating persons for carrying out a piecing operation in ring spinning machines. The yarn breakage remains an unavoidable problem in ring spinning machines which has forced a huge number of workers to continuously monitor the ring spinning machines at both sides throughout the length of the machine frame, which has normally more than 1600 spindles. The broken yarns have to be pieced manually and the yarn spinning sequence has to be restarted then and thereafter yarn breakage in order to avoid wastage of yarn.

[0004] To overcome the listed drawbacks, automatic piecing units are developed as an improvement towards the conventional method of manual piecing. The automatic piecing unit is in the form of a movable vehicle with wheels/rails. The piecing vehicle stops at respective spindle units which require piecing attention. The piecing unit in general moves longitudinally over the machine frame aisles. Before initiating the piecing operation, the piecing vehicle stops in front of the spindle position of the ring spinning machine.

[0005] The problem associated with the currently available automatic piecing units is that the ring spinning machines need to adapt the automatic piecing unit by incorporating various guides and rails for providing the travel path and movements for the automatic piecing units. Alternatively, the automatic piecing units travel directly on a floor with the aid of wheels. The problem associated with the arrangement is the floor may contain uneven surfaces which causes the improper positioning of the automatic piecing units in front of the spinning unit requiring piecing operation. As a result of improper positioning of the piecing unit, the piecing operation may end in failure or may result in more attempts to piece the broken yarn, which eventually leads to a large amount of yarn wastage, increased time and power consumption.

[0006] In order to prevent misalignment of the automatic piecing unit due to uneven floor surfaces, the automatic piecing unit must be provided with various additional elements such as sensing units, control units, levelling units such as electromechanical actuators which control and guide the automatic piecing unit against the uneven floor surface. The additional elements result in higher production costs of the automatic piecing units. The automatic piecing units, always rely upon guiding the rotating wheels over the plurality of rails provided along the ring-spinning machines or over the floor surface of the spinning mills.

[0007] Therefore, there exists a need to address the above mentioned shortcomings, to which the present invention provides an improved solution by providing an automatic yarn piecing unit.

OBJECTS OF THE INVENTION

[0008] An object of the present invention is to provide an automatic yarn piecing system for a plurality of the ring spinning machines to perform piecing operation for the broken yarns.

[0009] Another objective of the present invention is to provide an automatic yarn piecing system to perform a plurality of maintenance activities involved in a textile mill.

[0010] Another objective of the present invention is to provide an automatic yarn piecing system having a robot configured to switching between multiple ring spinning machines and is economical in operation.

[0011] Other objects and advantages of the present invention will be more apparent from the following description, which is not intended to limit the scope of the present invention.

SUMMARY OF THE INVENTION

[0012] Before the present methods, systems, and hardware enablement are described, it is to be understood that this invention in not limited to the particular systems, and methodologies described, as there can be multiple possible embodiments of the present invention which are not expressly illustrated in the present disclosure. It is also to be understood that the terminology used in the description is for the purpose of describing the particular versions or embodiments only, and is not intended to limit the scope of the present invention which will be limited only by the appended claims.

[0013] The present invention relates to an automatic yarn piecing system for a plurality of ring spinning machines. The automatic yarn piecing system comprises one or more spindle units disposed in the plurality of ring spinning machines. The automatic yarn piecing system may comprise a robot configured to provide dynamic movement in horizontal and/or traverse directions with respect to the plurality of ring spinning machines to locate a broken yarn. The robot is further configured to perform a piecing operation upon locating the broken yarn in the one or more spindle units, wherein the dynamic movement of the robot is performed without utilizing guide rails or wheels. The robot is further configured to perform a human-like walking movement.

[0014] In an aspect, a textile spinning mill is provided with an improved and versatile piecing robot for piecing the broken yarns in the plurality of ring spinning machines. In an embodiment, the robot can be a piecing robot or a service unit. The piecing robot receives the information about the yarn breakage in particular spindle through an individual spindle monitoring mechanism provided in the plurality of spinning machine or through the mill monitoring systems connected through internet and servers.

[0015] In an aspect, the versatile piecing robot is capable of piecing the broken yarns in the plurality of ring spinning machines placed anywhere across the spinning mills, without any guide rails and wheels, as humans walk. The piecing robot is capable of switching between multiple ring spinning machines. The piecing robot locates the broken yarn spindle either by its own image-capturing technique through the individual spindle monitoring system located in the ring spinning machine or by the centralized mill monitoring system. The piecing robot positions in front of broken yarn using at least one positioning element. The positioning element can be either mounted in at least one robotic arm or provided as an additional module, directly mounted on the piecing robot. The piecing robot is capable of positioning and adjusting itself at any height in front of the plurality of ring spinning machines to access whichever part of the machine is required. The piecing robot is capable of adjusting and moving on any axis horizontally and vertically. The piecing robot lifts the broken yarn end from the cop and subsequently hooks and inserts the broken yarn inside the ring traveller of the ring spinning machine. The piecing robot further joins the broken yarn end with a spun roving end being delivered from the drafting rollers. The piecing robot is capable of performing gaiting operations after doffing or after restarting breaks, to insert the yarn end from the external cop to wind yarn over the empty tube placed over the spindle. The piecing robot/service unit is provided with a plurality of pneumatic jets, blowers and a plurality of pneumatic, electric and electromechanical drives and actuators in the robotic arms and special in-built programs and parameters for the purpose of piecing the broken yarn in the ring spinning machines, for any types and counts of yarn and any different yarn characteristics and machine parameters.

[0016] In an aspect, the service unit is provided with at least two robotic arms. The robotic arm is preferably a humanoid robotic arm. The robotic arm is provided with a plurality of axes of freedom of movement for engaging in all piecing-related activities in the plurality of spinning machines. At least one of the robotic arms is provided with a tactile sensing element including piezoresistive, piezoelectric, optical, capacitive and elastoresistive sensors.

[0017] In an aspect, the service unit is provided with a control system capable of receiving instructions either from the plurality of spinning machines requiring maintenance activity or from a centralized mill monitoring system through the internet and cloud-based systems for performing the required maintenance activities. The service unit is further capable of receiving instructions and commands from the operating persons through a speech recognition module.

[0018] In an aspect, the service unit is provided with a leg-based locomotion system for the movement and navigation in the spinning mill as humans walk. The leg-based locomotion of the service unit provides better navigation over any planar and uneven surfaces with extreme height variations on the floor surface in the entire textile spinning mill. The leg-based service robot can reduce the footprint in between ring spinning machines as less space is sufficient similar to human access, unlike space required for lengthy automatic piecing units.

[0019] In an aspect, locomotion for the service unit is at least one type of robot with a walking function such as two legged or bipedal robot capable of walking as like human. The service robot is also a quadruped robot, a hexapod robot, an eight-legged robot.

[0020] In an aspect, the service unit is at least one type of humanoid robot with a walking function such as two-legged robots capable of performing at least one walking mechanism such as upright bipedal walking as human walking, stair climbing, and climbing over obstacles. The stair climbing is particularly advantageous in a scenario where the spinning machines are located on the different floors of the building in the spinning mill. In addition to bipedal walking, the service unit is also capable of skating with the aid of a skating board or skating shoes.

[0021] In an aspect, the service unit according to the present invention is provided with various sensing elements including Lidar sensors, ultrasound range sensors, optical range sensors, reflective sensors, inertial and navigation sensors, accelerometers, inclinometers, gyroscopes, magnetic compass, high definition camera, Global positioning system (GPS) for navigating in the spinning mill.

[0022] In an aspect, the service unit is capable of navigating in the spinning mill with the aid of visual sensors and dead reckoning sensors to process the Simultaneous Localization and Mapping (SLAM) technique. The navigation is achieved with the aid of a plurality of visual sensors and cameras to generate a three-dimensional real-time map. The navigation technique also employs a method of creating a plurality of landmarks for reference points in the spinning mill, with a plurality of images collected from the visual sensors and cameras. In addition, the existing spinning mill maps including the layout of a plurality of the spinning machines can also be stored in a memory database of the service units.

[0023] In an aspect, the service unit is provided with a collision avoidance system. The collision avoidance system is for the purpose of avoiding collision between the other service units and obstacles present in the spinning mill. The service unit is capable of differentiating obstacles like machine elements and human operating persons with the aid of image analysis by collecting data from the plurality of visual sensors and high-definition cameras to identify the different objects. The service unit is further configured with a machine learning technique such as neural networks and deep learning modules for continuous self-correction and self-learning of all the maintenance activities and navigating movements in the spinning mills.

[0024] In an aspect, the service unit is provided with at least one rechargeable battery. The battery supplies the required electric energy for the various operating modules provided in the said service units.

[0025] In an aspect, the service unit is capable of achieving an optimum travelling speed similar to a human walk, while navigating in the spinning mill.

[0026] In an advantageous embodiment, use of the above service unit significantly reduces the requirement of large number of skilled operating persons in the spinning mill.

[0027] Other aspects and advantages of the invention will become apparent from the following description, taken in conjunction with the accompanying drawing, illustrating by way of example the principles of the invention.

BRIEF DESCRIPTION OF DRAWING

[0028] The accompanying drawing is included to provide a further understanding of the present disclosure, and is incorporated in and constitute a part of this specification. The drawing illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.

[0029] In the figure, similar components and/or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label with a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.

[0030] Figure 1 illustrates an automatic yarn piecing system, in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION OF INVENTION

[0031] The detailed description set forth below in connection with the appended drawing is intended as a description of various embodiments of the present invention and is not intended to represent the only embodiments in which the present invention may be practiced. Each embodiment described in this disclosure is provided merely as an example or illustration of the present invention, and should not necessarily be construed as preferred or advantageous over other embodiments. The detailed description includes specific details for the purpose of providing a thorough understanding of the present invention. However, it will be apparent to those skilled in the art that the present invention may be practiced without these specific details.

[0032] The words “comprising,” “having,” “containing,” and “including,” and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items.

[0033] It must also be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. Although any systems and methods similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present invention, the preferred, systems and methods are now described.

[0034] The present invention relates to an automatic yarn piecing system for piecing a broken yarn in a spinning mill. Fig. 1 illustrates an automatic yarn piecing system, in accordance with an embodiment of the present invention. The automatic piecing system may comprise a plurality of ring spinning machines (2) and a robot (1). The plurality of ring spinning machines (2) may comprise one or more spindle units for twisting fibres into a yarn. The robot (1) is configured for providing dynamic movement in horizontal and/or traverse directions with respect to the plurality of ring spinning machines (2) to locate a broken yarn. In an embodiment, the robot (1) performs the dynamic movement without utilizing guide rails or wheels and is configured to perform a human-like walking movement.

[0035] In one embodiment, the automatic piecing system may comprise a detection unit to detect a fault in the one or more spindle units. In an embodiment, the fault includes broken yarns or mechanical failures in the spinning machine. In an embodiment, the detection unit comprises at least one sensor and/or monitoring unit disposed on the plurality of ring spinning machines (2). The detection unit receives the fault alert from the at least one sensor and/or monitoring unit based on changes in tension, vibration, or other parameters associated with the presence of intact or broken yarn and transmits the alert to a central monitoring system.

[0036] In one embodiment, the robot (1) may comprise a camera or image capturing module to self-inspect one or more spindles for faults or issues. During the operation, once real-time images are captured, the robot (1) transmits the captured visual images to the central monitoring system for processing thereby allowing for efficient monitoring of machinery health and facilitating an early detection of the fault in the one or more spindles. The early detection of the fault prevents potential breakdowns or malfunctions.

[0037] In one embodiment, the robot (1) is configured to switch between the plurality of ring spinning machines (2). The robot (1) may comprise at least one arm configured to perform the piecing operation upon detection of the broken yarn in the one or more spindle units. In an embodiment, the at least one arm is a humanoid robotic arm to provide flexibility, dexterity and precision in a wide range of setting, eliminating human limitations.

[0038] In one embodiment, the at least one arm is configured with multiple axes of freedom of movement. The multiple axes of freedom of movement provide the at least one arm moves in all directions and orientations thereby facilitating reaching different parts of the plurality of ring spinning machines (2). In an embodiment, the at least one arm may comprise a tactile sensing element to handle delicate yarn and perform piecing activities with accuracy. In an embodiment, the tactile sensing element is selected from the group consisting of a piezoresistive sensor, a piezoelectric sensor, an optical sensor, a capacitive sensor or an elastoresistive sensor.

[0039] In one embodiment, the robot (1) may comprise a positioning element to allow the robot (1) to align accurately in front of the broken yarn. In an embodiment, the positioning element may be integrated into at least one robotic arm or provided as an additional module directly mounted on the robot (1). The robot (1) is configured to position and adjust at any height in front of the plurality of ring spinning machines (2), facilitating the robot (1) to access any part of the plurality of spinning machines (2). In an embodiment, the robot (1) is flexible in movement, being able to adjust and move on any axis both horizontally and vertically. This adaptability allows the robot (1) to navigate and reach various locations within a working area of the spinning mill.

[0040] In one embodiment, the positioning element may be at least one sensor configured to determine a location of the one or more spindle units in which the broken yarn is identified by the detection unit. The robot (1) is configured to position the at least one arm to perform the piecing operation to join the broken yarn. In an embodiment, the at least one sensor is selected from the group consisting of Lidar sensors, ultrasound range sensors, optical range sensors, reflective sensors, inertial and navigation sensors, accelerometers, inclinometers, gyroscopes, magnetic compass, high-definition camera, and Global Positioning System (GPS).

[0041] During the operation, upon detection of the broken yarn, the robot (1) lifts the broken yarn end from a component called a “cop”, the cop is a cylindrical package of yarn. After lifting, the robot (1) hooks and inserts the broken yarn inside another component known as a "ring traveler" of the plurality of ring spinning machines (2). The “ring traveler” guides the yarn onto the plurality of ring spinning machines (2). Following the insertion of the broken yarn, the robot (1) is configured to join the broken yarn end with a spun roving end. The spun roving end is delivered from the drafting rollers, which are components involved in the spinning process.

[0042] In an embodiment, the robot (1) is further configured to perform a "gaiting operation." The gaiting operation occurs either after "doffing," the doffing is the process of removing a full package of yarn from the one or more spindles, or after restarting breaks in the spinning process. During the gaiting operation, the robot (1) inserts a yarn end from an external cop (another package of yarn) to wind yarn over an empty tube placed over the plurality of ring spinning machines (2).

[0043] In one embodiment, the robot (1) may comprise a navigation unit to generate a three-dimensional real-time map and configured to identify landmarks for reference points in the plurality of ring spinning machines (2). In an embodiment, a combination of visual sensors and dead reckoning sensors are utilized for navigation. Upon receiving information from visual and dead reckoning sensors, the information received is processed in real-time using SLAM (Simultaneous Localization and Mapping). Consequently, the navigation unit configured to simultaneously create a map of its environment and determine its own location within that map. The navigation unit may store and access an existing map of the spinning mill in its memory database for improved navigation and operational efficiency.

[0044] In one embodiment, the robot (1) may comprise a locomotion unit to provide movement in a planar surface or uneven surface, wherein the locomotion unit is configured to receive the three-dimensional real-time map and identified landmarks upon detection of the broken yarn in the one or more spindle units. In an embodiment, the locomotion unit is selected from the group consisting of a two-legged or bipedal robot, a quadruped robot, a hexapod robot, or an eight-legged robot.

[0045] In one embodiment, the robot (1) may be a service unit. The service unit may comprise a plurality of pneumatic jets, blowers and a plurality of pneumatic, electric and electromechanical drives and actuators in the robotic arms and special in-built programs and parameters for the purpose of piecing the broken yarn in the ring spinning machines, for any types and counts of yarn and any different yarn characteristics and machine parameters. In an embodiment, the service unit is configured to perform at least one or plurality of maintenance activities in the plurality of ring spinning machines (2) and not only limited to the following such as:

• Engaging and disengaging the roving stop motions in the plurality of ring spinning machines (2).
• Ensuring the availability of the roving in the feeding roving bobbin before initiating the piecing operation.
• Ensuring the presence of traveller on the ring before initiating the piecing operation.
• Picking and placing the roving bobbins in ring spinning machine.
• Replacing or inserting new traveller before initiating the piecing operation.
• Removing fibre lapping in drafting rollers and cots during the piecing operation.
• Feeding the auxiliary yarn based on the need during the piecing operation.
• Cleaning the spinning station with the aid of pneumatic blowers before the piecing operation.

[0046] In one embodiment, the automatic yarn piecing system may comprise a collision avoidance system to prevent collisions with obstacles within the operational environment. The collision avoidance system is configured to differentiate between various obstacles, including machine elements and human operating personnel within its vicinity. In an embodiment, the collision avoidance system is configured to perform sophisticated image analysis through information collected from a plurality of visual sensors and high-definition cameras to effectively identify and distinguish different objects within its operational environment.

[0047] In one embodiment, the collision avoidance system may be configured with machine learning techniques, incorporating neural networks and deep learning modules. The machine learning techniques enable continuous self-correction and self-learning of all activities related to maintenance tasks and navigating movements within the spinning mills. The collision avoidance system is configured to learn behavior based on past experiences, optimizing collision avoidance strategies and overall performance over time.

[0048] In one embodiment, the automatic yarn piecing system may comprise at least one rechargeable battery. In an embodiment, the at least one rechargeable battery powers the automatic yarn piecing system.

[0049] In one embodiment, the automatic yarn piecing system is capable of achieving an optimum travelling speed similar to human walk, while navigating in the spinning mill. The automatic yarn piecing system is economical and eliminates huge number of manpower in spinning mills.

[0050] In one embodiment, the automatic yarn piecing system is capable of providing maintenance activities for entire spinning machines across the textile spinning mill comprising blow room machines, Cards, Draw frames, Lap formers, combers, speed frames, ring frames and automatic winders.

[0051] In one embodiment, the automatic yarn piecing system may comprise a control system capable of receiving the instructions either from the plurality of spinning machines requiring maintenance activity or from a centralized monitoring system through internet and cloud-based systems for performing the required maintenance activities. In addition, the control unit is also capable of receiving instructions and commands from the operator through speech recognition module.

[0052] The foregoing descriptions of exemplary embodiments of the present disclosure have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the disclosure to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The exemplary embodiment was chosen and described in order to best explain the principles of the disclosure and its practical application, to thereby enable others skilled in the art to best utilize the disclosure and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions, substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but is intended to cover the application or implementation without departing from the spirit or scope of the claims of the present disclosure.

[0053] Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any component(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature or component of any or all the claims.

[0054] While specific language has been used to describe the disclosure, any limitations arising on account of the same are not intended. As would be apparent to a person in the art, various working modifications may be made to the apparatus in order to implement the inventive concept as taught herein.

[0055] In the above detailed description, reference is made to the accompanying drawing that form a part thereof, and illustrate the best mode presently contemplated for carrying out the invention. However, such description should not be considered as any limitation of scope of the present unit. The structure thus conceived in the present description is susceptible of numerous modifications and variations, all the details may furthermore be replaced with elements having technical equivalence.
,CLAIMS:
1. An automatic yarn piecing system for a plurality of ring spinning machines (2) comprising one or more spindle units;
the automatic yarn piecing system comprises a robot (1) configured for:
providing dynamic movement in horizontal and/or traverse directions with respect to the plurality of ring spinning machines (2) to locate a broken yarn;
performing a piecing operation upon locating of the broken yarn in the one or more spindle units;
wherein the dynamic movement of the robot (1) is performed without utilizing guide rails or wheels; and
the robot (1) is configured to perform a human-like walking movement.
2. The automatic yarn piecing system as claimed in claim 1, wherein the robot (1) is further configured to switch between the plurality of ring spinning machines (2).
3. The automatic yarn piecing system as claimed in claim 1, wherein the robot (1) further comprises:
at least one arm configured to perform the piecing operation upon detection of the broken yarn in the one or more spindle units.
4. The automatic yarn piecing system as claimed in claim 1, wherein the robot (1) further comprises:
a navigation unit to generate a three-dimensional real-time map and configured to identify landmarks for reference points in the plurality of ring spinning machines (2);
a locomotion unit to provide movement in a planar surface or uneven surface, wherein the locomotion unit is configured to receive the three-dimensional real-time map and identified landmarks upon detection of the broken yarn in the one or more spindle units; and
at least one sensor configured to:
determine a location of the one or more spindle units in which the broken yarn is identified upon detection from the detection unit;
position the at least one arm to perform the piecing operation to join the broken yarn.
5. The automatic yarn piecing system as claimed in claim 4, wherein the locomotion unit is selected from the group consisting of a two-legged or bipedal robot, a quadruped robot, a hexapod robot, or an eight-legged robot.

6. The automatic yarn piecing system as claimed in claim 4, wherein the at least one sensor is selected from the group consisting of Lidar sensors, ultrasound range sensors, optical range sensors, reflective sensors, inertial and navigation sensors, accelerometers, inclinometers, gyroscopes, magnetic compass, high-definition camera, and Global Positioning System (GPS).

7. The automatic yarn piecing system as claimed in claim 3, wherein the at least one arm is a humanoid robotic arm to provide flexibility, dexterity and precision in a wide range of setting, eliminating human limitations.

8. The automatic yarn piecing system as claimed in claim 1, further comprising a detection unit to detect the broken yarn in the one or more spindle units.

9. The automatic yarn piecing system as claimed in claim 1 further comprising a collision avoidance system capable of differentiating obstacles and human operating persons through image analysis using visual sensors and high-definition cameras.