CRATE MANAGEMENT SYSTEM BACKGROUND

Technical Field

[001] The embodiments herein generally relate to crate management system, and more particularly, to a system for managing one or more crates in a bobbins sorting apparatus.

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. Further, the above operation uses a mechanical sensing arrangement for detecting bobbins with remnant yarn. The mechanical sensing arrangement is not effective for sensing bobbins with very little amount of yarn. Currently, the empty bobbins 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, a system for managing one or more crates in an apparatus for sorting one or more bobbins is provided. The system includes (a) a storage unit including the one or more crates, (b) a distribution unit that includes a plate assembly that (i) receives the one or more bobbins, (ii) temporarily holds the one or more bobbins to retain an orientation, and (iii) transfers the one or more bobbins to a first crate of the one or more crates, (c) a transmission unit that includes a transmission assembly, and (d) a control unit which controls a movement of the transmission assembly. The control unit is configured to move at least one of the one or more crates to the distribution unit for receiving the one or more bobbins when the first crate is filled with a number of bobbins equal to a threshold value. The control unit may include a counter which counts a number of bobbins received in the crate management unit from the sorting unit. The control unit may control a movement of the transmission assembly when a value of the counter reaches the threshold value. The threshold value may be equal to a maximum number of bobbins which can accommodate in the first crate.

[004] In one aspect, an apparatus for sorting one or more bobbins is provided. The apparatus includes a sorting unit that performs a sorting operation on the one or more bobbins, a crate management unit and a control unit. The crate management unit includes (a) a storage unit which includes one or more crates, (b) a distribution unit that (i) receives the one or more bobbins from the sorting unit and (ii) transfers the one or more bobbins to a first crate of the one or more crates without disturbing an orientation of the one or more bobbins and (c) a transmission unit that is connected to the storage unit. The transmission unit includes a transmission assembly. The control unit controls a movement of the transmission assembly. The transmission assembly is configured to move at least one of the one or more crates to the distribution unit for receiving the one or more of bobbins when a number of bobbins in the first crate is equal to a threshold value. The distribution unit may include a plate assembly that temporarily holds the one or more bobbins to retain the orientation. The one or more crates may include a plurality of partitions that splits each of the one or more of crates into one or more portions. The plate assembly is configured to distribute the one or more bobbins to the one or more portions of the one or more of crates. The control unit may include a counter which counts a number of bobbins received in the distribution unit from the sorting unit. The control unit controls the transmission assembly when a value of the counter reaches the threshold value. The apparatus may further include a passage that is connected between the sorting unit and the crate management unit. The passage is configured to retain the orientation of the one or more bobbins during transmission from the sorting unit to the crate management unit.

[005] In yet another aspect, a method for managing one or more crates in an apparatus for sorting one or more of bobbins is provided. The method includes (i) receiving the one or more bobbins at a distribution unit, (ii) transferring a first set of bobbin of the one or more of bobbins to a first crate of the one or more crates, and (iii) moving a second crate of the one or more crates to the distribution unit to receive a second set of bobbins when a number of bobbins of the first crate is equal to a threshold value. The threshold value is equal to a maximum number of bobbins which can accommodate in the first crate.

[006] 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

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

[008] 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;

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

[0010] FIG. 3 illustrates a method for managing one or more crates in the bobbins sorting apparatus of FIG. 1 according to an embodiment herein; and

[0011] FIG. 4 illustrates a schematic diagram of the control unit of FIG. 1 according to an embodiment herein.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0012] 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.

[0013] 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 100A 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 includes a crate management unit 114 that manages one or more crates of the one or more 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 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.

[0014] 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 yam may be rejected bobbins (e.g., the first set of bobbins), in one example embodiment.

[0015] 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 a 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 the 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., passage or 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).

[0016] 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 an optical sensor). The object sensor is positioned at the entrance of the second sensor unit 110 to detect whether the one or more bobbins 104 are 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 bobbins 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.

[0017] In another embodiment, the actuator assembly 120 includes the 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) the first actuator 120A for first color characteristic, (ii) the second actuator 120B for second color characteristic and (iii) the third actuator 120C for third color characteristic.

[0018] The direction of force while ejecting out the one or more bobbins 104 is aligned to arrange the one or more bobbins 104 in parallel in the crates 124A-C. Each of the actuators 120A-C is actuated pneumatically or by 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.

[0019] The one or more bobbins 104 are (i) sorted, (ii) ejected from the second ejection unit 112, and (iii) collected in 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.

[0020] 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 (e.g., the first ejection unit 108 and the second ejection unit 112) to eject bobbins based on the first characteristic and second characteristic detected in the sensor unit.

[0021] 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 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 100A 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 bobbins 104 received from the sorting unit 100A to retain the orientation of the one or more sorted bobbins 104. In one embodiment, the one or more crates 124 include one or more of partitions which split the crates into one or more portions, such that the one or more bobbins 104 are equally distributed to the one or more portions 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 124A-C 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 100A. 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.

[0022] FIG. 3 illustrates a method for managing one or more crates 124A-C in the bobbins sorting apparatus 100 of FIG. 1 according to an embodiment herein. In step 302, the one or more bobbins 104 are received in the distribution unit 204. In step 304, a first set of bobbins from the one or more bobbin si 04 is transferred to a first crate of the one or more crates 124A-C in the transmission unit 208. In step 306, a second crate of the one or more crates 124A-C is moved to distribution unit 204 to receive a second set of bobbins when a number of bobbins of said first crate is equal to 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. The first set of bobbins and the second set of bobbins are identical.

[0023] With reference to FIG. 1, FIG. 4 illustrates a schematic diagram of the control unit 116 of FIG. 1 having a memory 402 having a set of instructions, a bus 404, a display 406, a speaker 408, and a processor 410 capable of processing the set of instructions to perform any one or more of the methodologies herein, according to an embodiment 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.

[0024] 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 (SPI/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.

[0025] The bobbins sorting apparatus 100 automatically (i) sorts and aligns the one or more bobbins 104 based on colour 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).

[0026] 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 collecting 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.

[0027] The bobbins sorting apparatus 100 further include the crate management unit 114 for managing the one or more crates 124 A-C. The transmission unit 206 includes a transmission assembly 210 for controlling movement of the one or more crates 124 A-C to the distribution unit 202 when the number of bobbins 104 ejected from the sorting unit 100A is equal to the threshold value.
[0028] 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 of the appended claims.

CLAIMS

What is claimed is:

1. A system for managing a plurality of crates in an apparatus for sorting a plurality of bobbins comprising:

a storage unit comprising said plurality of crates;

a distribution unit comprising:

a plate assembly that (i) receives said plurality of bobbins, (ii) temporarily holds said plurality of bobbins to retain an orientation, and (iii) transfers said plurality of bobbins to a first crate of said plurality of crates;

a transmission unit comprising a transmission assembly; and
a control unit which controls a movement of said transmission assembly,
wherein said control unit is configured to move at least one of said plurality of crates to said distribution unit for receiving said plurality of bobbins when said first crate is filled with a number of bobbins equal to a threshold value.

2. The system of claim 1, wherein said control unit comprises a counter which counts a number of bobbins received in said distribution unit.

3. The system of claim 2, wherein said control unit controls a movement of said transmission assembly when a value of said counter reaches said threshold value, and wherein said threshold value is equal to a maximum number of bobbins which can accommodate in said first crate.

4. An apparatus for sorting a plurality of bobbins and managing a plurality of crates comprising:

a sorting unit that performs a sorting operation on said plurality of bobbins;

a crate management unit comprising:

a storage unit which comprises said plurality of crates,

a distribution unit that (i) receives said plurality of bobbins from said sorting unit and (ii) transfers said plurality of bobbins to a first crate of said plurality of crates without disturbing an orientation of said plurality of bobbins, and

a transmission unit that is connected to said storage unit, wherein said transmission unit comprises a transmission assembly; and

a control unit which controls a movement of said transmission assembly;

wherein said transmission assembly is configured to move at least one of said plurality of crates to said distribution unit for receiving said plurality of bobbins when a number of bobbins of said first crate is equal to a threshold value.

5. The apparatus of claim 4, wherein said distribution unit comprises a plate assembly that temporarily holds said plurality of bobbins to retain said orientation.

6. The apparatus of claim 5, wherein each of said plurality of crates comprises a partition that splits each of said plurality of crates into a plurality of portions and wherein said plate assembly is configured to distribute said plurality of bobbins to said plurality of portions of said plurality of crates.

7. The apparatus of claim 4, further comprising a passage that is connected between said sorting unit and said crate management unit, wherein said passage is configured to retain said orientation of said plurality of bobbins during a transmission from said sorting unit to said crate management unit.

8. The apparatus of claim 4, wherein said control unit comprises a counter which counts said plurality of bobbins received in said distribution unit from said sorting unit, and wherein said control unit controls said transmission assembly when a value of said counter reaches said threshold value.

9. A method for managing a plurality of crates in an apparatus for sorting a plurality of bobbins comprising:

receiving said plurality of bobbins at a distribution unit;

transferring a first set of bobbins of said plurality of bobbins to a first crate of said plurality of crates; and

moving a second crate of said plurality of crates to said distribution unit to receive a second set of bobbins of said plurality of bobbins when a number of bobbins of said first crate is equal to a threshold value, wherein said threshold value is equal to a maximum number of bobbins which can accommodate in said first crate.

10. The method of claim 9, wherein said first set of bobbins and said second set bobbins are identical