SYSTEM AND METHOD FOR SORTING BOBBINS

BACKGROUND

Technical Field

[001] The embodiments herein generally relate to sorting of bobbins, and more particularly, to a bobbins sorting apparatus and method for automatically sorting and aligning the bobbins in crates based on a remnant yarn, and colour characteristics.

Description of the Related Art [002] Winding machines and spinning machines are operated in textile industries. The spinning machines are used to wind yarn to one or more bobbins. The winding machine unwinds the yarn (approx. 30 to 70g) from the one or more bobbin for obtaining a fully-wound cone that weighs approximately 1 to 2.5 kilograms. Typically different color bobbins are fed to the spinning machine for winding different types of yarn. Each of the winding machine discharges one or more empty bobbins after unwinding yarn from the bobbins. However, the winding machine may discharge bobbin with remnant yarn. The empty bobbins are then transported to a spinning machine after performing a sorting operation. The sorting operation is performed to discriminate the bobbins with remnant yarn and the bobbins with different colors. However, the empty bobbins are not aligned to a same orientation before transporting into the spinning machine. Currently, the empty bobbins of different colours and bobbins with remnant yarns are sorted, and aligned manually by employing large number of workers for each shift. Accordingly there remains a need for automatic sorting and aligning of bobbins with reduced man power.

SUMMARY

[003] In view of the foregoing, an embodiment herein provides an apparatus for sorting a one or more bobbins is provided. The apparatus includes (i) a first sensor unit that detects a first characteristic of the one or more bobbin, (ii) a first ejection unit that ejects a first set of bobbins from the one or more bobbins to a first collection unit based on the first characteristic, (iii) a second sensor unit that detects a second characteristic of the one or more bobbins received from the first ejection unit and (iv) a second ejection unit that ejects a second set of bobbins from the one or more bobbins to a second collection unit based on the second characteristic. The apparatus may further includes a control unit that is configured to (a) receive the first characteristics from the first sensor unit and the second characteristics from the second sensor unit and (b) control an operation of the first ejection unit and the second ejection unit.

[004] In one embodiment, the first characteristic and the second characteristic includes at least one of remnant yarn, a shape, a color, an orientation, and an overlapping of the one or more bobbins. The first sensor unit may include a light sensor that senses the first characteristic and the second sensor unit may include a one or more sensors. The one or more sensors in the second sensor may include an object sensor, an Infrared (IR) sensor, and a color sensor. In another embodiment, the combinational output from at least one of the one or more sensors in the second sensor unit may used to detect the second characteristic. The second ejection unit may include an actuator mat is pivotally mounted on the bobbins sorting apparatus. A direction of actuation of the actuator is controlled by the control unit based on the second characteristic.

[005] In one aspect, a bobbins sorting apparatus for performing a sorting operation of one or more bobbins is provided. The bobbins sorting apparatus includes (i) a sensor unit that detects a first characteristic and a second characteristic of the one or more bobbins and the second characteristic is different from the first characteristic, (ii) a first ejection unit that ejects a first set of bobbins from the one or more bobbins to a first collection unit based on the first characteristic and (iii) a second ejection unit that ejects a second set of bobbins from the one or more bobbins to a second collection unit based on the second characteristic. The bobbins sorting apparatus may further includes a receiving unit and a control unit that controls a direction of ejection of the first ejection unit and the second ejection unit based on the first characteristic and the second characteristic detected in the sensor unit. In one embodiment, the receiving unit includes a conveyer that includes a one or more projection and one or more projections are configured to (i) queue the one or more bobbins, and (ii) transfer the one or more bobbins to the sensor unit at a first interval.

[006] In yet another aspect, a method of sorting one or more bobbins includes (i) receiving, at a receiving unit, the one or more bobbins from a winding machine, (ii) sensing, at a sensor unit, a first characteristic and a second characteristic of the one or more bobbins, wherein the second characteristic is different from the first characteristic, (iii) ejecting, at a first ejection unit, a first set of bobbins from the one or more bobbins to a first collection unit based on the first characteristic and (iv) ejecting, at a second ejection unit, a second set of bobbins from the one or more bobbins to a second collection unit based on the second first characteristic. In one embodiment, the first characteristic and the second characteristic includes at least one of a remnant yarn in the one or more bobbins, a color, a shape, an orientation and an overlapping of the one or more bobbins.

[007] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF THE DRAWINGS

[008] The embodiments herein will be better understood from the following detailed description with reference to the drawings, in which:

[009] FIG. 1 illustrates a process view of automatically sorting, and aligning one or more bobbins using a bobbins sorting apparatus according to an embodiment herein;

[0010] FIG. 2A and FIG. 2B illustrates a crate management unit of the bobbins sorting apparatus of FIG. 1 according to an embodiment herein;

[0011] FIG. 3 is a flow diagram illustrating a method for sorting the one or more bobbins in the bobbins sorting apparatus of FIG. 1 according to an embodiment herein; and

[0012] FIG. 4 illustrates a schematic diagram of a control unit of FIG. 1 according to an embodiment herein.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0013] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

[0014] As mentioned, there remains a need for automatic sorting and aligning of bobbins. The embodiments herein achieve this by providing a bobbins sorting apparatus that automatically (i) sorts and aligns one or more bobbins based on colour characteristics, and size/shape and orientation of the one or more bobbins, (ii) segregates rejected bobbins based on remnant yarn and the colour characteristics and (iii) arranges the one or more bobbins in one or more crates/trolleys for using the bobbins in the next production cycle. Referring now to FIGS. 1 through 4, where similar reference characters denote corresponding features consistently throughout the figures, preferred embodiments are described herein.

[0015] FIG. 1 illustrates a process view of automatically sorting, and aligning one or more bobbins 104 using a bobbins sorting apparatus 100 according to an embodiment herein. In the bobbins sorting apparatus 100, a sorting operation of the one or more bobbins 104 is performed in a sorting unit which includes a receiving unit 102, a sensor unit (e.g. a first sensor unit 106 and a second sensor unit 110), a first ejection unit 108, a second ejection unit 112, a control unit 116, and a plurality collection units (a first collection unit 118, a second collection unit 124 and a third collection unit 128). The bobbins sorting apparatus 100 further include a crate management unit 114 that manages a plurality of crates of the plurality of collection unit 118, 124 and 128. The second ejection unit 112 includes an actuator assembly 120 that includes one or more actuators 120A-C. Each of the one or more actuators 120A-C includes a piston 122. The second collection unit 124 that includes one or more crates 124A-C. The bobbins sorting apparatus 100 is retrofit type that can be connected to any of a winding machine for receiving the one or more bobbins 104. The one or more bobbins 104 may be empty bobbins, and/or bobbins with remnant yarn. The receiving unit 102 is adapted to receive the one or more bobbins 104 that are discharged from the winding machine. The receiving unit 102 may include a buffer hopper assembly (not shown in FIG. 1) which regulates the supply of the one or more bobbins 104 to the first sensor unit 106 at an equal interval. The buffer hopper assembly includes a conveyor with one or more projections that queue the one or more bobbins 104 at the equal interval.

[0016] In one embodiment, the first sensor unit 106 includes a light sensor which is configured to detect a first characteristic that may include a remnant yarn or residual yarn in the one or more bobbins 104. The first ejection unit 108 may include a gate assembly (not shown in FIG. 1) for ejecting a first set of bobbins from the one or more bobbins 104 to the first collection unit 118 when the first sensor unit 106 detects the first characteristic. The actuation and opening of the gate assembly is controlled using the control unit 116. The gate assembly is actuated and/or opened when the first sensor unit 106 senses the remnant yarn in the one or more bobbins 104. The one or more bobbins with remnant yarn may be rejected bobbins (e.g. the first set of bobbins), in one example embodiment.

[0017] The second sensor unit 110 includes one or more sensors to detect a second characteristic of the one or more bobbin 104. The second characteristic includes at least one of a color, a shape, an overlapping and an orientation (e.g. a tip and/or a base in front) of the one or more bobbins 104. The second sensor unit 110 transmits the detected second characteristic to the control unit 116. The second ejection unit 112 includes the actuator assembly 120 which is controlled by the control unit 116 based on a combinational output from one or more sensors in the second sensor unit 104. The ejected bobbins (e.g. a second set of bobbins) at the actuator assembly 120 are transported to the crates 124A-C through a taper channel (e.g., bobbin slider) 126A-C, in one example embodiment. The taper channel 126A-C is configured to maintain the orientation of the ejected bobbins until the ejected bobbins are transported to the crates 124A-C. The second ejection unit 112 ejects the one or more bobbins 104 such that all bobbins are collected in the corresponding crates 124A-C with uniform orientation (e.g., tip and base aligned parallel).

[0018] In one embodiment, the second sensor unit 110 may include (i) a color sensor (e.g., a RGB sensor), (ii) an Infrared (IR) sensor and (iii) an object sensor (e.g., a light sensor or optical sensor). The object sensor is positioned at the entrance of second sensor unit to detects whether the one or more bobbins 104 is entering into the second sensor unit 104. The color sensor is positioned next to the object sensor for sensing the color characteristics once the object sensor detects the one or more bobbin 104. The color sensor (also referred as an RGB sensor) is configured to detect the color characteristic based on an entire length of the one or more bobbins 104 for color and/or uniformity. The IR sensor is used to detect the orientation of the one or more bobbins 104.

[0019] In another embodiment, the actuator assembly includes one or more actuators 120A-C to eject the one or more bobbins. The control unit 116 is programmed to actuate at least one of the actuator 120A-C based on the second characteristic received from the second sensor unit 110. For example, the control unit 116 is programmed actuate (i) actuator 120A for first color characteristics, (ii) actuator 120B for second color characteristics and (iii) actuator 120C for third color characteristics.

[0020] The direction of force while ejecting out the bobbins is aligned to arrange the bobbins in parallel in the crates 124A-C. Each of the actuators 120A-C is actuated pneumatically or other actuating mechanism such as hydraulic etc. Each of the one or more actuators 120A-C is programmable, in one example embodiment. The one or more actuators 120A-C perform sorting of the one or more bobbins 104 for different color characteristic. The piston 122 is pivotally mounted on the actuator assembly 120. The movement of the piston 122 is controlled by the control unit 116. The piston 122 is adapted to eject the one or more bobbins 104 in a single orientation based on the orientation sensed in the second sensor unit 110..

[0021] The one or more bobbins 104 are (i) sorted, (ii) ejected from the second ejection unit 112, and (iii) collected in a respective crates 124A-C using the crate management unit 114. The one or more sorted bobbins are collected and stored in the respective crates through corresponding taper channel 126A-C. For example, a first sorted bobbin is collected in the crate 124A through a corresponding taper channel 126A. Similarly, a second sorted bobbin may be collected in the crate 124B through a corresponding taper channel 126B, and a third sorted bobbin may be collected in the crate 124C through a corresponding taper channel 126C. The one or more sorted bobbins (e.g., the first sorted bobbin, the second sorted bobbin, and the third sorted bobbin) are collected and stored in corresponding crates (e.g., the crate 124A, the crate 124B, and the crate 124C) based on the colour characteristics. The one or more bobbins 104 that are not sensed by the first sensor unit 106 and the second sensor unit 110 may be collected in a third collection unit 128. The third collection unit 128 may be a crate that collects and stores one or more bobbins with remnant yarn which is not detected in the first sensor unit 106, in one example embodiment. The bobbins of completely different colors which are not meant to be in this production cycle are collected and stored in the third collection unit 128, in another example embodiment.

[0022] In another embodiment, the bobbins sorting apparatus 100 include (i) a sensor unit that includes one or more sensors to detect both first characteristic and second characteristic of the one or more bobbins 104 and (ii) the one or more ejection unit to eject bobbins based on the first characteristic and second characteristic detected in the sensor unit.

[0023] With reference to FIG. 1, FIG. 2A and FIG. 2B illustrate the crate . management unit 114 of the bobbins sorting apparatus 100 of FIG. 1 according to an embodiment herein. The crate management unit 114 includes a storage unit 202, a distribution unit 204, and a transmission unit 206. The storage unit 202 includes a one or more crates 124 which can be stacked vertically or horizontally. The distribution unit 204 includes a plate assembly 208 (as shown in FIG. 2B). The distribution unit 204 receives the one or more sorted bobbins 104 from the sorting unit and transfers the one or more sorted bobbins to at least one of the one or more crates 124. The plate assembly 208 is configured to temporarily hold the one or more sorted bobbins 104 received from the sorting unit to retain the orientation of the one or more sorted bobbins 104. In one embodiment, the one or more crates 124 include a partition which equally splits the crates into two partitions, such that the one or more sorted bobbins 104 are equally distributed through the plate assembly 208. The transmission unit 206 is connected with the storage unit 202. The transmission unit 206 includes a transmission assembly 210 for transporting the one or more crates 124 to the distribution unit 204 based on a control signal received from the control unit 116. The control unit 116 includes a counter which counts a number of bobbins ejected from the sorting unit. The control unit 116 sends the control signal to the transmission unit 208, when a counter value of the counter reaches a threshold value. The threshold value refers to a maximum number of bobbins can accommodate in an each of the one or more crates 124A-C. In one embodiment, the threshold value is programmable in the control unit 116.

[0024] FIG. 3 is a flow diagram illustrating a method for sorting the one or more bobbins 104 in the bobbins sorting apparatus 100 of FIG. 1 according to an embodiment herein. In step 302, the one or more bobbins are received in the receiving unit 102 from the winding machine. In step 304, the first characteristic and the second characteristics are sensed in the sensor unit (e.g. the first sensor unit and the second sensor unit). The second characteristic is different from the first characteristic. In step 306, the first ejection unit ejects the first set of bobbins to the first collection unit based on the first characteristic detected in the sensor unit. In step 308, the second ejection unit ejects the second set of bobbins to a second collection unit based on the second characteristic detected in the sensor unit. In one embodiment, the first characteristic and the second characteristic includes at least one of a remnant yarn in said plurality of bobbins, a color, a shape, an orientation and an overlapping of the one or more of bobbins 104.

[0025] With reference to FIG. 1, FIG. 4 illustrates a schematic diagram of the control unit 116 of FIG. 1 according to an embodiment herein. The control unit 116 includes a memory 402 that having a set of instructions, a bus 404, a display 406, a speaker 408, and a processor 410 that is capable of processing the set of instructions to perform any one or more of the methodologies herein. The processor 410 may also enable digital content to be consumed in the form of video for output via one or more displays 406 or audio for output via speaker and/or earphones 408. The processor 410 may also carry out the methods described herein and in accordance with the embodiments herein.

[0026] Digital content (e.g., the count) may also be stored in the memory 402 (e.g., a counter) for future processing or consumption. The memory 402 may also store program specific information and/or service information (PSI/SI), including information about digital content (e.g., the detected information bits) available in the future or stored from the past. A user of the bobbins sorting apparatus 100 may view this stored information on the display 406 and select an item of for viewing, listening, or other uses via input, which may take the form of keypad, scroll, or other input device(s) or combinations thereof. When digital content is selected, the processor 410 may pass information. The content and PSI/SI may be passed among functions within the receiver using the bus 404.

[0027] The bobbins sorting apparatus 100 automatically (i) sorts and aligns the one or more bobbins 104 based on color characteristics, and size/shape and orientation of the one or more bobbins 104, (ii) segregates rejected bobbins based on remnant yarn and the colour characteristics, and (iii) arranges the one or more bobbins in one or more crates/trolleys for using the bobbins in the next production cycle. The bobbins sorting apparatus 100 enables each worker to manage the operation of collecting and transporting empty bobbin crates from a set of automatic winding machines to ring frames (e.g., a ring spinning machine, or a spinning machine).

[0028] The bobbins sorting apparatus 100 further queues the one or more bobbins one after the other based on a pre-defined time interval. The bobbins sorting apparatus 100 (i) identifies the bobbins with remnant yarn or full bobbin, (ii) ejects the bobbins with remnant yarns and full bobbins out of the sorting process, and (iii) collects a) the bobbins with remnant yarn in a separate crate (e.g., the first collection unit 118), and b) full bobbins in corresponding crates (e.g., the crates 124A-C). The receiving unit 102 (i) receives one or more bobbins for each colour, (ii) guides into the respective crate without disrupting the alignment, and (iii) arranges the bobbins in parallel in the corresponding crates, thus reducing alignment errors.

[0029] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope.

CLAIMS
What is claimed is:

1. An apparatus for sorting a plurality of bobbins comprising:

a first sensor unit that detects a first characteristic of said plurality of bobbins;

a first ejection unit that ejects a first set of bobbins from said plurality of bobbins to a first collection unit based on said first characteristic;

a second sensor unit that detects a second characteristic of said plurality of bobbins received from said first ejection unit; and

a second ejection unit that ejects a second set of bobbins from said plurality of bobbins to a second collection unit based on said second characteristic.

2. The apparatus of claim 1, further comprising:

a control unit that is configured to (i) receive said first characteristics from said first sensor unit and said second characteristics from said second sensor unit and (ii) control an operation of said first ejection unit and said second ejection unit.

3. The apparatus of claim 1, wherein said first characteristic and said second characteristic comprises at least one of remnant yarn, a shape, a color, an orientation, and an overlapping of said plurality of bobbins.

4. The apparatus of claim 1, wherein said first sensor unit comprises a light sensor that senses said first characteristic.

5. The apparatus of claim 1, wherein said second sensor unit comprising a plurality of sensors, wherein said plurality of sensors comprises an object sensor, an Infrared (IR) sensor, and a color sensor;

wherein a combinational output from at least one of said plurality of sensors is used to detect said second characteristic.

6. The apparatus of claim 2, wherein second ejection unit comprises:

an actuator that is pivotally mounted on said bobbins sorting apparatus, wherein a direction of actuation of said actuator is controlled by said control unit based on said second characteristic.

7. An apparatus for performing a sorting operation of a plurality of bobbins comprising:

a sensor unit that detects a first characteristic and a second characteristic of said plurality of bobbins, wherein said second characteristic is different from said first characteristic;

a first ejection unit that ejects a first set of bobbins from said plurality of bobbins to a first collection unit based on said first characteristic; and

a second ejection unit that ejects a second set of bobbins from said plurality of bobbins to a second collection unit based on said second characteristic.

8. The bobbins sorting apparatus of claim 7, further comprising:
a receiving unit that comprises:

a conveyer that comprises a plurality of projections, wherein said plurality of projections are configured to
(i) queue said plurality of bobbins, and (ii) transfer said plurality of bobbins to said sensor unit at a first interval; and a control unit that controls a direction of ejection of said first ejection unit and said second ejection unit based on said first characteristic and said second characteristic detected in said sensor unit.

9. A method of sorting a plurality of bobbins comprising:

receiving, at a receiving unit, said plurality of bobbins from a winding machine;.

sensing, at a sensor unit, a first characteristic and a second characteristic of said plurality of bobbins, wherein said second characteristic is different from said first characteristic;

ejecting, at a first ejection unit, a first set of bobbins from said plurality of bobbins to a first collection unit based on said first characteristic;

ejecting, at a second ejection unit, a second set of bobbins from said plurality of bobbins to a second collection unit based on said second first characteristic.

10. The method of claim 9, wherein said first characteristic and said second characteristic comprises at least one of a remnant yarn in said plurality of bobbins, a color, a shape, an orientation and an overlapping of said plurality of bobbins.