Description:FORM 2
THE PATENTS ACT, 1970
(39 OF 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
[See Section 10, Rule 13]

TITLE OF INVENTION
SYSTEM AND METHOD FOR AUTOMATIC FEEDING OF YARN-WOUND COPS TO A MAGAZINE

APPLICANT
Lakshmi Precision Technologies Limited, an Indian company, having its address at SF No: 163/2, Arasur, Coimbatore – 641407, Tamil Nadu, India.

PREAMBLE TO THE DESCRIPTION
The following specification particularly describes the invention and the manner in which it is to be performed.
FIELD OF THE INVENTION
[0001] Present invention relates to yarn processing, more specifically, to a system and a method for automatic feeding of a plurality of yarn-wound cops to at least one magazine of a winding machine.

BACKGROUND OF THE INVENTION
[0002] A yarn winding machine transfers yarn from a small package to a larger package, typically onto a cone or a bobbin, for reducing the number of package changes during downstream processing. The yarn winding machine also allows for identification and removal of defects such as knots and neps from the yarn for improving the quality of the finished textile product. A conventional yarn winding machine comprises a cylindrical magazine having a plurality of peripheral pockets to receive yarn-wound cops. A suction chamber is provided in the magazine surrounding a central longitudinal axis of the magazine, for receiving yarns from the yarn-wound cops placed in the pockets and facilitating winding of the yarns onto a larger bobbin by the winding machine.
[0003] Yarn processing typically involves multiple operations that are interconnected with respect to the positioning and orientation of yarn-wound cops, which are conventionally performed by skilled manual labour. Labour must be trained to perform specific operations while having knowledge of the preceding and succeeding operations of yarn processing. The yarn-wound cops are stored in a storage trolley and are manually carried near to the magazines and manually positioned into the pockets of the magazines for each cycle of winding operation. There exists a possibility of improper alignment and/or orientation of the yarn-wound cops in the receiving pockets due to human error, which affects the whole set of interdependent operations and results in improper winding of yarn and/or downtime of the winding machine. Further, owing to the drudgery involved in the feeding operation of yarn-wound cops, there also exists a challenge of procuring sufficient skilled labour during seasons of peak demand, thereby increasing labour cost. The cost of manual labour in addition to loss of productivity increases the overall cost of operation of the winding machines. Accordingly, such conventional processes are disadvantageous in that they cumbersome, laborious and account for significant non-productive time between winding operations.
[0004] Thus, there has been identified a need for an automated system / method of feeding yarn-wound cops to the winding machine which requires minimal to no human intervention and addresses the aforementioned problems in the prior art.

SUMMARY OF THE INVENTION
[0005] Accordingly, an aspect of the present invention provides a system for automatic feeding of a plurality of yarn-wound cops to at least one magazine of a winding machine. The system comprises a hopper configured to receive the plurality of yarn-wound cops and oscillate for discharging one yarn-wound cop among the plurality of yarn-wound cops to an orientation unit in each cycle of oscillation. The orientation unit is configured to orient a first end of each yarn-wound cop vertically above a second end of each yarn-wound cop. The system includes a preparation unit configured to receive the yarn-wound cops from the orientation unit in succession. The preparation unit is configured to capture a yarn from each yarn-wound cop and insert each captured yarn into each yarn-wound cop. The system includes a robotic arm configured to pick up the yarn-wound cops prepared by the preparation unit and place the yarn-wound cops into pockets of at least one magazine.
[0006] In an embodiment, an eccentric cam mechanism is operably coupled to the hopper to oscillate the hopper for discharging one of the yarn-wound cops through an outlet of the hopper in each cycle of oscillation to the orientation unit.
[0007] In an embodiment, the orientation unit comprises a vertical conveyor, a plurality of positioning members, a plurality of orienting means, and an inclined delivery chute. The vertical conveyor has a conveyance track and a plurality of platforms mounted along the length of the conveyance track, wherein each platform receives and transports a yarn-wound cop of the plurality of yarn-wound cops from a receiving end of the conveyance track towards a discharging end of the conveyance track. The plurality of positioning members is configured to align a portion between the first end and the second end of each yarn-wound cop centrally on the corresponding platform. The plurality of orienting means is configured to orient the first end of each yarn-wound cop vertically above the second end of each yarn-wound cop at the discharging end of the conveyance track. The inclined delivery chute is configured to guide the plurality of yarn-wound cops from the vertical conveyor to the preparation unit.
[0008] According to an embodiment, the plurality of positioning members comprises a locker block and a pair of aligner rods. The locker block is configured to contact and align the portion between the first end and the second end of each yarn-wound cop horizontally on the corresponding platform. The pair of aligner rods are configured to push against the first end and the second end of each yarn-wound cop and align each yarn-wound cop centrally on the corresponding platform. The aligner rods and the locker block are configured to retract from each yarn-wound cop upon alignment of each yarn-wound cop on the corresponding platform.
[0009] According to an embodiment, the plurality of orienting means comprises a left actuator and a right actuator spaced apart from one another along a width of the vertical conveyor, the left actuator and the right actuator configured to contact one of the first end and the second end of each yarn-wound cop at the discharging end of the conveyance track. Each of the left actuator and the right actuator is configured to plunge upon contact thereof with the first end of each yarn-wound cop for rotatably orienting each yarn-wound cop.
[0010] According to an alternate embodiment, the plurality of orienting means comprises: a left actuator operably connected to a first sensor; and a right actuator operably connected to a second sensor; wherein the first sensor and the second sensor are configured to: determine the positions of the first end and the second end of each yarn-wound cop at the discharging end of the conveyance track, and send a signal to either the left actuator or the right actuator to rotate each yarn-wound cop such that the first end of each yarn-wound cop is oriented vertically above the second end of each yarn-wound cop.
[0011] According to an embodiment, the orientation unit is configured to orient the plurality of yarn-wound cops such that the first end of each yarn-wound cop having a diameter less than or equal to a diameter of the second end of each yarn-wound cop is disposed vertically above the second end of each yarn-wound cop.
[0012] According to an embodiment, the preparation unit comprises a conical duct, a bobbin holder, a bobbin locker, a motor assembly, a blower, an upper suction unit, and a lower suction unit. The conical duct is configured to guide the plurality of yarn-wound cops to the bobbin holder in succession. The bobbin locker is configured to receive one of the yarn-wound cops from the bobbin holder and hold the received yarn-wound cop. The motor assembly is configured to rotate the received yarn-wound cop held by the bobbin locker. The blower is configured to blow air to the rotating yarn-wound cop for slacking the yarn from the yarn-wound cop. The upper suction unit is configured to capture the yarn from the yarn-wound cop and dispose an end of the captured yarn above the first end of the yarn-wound cop. The lower suction unit is configured to insert the captured yarn into the yarn-wound cop.
[0013] According to an embodiment, the system comprises a horizontal conveyor extending out from the preparation unit for carrying the prepared yarn-wound cops proximate to the robotic arm.
[0014] According to an embodiment, the robotic arm comprises one or more grippers, each gripper configured to selectively grip one yarn-wound among the plurality of yarn-wound cops.
[0015] According to an embodiment, the robotic arm comprises a rectilinear guide for each gripper, the rectilinear guide configured to selectively raise and lower each gripper for inserting the yarn-wound cops into pockets of at least one magazine.
[0016] According to an embodiment, the robotic arm comprises tilting means to tilt each gripper for orienting longitudinal axes of the yarn-wound cops gripped thereby parallel to the longitudinal axes of the corresponding pockets.
[0017] According to an embodiment, the robotic arm comprises a cup moving arm and a yarn moving arm. The cup moving arm is configured to engage with a central cup that covers a suction chamber of at least one magazine and rotate the central cup for uncovering an orifice of the suction chamber. The yarn moving arm is configured to place the yarn inserted in each yarn-wound cop into the orifice of the suction chamber, for facilitating suction of the yarn of each yarn-wound cop into the winding machine.
[0018] Another aspect of the present invention provides a method for automatic feeding of a plurality of yarn-wound cops to at least one magazine of a winding machine. The method comprises: receiving the yarn-wound cops in a hopper; oscillating the hopper for discharging one of the yarn-wound cops from the hopper to an orientation unit in each cycle of oscillation; orienting, in the orientation unit, a first end of each yarn-wound cop vertically above a second end of each yarn-wound cop; preparing each oriented yarn-wound cop in a preparation unit by capturing a yarn from each yarn-wound cop and inserting each captured yarn into each yarn-wound cop; and picking up the prepared yarn-wound cops with a robotic arm and placing the yarn-wound cops into pockets of at least one magazine.
[0019] According to an embodiment, orienting the yarn-wound cops comprises orienting the first end of each yarn-wound cop having a diameter less than or equal to a diameter of the second end of each yarn-wound cop vertically above the second end of each yarn-wound cop.
[0020] According to an embodiment, preparing each oriented yarn-wound cop comprises: guiding the yarn-wound cop to a bobbin holder through a conical duct; transferring the yarn-wound cop from the bobbin holder to a mounted bobbin locker; rotating the yarn-wound cop held by the bobbin locker; blowing air to the rotating yarn-wound cop for slacking the yarn from the yarn-wound cop; capturing, by an upper suction unit, the yarn of the yarn-wound cop and disposing an end of the captured yarn above the first end of the yarn-wound cop and inserting, by a lower suction unit, the captured yarn into the yarn-wound cop.
[0021] According to an embodiment, picking and placing the yarn-wound cops further comprises: rotating, by a cup moving arm, a central cup that covers a suction chamber of at least one magazine for uncovering an orifice of the suction chamber; and placing, by a yarn moving arm, the yarn inserted in each yarn-wound cop into the orifice of the suction chamber, for facilitating suction of the yarn of each yarn-wound cop into the winding machine.

BRIEF DESCRIPTION OF DRAWINGS
[0022] Reference will be made to embodiments of the invention, examples of which may be illustrated in accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.
Figure 1 illustrates a system for automatic feeding of a plurality of yarn-wound cops into pockets of at least one magazine of a winding machine, the system having a hopper, an orientation unit, a preparation unit, and a robotic arm.
Figure 2 illustrates the hopper coupled to an eccentric cam mechanism in accordance with an embodiment of the present invention.
Figure 3 partially illustrates the orientation unit comprising a vertical conveyor provided with a locker block and a pair of aligner rods, in accordance with an embodiment of the present invention.
Figures 4A through 4C illustrate alignment of a yarn-wound cop centrally on a corresponding platform of the vertical conveyor, in accordance with an embodiment of the present invention.
Figures 5A through 5C illustrate orientation of a yarn-wound cop at a discharging end of a conveyance track of the orientation unit so as to maintain the first end of each yarn-wound cop vertically above the second end of each yarn-wound cop, in accordance with an embodiment of the invention.
Figure 6 illustrates the discharging end of the conveyance track showing orienting means and an inclined delivery chute, in accordance with an embodiment of the invention.
Figure 7 illustrates a side view of the preparation unit in accordance with an embodiment of the invention.
Figure 8 illustrates a yarn-wound cop guided through a conical duct into the preparation unit, in accordance with an embodiment of the invention.
Figures 9A through 9D illustrate various configurations of a bobbin holder in accordance with an embodiment of the invention.
Figure 10 illustrates a bobbin locker in accordance with an embodiment of the invention.
Figure 11 illustrates a motor assembly for rotating the yarn-wound cop in accordance with an embodiment of the invention.
Figure 12 illustrates a blower in accordance with an embodiment of the invention.
Figure 13 illustrates an upper suction unit of the preparation unit in accordance with an embodiment of the invention.
Figure 14 illustrates a lower suction unit of the preparation unit in in accordance with an embodiment of the invention.
Figure 15 illustrates the robotic arm in accordance with an embodiment of the invention.
Figure 16 illustrates a frame connected to the robotic arm comprising yarn moving rods and cup moving rods in accordance with an embodiment of the invention.
Figure 17 illustrates operation of the cup moving rods in accordance with an embodiment of the invention.
Figure 18 illustrates operation of the yarn moving rods in accordance with an embodiment of the invention.
Figure 19 illustrates a method for automatic feeding of a plurality of yarn-wound cops into pockets of at least one magazine of a winding machine.
Throughout the description, reference numerals corresponding to the specific drawings are used to refer to the specific elements.

DETAILED DESCRIPTION OF THE INVENTION
[0023] The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of various embodiments of the present disclosure as defined by the claims and their equivalents. It includes various specific details to assist in that understanding, but these are to be regarded as merely exemplary. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope and spirit of the present disclosure.
[0024] The terminology used herein is for the purpose of describing particular various embodiments. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “includes”, “has”, “have” and “having” used herein specify the presence of stated features, integers, steps, operations, members, components and/or groups thereof, but do not exclude the presence or addition of one or more other features, integers, steps, operations, members, components and/or groups thereof. Various features and embodiments of the present invention here will be discernible from the following further description thereof, set out hereunder.
[0025] Figure 1 illustrates a system (100) for automatic feeding of a plurality of yarn-wound cops (102) to at least one magazine of a winding machine. The system (100) has the following sub-systems: a hopper (104), an orientation unit (106), a preparation unit (108) and a robotic arm (110). The hopper (104) receives the plurality of yarn-wound cops (102) and discharges one yarn-wound cop (102) among the plurality of yarn-wound cops (102) to the orientation unit (106) in each cycle of oscillation of the hopper (104). The orientation unit (106) receives the discharged yarn-wound cops (102) in succession (one by one) from the hopper (104) and orients a first end of each yarn-wound cop (102) vertically above a second end of each yarn-wound cop (102). The preparation unit (108) receives the oriented yarn-wound cops (102) from the orientation unit (106) in succession (one by one). The preparation unit (108) captures a yarn (102Y) from a received yarn-wound cop (102) and inserts the captured yarn (102Y) into the yarn-wound cop (102). In an embodiment, the yarn-wound cop (102) has a central hollow portion. The preparation unit (108) is configured to insert the captured yarn into the hollow portion of the yarn-wound cop (102). The robotic arm (110) picks up the prepared yarn-wound cops (102) and places the yarn-wound cops (102) into pockets of at least one magazine.
[0026] Each of these sub-systems will now be explained with respect to their relevant figures in detail.
[0027] Figure 2 illustrates a hopper (104) in accordance with an embodiment of the invention. The hopper (104) has a hopper body (202) and an outlet (210) which may be provided in the form of a cut-out on the hopper body (202). The hopper (104) may be adapted to receive about 300 to 500 yarn-wound cops at a time and store them. An eccentric cam mechanism (206) is operably coupled to the hopper (104) for oscillating the hopper back and forth in the direction ‘A’ along a guide rail (208) with a predetermined frequency, so that a single yarn-wound cop (102) is ejected from the hopper outlet (204) after each cycle of oscillation of the hopper (104). For example, the hopper (104) may be slid back and forth by a distance ranging from 25 mm to 55 mm along the guide rail (208).
[0028] In an exemplary embodiment, the eccentric cam mechanism (206) has a cam mounted on a shaft and a follower. The cam is a circular disc with a groove cut into its circumference and the follower is a piece that rides in the groove of the cam. The cam may be rotated at a predetermined speed by a motor. As the cam rotates, the follower is forced to move back and forth along the groove. The extent of offset between the centre of the cam and the groove determines the amplitude of the follower’s motion and therefore, the extent of oscillation of the hopper body (202) coupled to the eccentric cam mechanism (206). As a result, one yarn-wound cop (102) among the plurality of yarn-wound cops (102) is discharged from the outlet (210) of the hopper (104) in each cycle of oscillation of the hopper (104). Thereby, the hopper (104) successively feeds / provides yarn-wound cops (102) to the orientation unit (106) for further processing.
[0029] Figure 3 partially illustrates the orientation unit (106) in accordance with an embodiment of the invention. The orientation unit (106) has a vertical conveyor (300), a plurality of positioning members (306), a plurality of orienting means (502) (shown in Figures 5A-5C), and a delivery chute (602) (shown in Figure 6). The vertical conveyor (300) has a conveyance track (302) and a plurality of platforms (304) mounted along the length of the conveyance track (302). Each platform (304) receives one yarn-wound cop (102) from the hopper outlet (210) and transports the received yarn-wound cop (102) from a receiving end of the conveyance track (302) to a discharging end of the conveyance track (302). The plurality of positioning members (306) aligns a portion between the first end and the second end of each yarn-wound cop (102) centrally on the corresponding platform (304). The manner in which the positioning members (306) align a yarn wound cop (102) is explained below with respect to Figures 4A-4C.
[0030] Figures 4A-4C illustrate the plurality of positioning members (306) and their movement to align the yarn-wound cop (102) in accordance with an exemplary embodiment of the invention. The positioning members (306) include a locker block (306a) and a pair of aligner rods (306b, 306c). The locker block (306a) contacts and aligns the portion between the first end and the second end of the yarn-wound cop (102) horizontally on the corresponding platform (304). The direction of motion of the locker block (306a) is shown as ‘B’ in Figure 4B. By moving the locker block (306a) in the direction of ‘B’, the yarn-wound cop (102) is moved inwards on the corresponding platform (304), and the aligner rods (306b, 306c) are actuated to position the yarn-wound cop (102) on the first end and the second end of the yarn-wound cop (102). The pair of aligner rods (306b, 306c) pushes against the first end and the second end of the yarn-wound cop (102) along the directions ‘C’ shown in Figure 4C and aligns the yarn-wound cop (102) centrally on the corresponding platform (304). The locker block (306a) and the aligner rods (306b, 306c) are retracted to their initial positions after positioning the yarn-wound cop (102) on the corresponding platform (304). The yarn-wound cops (102) positioned centrally on the corresponding platforms (304) are then transported to the discharging end of the conveyance track (302) for orienting the yarn-wound cops (102) such that the first end of each yarn-wound cop (102) is oriented vertically above the second end of each yarn-wound cop (102).
[0031] Figures 5A - 5C illustrate the orientation of the yarn-wound cops (102) at the discharging end of the conveyance track (302) so as to maintain the first end of each yarn-wound cop (102) vertically above the second end of each yarn-wound cop (102), in accordance with an embodiment of the invention. In one embodiment, the plurality of orienting means (502) includes a left actuator (502a) and a right actuator (502b) that are spaced apart from one another along a width-wise direction of the vertical conveyor (300). The left actuator (502a) and the right actuator (502b) each contact either the first end or the second of each yarn-wound cop (102) at the discharging end of the conveyance track (302). Each of the left actuator (502a) and the right actuator (502b) plunges upon contact with the first end of each yarn-wound cop (102) for rotatably orienting each yarn-wound cop (102).For example, if the left actuator (502a) contacts the first end of the yarn-wound cop (102) and the right actuator (502b) contacts the second end of the yarn-wound cop (102), the left actuator (502a) plunges towards the first end of the yarn-wound cop (102) for rotating the yarn-wound cop (102) such that the first end of the yarn-wound cop (102) is disposed vertically above the second end of the yarn-wound cop (102). After rotating the yarn-wound cop (102), the left actuator (502a) and the right actuator (502b) retract to their respective original positions.
[0032] In an alternate embodiment, the plurality of orienting means (502) includes a left actuator (502a) operably connected to a first sensor (not shown) and a right actuator (502b) operably connected to a second sensor (not shown). The first sensor and the second sensor sense the positions of the first end and the second end of each yarn-wound cop (102) at the discharging end of the conveyance track (302), and a control unit (not shown) determines the positions of the first end and the second end of each yarn-wound cop (102). The control unit sends a signal to either the left actuator (502a) or the right actuator (502b) to rotate each yarn-wound cop (102) such that the first end of each yarn-wound cop (102) is oriented vertically above the second end of each yarn-wound cop (102). After orienting each yarn-wound cop (102), the left actuator (502a) and the right actuator (502b) retract to their original positions.
[0033] In an embodiment, the orientation unit (106) orients the yarn-wound cop (102) such that the first end of the yarn-wound cop (102) having a diameter less than or equal to a diameter of the second end of the yarn-wound cop (102), is disposed vertically above the second end of the yarn-wound cop (102). In other words, the diameter of the first end of the yarn-wound cop (102) is less than or equal to the diameter of the second end of the yarn-wound cop (102). In a further embodiment, the diameter of the first end of the yarn-wound cop (102) is less than the diameter of the second end of the yarn-wound cop (102). For further processing of the yarn-wound cop (102) by the preparation unit (108), it is necessary that the preparation unit (108) positioned downstream of the orientation unit (106) receives the yarn-wound cop (102) in the orientation in which the first end of the yarn-wound cop (102) is positioned vertically above the second end of the yarn-wound cop (102). The oriented yarn wound cop (102) is then transferred to an inclined delivery chute (602).
[0034] Figure 6 illustrates the inclined delivery chute (602) that guides the oriented yarn-wound cop (102) from the vertical conveyor (300) to the preparation unit (108). The inclined delivery chute (602) is pivotably connected to a support frame adjacent to the discharging end of the conveyance track (302). The inclined delivery chute (602) pivots at an angle ranging from 0° to 60° for delivering each oriented yarn-wound cop (102) to the preparation unit (108). The inclined delivery chute (602) has converging side surfaces to prevent a change in orientation of each yarn-wound cop (102). The inclined delivery chute (602) ensures proper conveyance of the yarn-wound cops (102) into the preparation unit (108) in succession (one by one) while maintaining the orientation of each yarn-wound cop (102). The manner in which an oriented yarn wound cop (102) is processed in a preparation unit is explained with respect to Figure 7 below.
[0035] Figure 7 illustrates the preparation unit (108) in accordance with an embodiment of the invention. The preparation unit (108) receives the yarn wound cop (102) from the orientation unit (106) and performs specific operations on the yarn-wound cop (102). The orientation of the yarn-wound cop (102) received by the preparation unit (108) is such that the first end of the yarn-wound cop (102) is vertically above the second end of the yarn-wound cop (102). The preparation unit (108) is configured to capture the yarn (102Y) from the received yarn-wound cop (102) and insert the captured yarn (102Y) into the yarn-wound cop (102). In an embodiment, the preparation unit (108) is configured to insert the captured yarn into the hollow portion of the yarn-wound cop (102). The preparation unit (108) has a conical duct (702), a bobbin holder (704), a bobbin locker (706), a motor assembly (708) for rotating the yarn-wound cop (102), a blower (710), an upper suction unit (712), and a lower suction unit (714), which are explained in detail below.
[0036] Figure 8 illustrates a conical duct (702) that guides the vertically oriented yarn-wound cop (102) to a bobbin holder (704). The conical duct (702) has a reducing cross-section area from the top towards the bottom. Figures 9A-9D illustrates the bobbin holder (704) and the operations of the bobbin holder (704). The bobbin holder (704) is provided with hinged members. The hinged members are provided with pads (902a, 902b) to hold the oriented yarn-wound cop (102) in place. Figure 10 illustrates the bobbin locker (706) which receives the oriented yarn-wound cop (102) from the bobbin holder (704). Figure 11 illustrates the motor assembly (708) for rotating the yarn-wound cop (102) in the direction ‘R’ as shown. Figure 12 illustrates the blower (710) which blows air to the rotating yarn-wound cop (102) for slacking the yarn (102Y) from the yarn-wound cop (102). In an embodiment, the blower (710) has multiple orifices (O) through which flow of air is directed to the yarn-wound cop (102). Figure 13 illustrates the upper suction unit (712) that captures yarn (102Y) from the yarn-wound cop (102) and disposes an end of the captured yarn (102Y) above the first end of the yarn-wound cop (102). The upper suction unit (712) has a suction chamber (1302) for facilitating the capture of the yarn (102Y). Figure 14 illustrates the lower suction unit (714) that inserts the captured yarn (102Y) into the yarn-wound cop (102), thereby preparing the yarn-wound cop (102) for insertion into a pocket of at least one magazine of the winding machine. Each prepared yarn-wound cop (102) is then moved towards the robotic arm (110) using a horizontal conveyor (112) (shown in Figure 1).
[0037] Preparation of the yarn-wound cop (102) carried out by the preparation unit (108) is explained below with reference to Figures 7-14.
[0038] When the yarn-wound cop (102) is received from the orientation unit (106) via the inclined delivery chute (602) by the conical duct (702), the preparation of the yarn-wound cop (102) is initiated. The conical duct (702) guides the yarn-wound cop (102) to the bobbin holder (704). The bobbin holder (704) holds the received yarn wound cop (102) in position before transferring the yarn wound cop to the bobbin locker (706). The bobbin locker (706) receives the yarn-wound cop (102) from the bobbin holder (704) and holds the yarn-wound cop (102) in place. The motor assembly (708) rotates the received yarn-wound cop (102) held by the bobbin locker (706). The blower (710) blows air to the rotating yarn-wound cop (102) along the surface of the yarn wound cop (102) for slacking the yarn (102Y) from the yarn-wound cop (102). The yarn-wound cop (102) is then moved towards the upper suction unit (712). The upper suction unit (712) captures the yarn (102) from the yarn-wound cop (102) and disposes an end of the captured yarn (102Y) above the first end of the yarn-wound cop (102). The lower suction unit (714) then inserts the captured yarn (102Y) into the yarn-wound cop (102). The horizontal conveyor (112) extends out from the preparation unit (108) for carrying the prepared yarn-wound cops near to the robotic arm (110).
[0039] Figure 15 illustrates the robotic arm (110) in accordance with an embodiment of the invention. The robotic arm (110) is used for picking up the prepared yarn-wound cops (102) from the horizontal conveyor (112) and placing the yarn-wound cops (102) into pockets (1708) of at least one magazine (1702) (shown in Figure 17). The robotic arm (110) has a base (1502) supporting a plurality of arms (1504) jointed at a plurality of joints (1506) for facilitating a flexible motion of the robotic arm (110) along multiple degrees of freedom. In an embodiment, the robotic arm (110) may be slideable along a length direction of the horizontal conveyor (112). Further, the robotic arm (110) has a frame (1508) provided with end manipulators having one or more grippers (1604a, 1604b) (shown in Figure 16) for picking up the yarn-wound cops (102) prepared by the preparation unit (108) and inserting the yarn-wound cops (102) into pockets (1708) of at least one magazine (1702) (shown in Figure 17) of the winding machine. The frame arrangement is explained in detail with respect to Figure 16.
[0040] Figure 16 illustrates the frame (1508) of the robotic arm (110). The frame (1508) has a main frame portion (1602) supporting two grippers (1604a, 1604b). In an embodiment, the two grippers (1604a, 1604b) are of vacuum-gripper or suction-gripper type. In another embodiment, there could be a single gripper in place of two grippers (1604a, 1604b). At a given instant, each gripper selectively grips one yarn-wound cop among the plurality of yarn-wound cops. The grippers (1604a, 1604b) are configured to align with the pockets (1708) of the magazine (1702) and release the gripped yarn-wound cops (102) into the pockets (1708).
[0041] In an embodiment, the robotic arm (110) has a rectilinear guide for each gripper (1604a, 1604b). The rectilinear guide selectively raises and lowers each gripper (1604a, 1604b) for inserting the yarn-wound cops into pockets of at least one magazine (1702).
[0042] In an embodiment, the robotic arm (110) has tilting means for tilting each gripper for orienting longitudinal axes of the yarn-wound cops (102) gripped thereby parallel to the longitudinal axes of the corresponding pockets (1708) of at least one magazine (1702) (shown in Figures 17-18).
[0043] Figure 17 illustrates the manner in which the processed yarn wound cops are inserted into at least one magazine (1702). Figure 17 shows round or cylindrical magazines each having the plurality of peripheral pockets (1708) to receive the yarn-wound cops (102). Suction chambers surround central longitudinal axes of each of the magazines (1702) for receiving yarns (102Y) from the yarn-wound cops (102), for facilitating winding of the yarns (102Y) onto larger bobbins by the winding machine. Further, each magazine (1702) is rotatable about its central longitudinal axis to bring empty pockets (1708) in proximity to the grippers (1604a, 1604b). The manner in which the yarns (102Y) of the yarn-wound cops (102) are received in at least one magazine (1702) is explained with respect to Figures 16-18 below.
[0044] Referring Figures 16-18, in an embodiment, the frame (1508) of the robotic arm (110) has at least one cup moving arm (1606a, 1606b) and at least one yarn moving arm (1608a, 1608b). The cup moving arm (1606a, 1606b) engages with a central cup (1704) that covers a suction chamber of at least one magazine (1702) and rotates the central cup (1704) for uncovering an orifice (1710) of the suction chamber. The cup moving arm (1606a, 1606b) engages with a protrusion (1706) on the central cup (1704) for rotating the cup (1704). The yarn moving arm (1608a, 1608b) then places the yarn (102Y) inserted in each yarn-wound cop (102) into the orifice (1710) of the suction chamber, for facilitating suction of the inserted yarn (102Y) into the winding machine. The winding machine receives multiple yarns through the suction chamber of at least one magazine (1702), when the other yarn-wound cops (102) are processed, and the received yarns (102Y) are wound onto a large cone or a bobbin for further textile processing.
[0045] The manner in which the yarn-wound cops (102) are processed is explained below with respect to Figure 19.
[0046] Figure 19 illustrates a method for automatic feeding of a plurality of yarn-wound cops (102) to at least one magazine (1702) of the winding machine. The yarn wound cops (102) are received in the hopper (104) (step 1902). The hopper (104) is oscillated for discharging one of the yarn-wound cops (102) from the hopper (104) to an orientation unit (106) in each cycle of oscillation (step 1904). In the orientation unit (106), each of the received yarn-wound cops (102) are successively oriented such that the first end of each yarn-wound cop (102) is disposed vertically above the second end of each yarn-wound cop (102) (step 1906). In an embodiment, the first end of each yarn-wound cop (102) has a diameter less than or equal to the diameter of the second end of each yarn-wound cop (102). Each yarn-wound cop (102) is then prepared in the preparation unit (108). In the preparation unit, yarn (102Y) from each yarn-wound cop (102) is captured and each captured yarn (102Y) is inserted into each yarn-wound cop (step 1908). The prepared yarn-wound cops (102) are then picked up by the robotic arm (110) and placed onto pockets (1708) of at least one magazine (1702).
[0047] The manner in which the yarn-wound cop (102) is processed in the preparation unit (108) is explained below.
[0048] The oriented yarn-wound cop (102) received from the orientation unit (106) is guided to the bobbin holder (704) through a conical duct (702). The yarn-wound cop is then transferred from the bobbin holder (704) to a bobbin locker (706). The yarn-wound cop (102) held by the bobbin locker (706) is then rotated about its longitudinal axis. Air is blown to the rotating yarn-wound cop (102) for slacking the yarn (102Y) from the yarn-wound cop (102). The yarn-wound cop (102) is then guided towards the upper suction unit (712). The upper suction unit (712) captures the yarn (102Y) from the yarn-wound cop (102) and disposes an end of the captured yarn (102Y) above the first end of the yarn-wound cop (102). The lower suction unit (714) inserts the captured yarn (102Y) into the yarn-wound cop (102), and thereby prepares the yarn-wound cop (102) for further feeding operation onto a pocket of at least one magazine (1702).
[0049] According to an embodiment, once the yarn-wound cops (102) are positioned into pockets (1708) of at least one magazine (1702), the following operations are performed. The cup moving arm (1606a, 1606b) provided to the robotic arm (110) rotates the central cup (1704) that covers the suction chamber of at least one magazine (1702) for uncovering the orifice (1710) of the suction chamber. The yarn moving arm (1608a, 1608b) provided to the robotic arm (110) places the yarn (102Y) inserted in each yarn-wound cop (102) into the orifice (1710) of the suction chamber, for facilitating suction of the yarn (102Y) of each yarn-wound cop (102) into the winding machine. The winding machine receives multiple yarns (102Y) through the suction chamber of the magazine (1702) and the received yarns (102Y) are wound onto a large cone or a bobbin for further textile processing.
[0050] Advantageously, the system and the method of the present invention allow for an increase in productivity of yarn-processing, eliminate the risk of human error in yarn feeding and improve winding efficiency. Compared to conventional manual cop feeding methods, the method of the present invention requires lesser time to load the yarn-wound cops in one or more magazines of the winding machine. The system of the present invention can also be easily integrated with existing winding machines. Even unskilled labourers can operate the system with minimal training. Further, the need for manually dragging cops in a storage trolley near to the magazines is dispensed, thereby reducing downtime of the winding machine.
[0051] While the present invention has been described with respect to certain embodiments, it will be apparent to those skilled in the art that various changes and modification may be made without departing from the scope of the invention as defined in the following claims.
, C , Claims:WE CLAIM:
1. A system (100) for automatic feeding of a plurality of yarn-wound cops (102) to at least one magazine (1702) of a winding machine, the system (100) comprising:
a hopper (104) configured to receive the plurality of yarn-wound cops (102) and oscillate for discharging a yarn-wound cop among the plurality of yarn-wound cops (102) to an orientation unit (106) in each cycle of oscillation,
the orientation unit (106) configured to orient a first end of each yarn-wound cop (102) vertically above a second end of each yarn-wound cop (102);
a preparation unit (108) configured to receive the yarn-wound cops (102) from the orientation unit (106) in succession, the preparation unit (108) configured to capture a yarn (102Y) from each yarn-wound cop (102) and insert each captured yarn (102Y) into each yarn-wound cop (102); and
a robotic arm (110) configured to pick up the yarn-wound cops (102) prepared by the preparation unit (108) and place the yarn-wound cops (102) into pockets (1708) of at least one magazine (1702).

2. The system (100) as claimed in claim 1, wherein an eccentric cam mechanism (206) is operably coupled to the hopper (104) to oscillate the hopper (104) for discharging one of the yarn-wound cops (102) through an outlet (204) of the hopper (104) in each cycle of oscillation to the orientation unit (106).

3. The system (100) as claimed in claim 1, wherein the orientation unit (106) comprises:
a vertical conveyor (300) having a conveyance track (302) and a plurality of platforms (304) mounted along the length of the conveyance track (302), wherein each platform (304) receives and transports a yarn-wound cop (102) of the plurality of yarn-wound cops (102) from a receiving end of the conveyance track (302) towards a discharging end of the conveyance track (302);
a plurality of positioning members (306) configured to align a portion between the first end and the second end of each yarn-wound cop (102) centrally on the corresponding platform (304);
a plurality of orienting means (502) configured to orient the first end of each yarn-wound cop (102) vertically above the second end of each yarn-wound cop (102) at the discharging end of the conveyance track (302); and
an inclined delivery chute (602) configured to guide the plurality of yarn-wound cops (102) from the vertical conveyor (300) to the preparation unit (108).

4. The system (100) as claimed in claim 3, wherein the plurality of positioning members (306) comprises:
a locker block (306a) configured to contact and align the portion between the first end and the second end of each yarn-wound cop (102) horizontally on the corresponding platform (304); and
a pair of aligner rods (306b, 306c) configured to push against the first end and the second end of each yarn-wound cop (102) and align each yarn-wound cop (102) centrally on the corresponding platform (304);
wherein the aligner rods (306b, 306c) and the locker block (306a) are configured to retract from each yarn-wound cop (102) upon alignment of each yarn-wound cop (102) on the corresponding platform (304).

5. The system (100) as claimed in claim 3, wherein the plurality of orienting means (502) comprises:
a left actuator (502a) and a right actuator (502b) spaced apart from one another along a width of the vertical conveyor, the left actuator (502a) and the right actuator (502b) configured to contact one of the first end and the second end of each yarn-wound cop (102) at the discharging end of the conveyance track (302),
wherein each of the left actuator (502a) and the right actuator (502b) is configured to plunge upon contact thereof with the first end of each yarn-wound cop (102) for rotatably orienting each yarn-wound cop (102).

6. The system (100) as claimed in claim 3, wherein the plurality of orienting means (502) comprises:
a left actuator (502a) operably connected to a first sensor; and
a right actuator (502b) operably connected to a second sensor;
wherein the first sensor and the second sensor are configured to:
determine the positions of the first end and the second end of each yarn-wound cop (102) at the discharging end of the conveyance track (302), and
send a signal to either the left actuator (502a) or the right actuator (502b) to rotate each yarn-wound cop (102) such that the first end of each yarn-wound cop (102) is oriented vertically above the second end of each yarn-wound cop (102).

7. The system (100) as claimed in claim 1, wherein the orientation unit (106) is configured to orient the plurality of yarn-wound cops (102) such that the first end of each yarn-wound cop (102) having a diameter less than or equal to a diameter of the second end of each yarn-wound cop (102) is disposed vertically above the second end of each yarn-wound cop (102).

8. The system (100) as claimed in claim 1, wherein the preparation unit (108) comprises:
a conical duct (702) configured to guide the plurality of oriented yarn-wound cops (102) to a bobbin holder (704) in succession;
a bobbin locker (706) configured to receive one of the yarn-wound cops (102) from the bobbin holder (704) and hold the received yarn-wound cop (102);
a motor assembly (708) configured to rotate the yarn-wound cop (102) held by the bobbin locker (706);
a blower (710) configured to blow air to the rotating yarn-wound cop (102) for slacking the yarn (102Y) from the yarn-wound cop (102);
an upper suction unit (712) configured to capture the yarn (102Y) from the yarn-wound cop (102) and dispose an end of the captured yarn (102Y) above the first end of the yarn-wound cop (102); and
a lower suction unit (714) configured to insert the captured yarn (102Y) into the yarn-wound cop (102).

9. The system (100) as claimed in claim 1, wherein the system (100) comprises a horizontal conveyor (112) extending out from the preparation unit (108) for carrying the prepared yarn-wound cops (102) proximate to the robotic arm (110).

10. The system (100) as claimed in claim 1, wherein the robotic arm (110) comprises one or more grippers (1604a, 1604b), each gripper (1604a, 1604b) configured to selectively grip one yarn-wound cop among the plurality of yarn-wound cops (102).

11. The system (100) as claimed in claim 10, wherein the robotic arm (110) comprises a rectilinear guide for each gripper (1604a, 1604b), the rectilinear guide configured to selectively raise and lower each gripper (1604a, 1604b) for inserting the yarn-wound cops (102) into pockets (1708) of at least one magazine (1702).

12. The system (100) as claimed in claim 10, wherein the robotic arm (110) comprises tilting means to tilt each gripper (1604a,1604b) for orienting longitudinal axes of the yarn-wound cops (102) gripped thereby parallel to the longitudinal axes of the corresponding pockets (1708).

13. The system (100) as claimed in claim 10, wherein the robotic arm (110) comprises:
a cup moving arm (1606a, 1606b) configured to engage with a central cup (1704) that covers a suction chamber of at least one magazine (1702), and rotate the central cup (1704) for uncovering an orifice (1710) of the suction chamber; and
a yarn moving arm (1608a, 1608b) configured to place the yarn (102Y) inserted in each yarn-wound cop (102) into the orifice (1710) of the suction chamber, for facilitating suction of the yarn (102Y) of each yarn-wound cop (102) into the winding machine.

14. A method for automatic feeding of a plurality of yarn-wound cops (102) to at least one magazine (1702) of a winding machine, the method comprising:
receiving the yarn-wound cops (102) in a hopper (104);
oscillating the hopper for discharging one of the yarn-wound cops (102) from the hopper (104) to an orientation unit (106) in each cycle of oscillation;
orienting, in the orientation unit (106), a first end of each yarn-wound cop (102) vertically above a second end of each yarn-wound cop (102);
preparing each oriented yarn-wound cop (102), in a preparation unit (108), by capturing a yarn (102Y) from each yarn-wound cop (102) and inserting each captured yarn (102Y) into each yarn-wound cop (102); and
picking up the prepared yarn-wound cops (102) with a robotic arm (110) and placing the yarn-wound cops (102) into pockets (1708) of at least one magazine (1702).

15. The method as claimed in claim 14, wherein orienting the yarn-wound cops (102) comprises: orienting the first end of each yarn-wound cop (102) having a diameter less than or equal to a diameter of the second end of each yarn-wound cop (102) vertically above the second end of each yarn-wound cop (102).

16. The method as claimed in claim 14, wherein preparing each oriented yarn-wound cop (102) comprises:
guiding the yarn-wound cop (102) to a bobbin holder (704) through a conical duct;
transferring the yarn-wound cop (102) from the bobbin holder (704) to a bobbin locker (706);
rotating the yarn-wound cop (102) held by the bobbin locker (706);
blowing air to the rotating yarn-wound cop (102) for slacking the yarn from the yarn-wound cop;
capturing, by an upper suction unit (712), the yarn (102Y) of the yarn-wound cop (102) and disposing an end of the captured yarn (102Y) above the first end of the yarn-wound cop (102); and
inserting, by a lower suction unit (714), the captured yarn (102Y) into the yarn-wound cop (102).

17. The method as claimed in claim 14, wherein picking and placing the yarn-wound cops (102) further comprises:
rotating, by a cup moving arm (1606a, 1606b), a central cup (1704) that covers a suction chamber of at least one magazine (1702) for uncovering an orifice (1710) of the suction chamber; and
placing, by a yarn moving arm (1608a, 1608b), the yarn (102Y) inserted in each yarn-wound cop (102) into the orifice (1710) of the suction chamber, for facilitating suction of the yarn (102Y) of each yarn-wound cop (102) into the winding machine.

Dated this 19th day of January 2024

Lakshmi Precision Technologies Limited
By their Agent & Attorney

(Adheesh Nargolkar)
of Khaitan & Co
Reg No IN/PA-1086