FIELD OF THE INVENTION

The present invention relates to a method of controlling tube loading apparatus of an auto doffer ring spinning machine. More particularly this invention relates to a control system defined to monitor and control the loading cycle of a tube loading apparatus of an auto doffer ring spinning machine.

BACKGROUND OF THE INVENTION

This invention is with respect to the tube loading apparatus explained in co-pending Indian application 2990/CHE/2010.

In a typical arrangement of a textile spinning or twisting machine includes a plurality of spindles uniformly spaced along the longitudinal extent of the textile machine. The spindles individually supports the conical tubes during the building of yarn named as yarn package. Soon after the built up of predetermined length of yarn, the full yarn packages referred as cops are exchanged with empty conical tubes.

For exchanging of the same, modern ring spinning machines employ auto doffers, some of them employ mechanism of pegs moving in peg trays. The peg tray forms a closed loop contains plurality of pegs arranged in a predetermined centre distance between them to carry the conical tubes as well as to receive the cops and to transport them to the loading or unloading zone of the ring spinning and twisting machine. Pushing means are arranged on both sides of the machine for the displacement of the pegs in the peg tray in the longitudinal direction of the machine.

As a preliminary work to facilitate auto doffing, the tube loader system performs the sequentially loading of conical tubes one after the other into the pegs. As a part of tube loading process, unloading of full bobbins from pegs and the transportation of the pegs to the loading area is carried out by the drive elements of peg tray arrangement. The drive elements of peg tray arrangement and bobbin loading apparatus are operated in co-operation with each other. Pushing means displaces the pegs loaded with conical tubes along the row of spindles so that each conical tube is positioned in front of respective spindle. Soon after the cop built up is completed, conical tubes present in the pegs are exchanged with the full yarn packages otherwise known as cops and the pegs carrying the cops, subsequently transported to the unloading zone of the machine.

According to the tube loading apparatus defined in 2990/CHE/2010, one conical tube per peg is loaded by the tube loader, pushing means are arranged to shift the loaded peg in the peg tray and as well as a empty peg is arrived to the loading position underneath the tube loader. A sensor is arranged at the tube loading position, to provide feedback signal to the control unit for each correct loading of bobbin into pegs. The control unit is committed to carry out the successive steps of auto doffing operation, in correspond to the feedback signal of the sensor and its algorithm. In this manner, tube loading process is being done for both sides of the machine.

The control unit is a part of automatic tube loading apparatus provided with set of instructions called as algorithm. Algorithm is defined to manage the activities of tube loading apparatus so as to carry out the bobbin loading activity automatically. The remedial actions are also defined in the algorithm for any of the situation to continue its operation almost without manual intervention. Automatic tube loading operation has three main steps namely: 1) collection of conical tube from storage chamber, 2) orienting the position of conical tube before delivery into funnel and 3) loading of the conical tube into peg in the upstanding condition. These three steps are inter-related and being executed by the control unit in a sequential manner for every single bobbin loading. The success of loading is considered based on the upstanding position of the bobbin tube over the peg and its corresponding feedback signal of sensor to the control unit. Thus the bobbin loading steps are executed continuously for both sides of the machine. Once the feedback signal received from the sensor by sensing the bobbin tube, the control unit executes the pushing means to displace the peg loaded with bobbin tube away from the tube loading position and empty peg comes to the tube loading position. Incase of no signal received from the sensor due to failure in any of three steps (1,2,3), the control unit assumes that no bobbin tube is being delivered into the funnel for loading. Some times tubes are loaded with slight yarn remnants which hold the tube midway in the funnel. The bottom sensor assuming that no tube is loaded activates the tube loading cycle once more resulting in bobbin tubes get blocked or due to additional weight, second or third or fourth of fifth tube falls down together activating the sensor, per tray will move resulting in peg damages. Hence it is clear that the exclusive monitoring with a single sensor at the tube loading position is inadequate to determine the obstruction in any of the above three steps. In order to make a reliable and foolproof automatic tube loading system, plurality of sensors are to be provided to monitor every step of tube loading operation.

Apart from it, following problems are also taken care in this invention. There are some occurrences found that during peg tray movement, bobbin tubes at the pegs may fall because of improper seating. Due to this problem there exists missing of conical tubes in peg tray chain., when exchanging the full cops with empty conical tubes, yarn gets wound over the bare spindles. This problem of proper seating of conical tubes over the pegs could not be confirmed by the existing sensor provided at the tube loader position and it is better to examine the proper seating of bobbin tube into the peg, only after few shifting is done by pushing means.

And generally the tube loading apparatus are congested in construction having lots of components and covers. So regular cleaning inside the apparatus is critical and so fluffs are accumulated over the components, covers, sensors, etc., fluff accumulation over the sensors which affect the working, especially optical sensors.

So it is necessary to provide an improved bobbin tube orienting and loading apparatus, which should be highly reliable and efficient in operation and it should be provided with a new algorithm along with plurality of sensors for checking each steps of the tube loading system. Hence this invention would be more useful and takes care of said problems, assuring to the trouble free operation and the productivity of the machine.

OBJECTS OF THE INVENTION

It is an object of the invention to provide an improved method of controlling the bobbin tube loading apparatus of an auto doffer ring spinning and twisting machine.

It is one of an object of the invention to provide a suitable algorithm for a bobbin tube loading apparatus of an auto doffer ring spinning and twisting machine.

It is an another object of the invention to provide an algorithm along with plurality of sensor checking system for a of bobbin tube loading apparatus of an auto doffer ring spinning and twisting machine

Yet another object of the invention to provide a trouble free automation process of bobbin tube loading apparatus for an auto doffer ring spinning and twisting machine.

SUMMARY OF INVENTION

According to the aspects of present invention, provided a new and improved method of controlling the bobbin tube loading apparatus (1) of an auto doffer ring spinning and twisting machine, said apparatus comprising: tube catching zone (A), tube delivering zone (B) and tube loading zone (C), wherein the said zones (A.B.C) are provided with sensors (13a, 13b, 14a, 14b, 15a, 15b) at specific locations to sense bobbins (4) at these positions.

A control unit (not shown) is provided to execute the automatic tube loading process, in correspond to the signals of sensors (13, 14, 13a, 13b, 14a, 14b, 15a, 15b) and algorithm. The control unit receives the series of signal from these sensors (13, 14, 13a, 13b, 14a, 14b, 15a, 15b) during loading of bobbin (4) into the funnel (9, 9a, 9b). The sensor (13, 13a, 13b) at the tube delivering zone (B) provides a signal to control unit to ensure that the bobbin (4) is delivered into the funnel (9, 9a, 9b). And control unit awaits signal from the tube loading sensor (14, 14a, 14b) provided at the tube loading position (C) to confirm the upstanding position of bobbin tube (4) over the peg (11). Once a bobbin tube is loaded into the peg (11), both feedback signals from the sensors (13, 14, 13a, 13b, 14a, 14b) are delivered to the control unit, which activates the pushing means (not shown) to shift the pegs for one stroke.

Whenever there is no stock of bobbin tubes (4), there will be no delivery of bobbin tube (4) into the funnel (9, 9a, 9b) by the bobbin carrier (3). So the sensor (13, 13a, 13b) does not sense the tube (4) delivery into the funnel (9, 9a, 9b) and the sensor (14, 14a, 14b) also does not sense the tube presence at the funnel (9, 9a, 9b). When both the sensors (13, 14, 13a, 13b, 14a, 14b) are not sensing the bobbin tubes, as per the algorithm defined, the control unit demands the bobbin carrier (3) for picking the bobbin tube from storage chamber (2).

when there is jamming of the bobbin tube (4) inside the funnel (9, 9a, 9b), no delivery of bobbin tube (4) takes place from the funnel (9, 9a, 9b). The sensor (13, 13a, 13b) senses the movement of bobbin tube (4) when it is passing the delivering zone (b) and due to blockage in the funnel (9, 9a, 9b), no signal is obtained from the sensor (14, 14a, 14b). Hence error message regarding the blockage inside the funnel will be shown in the display. So that it can be attended manually.

In this manner, the tube loading operation continued in both sides of machine. During shifting movement of pegs (11, 11a, 11b) along with bobbin tubes, bobbin tubes may fall from the stem (16) because of improper seating. To monitor this, further pair of sensors (15a, 15b) are installed adjacent to the sensors (14a, 14b) in the peg tray.

BRIEF DESCRIPTION OF THE DRAWING

Fig.1 schematically illustrates the three dimensional view of single bobbin tube loading apparatus provided with plurality of sensors in the funnel region according to the invention.

Fig. 2 schematically illustrates the three dimensional view of double bobbin tube loading apparatus provided with plurality of sensors in the peg tray system according to an embodiment of the invention.

BRIEF DESCRIPTION OF THE INVENTION

This invention relates to a tube loading apparatus (1) of an auto doffer ring spinning machine as explained in co-pending Indian application 2990/CHE/2010. according to this invention construction shown in figure 1, tube loading apparatus (1) has 3 zones namely: (A) Tube catching position is the process of collecting the tube from the storage chamber, (B) Tube delivering position is the process of preparing the tube and delivering into the funnel and (C) Tube loading position is the process of changing the tube from horizontal axis to vertical position so as to load in the peg suitably.

According to this invention, the tube catching zone (A) comprises a storage chamber (2) and a pneumatically reciprocating bobbin carrier (3). The bobbin tubes (4) stored in the storage chamber (2) are distributed in sequence one after the other to the reciprocating bobbin carrier (3). The reciprocating bobbin carrier (3) has a U channel recess (not shown) to carry the bobbin in horizontal way as of delivered from the outlet of storage chamber (2). By means of pneumatic cylinder (5), the bobbin carrier linearly reciprocates between the tube catching position (a) and tube delivering position (B). The tube delivering position (B) is arranged downstream of the tube catching position (A), which comprising the reciprocating bobbin carrier (3) and a pair of rest plates (6a, 6b). During the reciprocating movement of the pneumatic cylinder (5), bobbin carrier (3) moves between the tube catching position (A) and the tube delivering position (B). During the forward movement of the bobbin carrier (3), the U channel recess carries the bobbin (4) in horizontal way such that the both ends of the bobbin slides over the rest plates (6a, 6b) also. During transportation over rest plates (6a, 6b) the larger diameter (bottom end) of bobbin tube engages with either of the guide surfaces (7a, 7b) of stationary cams (8). While being so transported through the guide surfaces (7a, 7b) of stationary cams (8), as the guide surfaces (7a, 7b) converges in the delivery direction which axially shifts the bobbin tube (4) in the direction of smaller end, which passes freely beneath the similar cam members (8) up to the tube delivering position (b). Thus the bobbin tube (4) is delivered into the tube loading zone (c), which comprises a vertically placed funnel (9) having pair of swap plates (10a, 10b), provided to change the bobbin tube (4) from horizontal axis to vertical position so as to load in the pegs (11) in sequence one after the other. As the funnel (9) has swap plates (10a, 10b), which engages with the axially shifted bobbin tube (4) at its smaller diameter and changes the position of the bobbin tube to upright position. Like wise, the apparatus (1) continues its operation, the bobbin tubes (4) are being loaded over transporting pegs (11) in the upright position.

An another feature of this invention, the tube loading apparatus includes a storage chamber (2) and a reciprocating bobbin carrier (3) along with an agitating member (not shown). The reciprocating bobbin carrier (3) is disposed operatively below the storage chamber (2). The agitating member extends from the bobbin carrier (3) into the interior of the storage chamber (2) for agitating the bobbins held inside the storage chamber to prevent i jamming of the bobbins.

According to this invention shown in figure 1, plurality of sensors (13, 14) are provided for monitoring the execution of operation at the tube delivering zone (b) and tube loading zone (c) respectively. Control unit (not shown) is provided to evaluate the signals from the sensors (13, 14) and appropriate next course of action is being executed.

The control unit receives the series of signal from these sensors (13, 14) during every correct loading of bobbin, for example: for every single bobbin (4) delivery into the funnel (9) the sensor (13) at the tube delivering zone (b) provides a signal to control unit, so it confirms that the bobbin (4) is delivered into the funnel (9). And control unit awaits for the signal from the tube loading sensor (14) provided at the tube loading position (c) to confirm the upstanding position of bobbin tube (4) over the peg (11). Once a bobbin tube is loaded into the peg (11), both feedback signals from the sensors (13, 14) are delivered to the control unit, which activates the pushing means (not shown) to shift the pegs for one stroke. In this manner, the tube loading operation continued in both sides of machine.

Whenever there is no stock of bobbin tubes (4) or any jamming inside the storage chamber (2), there will be no delivery of bobbin tube (4) into the funnel (9) by the bobbin carrier (3). So the sensor (13) does not sense the tube (4) delivery into the funnel (9) and the sensor (14) also does not sense the tube presence at the funnel (9). When both the sensors (13, 14) are not sensing the bobbin tubes, as per the algorithm defined, the control unit demands the bobbin carrier (3) for picking the bobbin tube from storage chamber (2). By this attempt, bobbin tubes (4) jamming inside the storage chamber (2) could be corrected by the agitating member and in case of no stock of bobbin tubes (4) in the storage chamber (2), display shows the error message.

When jamming of the bobbin tube (4) inside the funnel (9) as shown in figure 2, no delivery of bobbin tube (4) takes place from the funnel (9). The sensor (13) senses the movement of bobbin tube (4) when it is passing the delivering zone (b) and due to blockage in the funnel (9), no signal obtained from the sensor (14). So for this instance, the error regarding the blockage inside the funnel will be shown in the display. So that it can be attended manually.

By referring figure 1 & 2, the sequence of operation is explained in detail as follows, when the sensor (13) senses the bobbin tube (4) delivery into the funnel (9) and soon the tube (4) reaches the tube loading position of the tube loader, the sensor (14) senses it. Now the control unit executes the peg tray (12) moving operation through pushing means. Both the sensors (13, 14) are turned "on", peg tray moves. Where, "ON" denotes - Signal received. "OFF" denotes - Signal not received.

SENSOR (13) ON & SENSOR (14) ON PEG TRAY MOVEMENT; when the sensor (13) senses the bobbin tube (4) delivery into the funnel (9) and the bobbin tube (4) is not reached the peg (11) due to blockage inside the funnel (9), no feedback signal is received from sensor (14). Since tube delivering zone sensor (13) is turned "on" and tube loading zone sensor (14) is at turned "off', error message is displayed.

SENSOR (13) ON & SENSOR (14) OFF JAMMING INSIDE THE FUNNEL
(ERROR MESSAGE);

when the sensor (13) does not sense the bobbin tube (4) delivery into the funnel (9) and the sensor (14) also does not sense the tube presence at the funnel (9), the control unit actuates the bobbin carrier (3) reciprocating operation through pneumatic cylinder to continue the bobbin loading operation.

SENSOR (13) OFF & SENSOR (14) OFF ATTEMPT TO COLLECT THE TUBE FROM STORAGE CHAMBER (2);

according to the invention shown in figure 2, modern systems have utilized plurality of tube loader units (1a, 1b) each having individual funnel units (9a, 9b) respectively, according to this invention, two funnel units (9a, 9b) vertically arranged adjacent to each other and maintaining a space equal to spindle pitch distance. These funnel units (9a, 9b) are individually constructed with drive elements (not shown) and jointly controlled by a control unit (not shown). During every successive execution of tube loading steps, each funnel unit (9a, 9b) delivers a bobbin tube (4) into the pegs (11a, 11b) respectively. So pushing means shifts those two pegs (11a, 11b) loaded with bobbin tubes (4) and two empty pegs comes to the loading position underneath the tube loader units (1a, 1b). In this manner, bobbin tube (4) loading steps are continued to load the pegs (11a, 11b) on both sides of the machine.

There are plurality of sensors (14a, 14b) placed near the peg tray (12) corresponding to each funnel unit (9a, 9b), for ensuring the vertical loading of bobbin tubes (4) into the pegs (11a, 11b). The two sensors (14a, 14b) are serially connected and both are turned "on", only when both the bobbin tubes (4) are loaded into the pegs (11a, 11b) in upright position. In case of any fault such as missing of bobbin (4) loading in any of the pegs (11a, 11b), automation cycle stops and starts only when the fault is corrected. As the drive elements of the tube loader units (1a, 1b) are independent with each other, the fault can be corrected individually by the concerned drive elements.

There are some occurrences found that during pegs (11) movement, the bobbin tubes (4) at the pegs (11a, 11b) may fall because of improper seating. To monitor this, further pair of sensors (15a, 15b) are installed adjacent to the sensors (14a, 14b) in the peg tray. The sensors (15a, 15b) are also serially connected which performs along with sensors (14a, 14b). A display arrangement shows the message regarding the falling of bobbin tubes (4) from the pegs (11) whenever happens.

By referring figure 2, the sequence of peg tray movement is explained in detail as follows,

when both the sensors (14a, 14b) are turned "on", pushing means shifts those bobbin tube (4) loaded pegs (11a, 11b) and subsequently two empty pegs comes to the loading position underneath the tube loader units (1a, 1b).

BOTH SENSORS (14A, 14B) ON PEG TRAY MOVEMENT;

when either of sensors (14a, 14b) are in turned "off' condition, no shifting takes place and error message "missing of bobbin tube" is displayed.

EITHER OF SENSORS (14A, 14B) OFF MISSING OF BOBBIN TUBE ERROR SHOWN IN DISPLAY;

With the above condition, bobbin tube loading over the pegs (11a, 11b) are being continued to the rest of all spindles. However incase of tubes falling during peg tray movement, two sensors (15a, 15b) are provided to monitor the same. Similar to the sensors (14a, 14b), both sensors (15a, 15b) are turned "on" when the bobbin tube (4) are seated properly in the stem (16) and peg tray movement continues. If either of the sensors (15a, 15b) are turned "off, the fault regarding the missing of tube will be shown in the display. This could be attended manually by placing a bobbin tube (4) in the concerned peg, thus yarn gets wound over the bare spindles could be avoided.

EITHER OF SENSORS (15A, 15B) OFF MISSING OF BOBBIN TUBE ERROR SHOWN IN DISPLAY;

If fluff is accumulated in the peg sensors, they will be continuously in turned on condition so that the peg tray moves continuously even without tubes. This leads to yarn gets wound over the bare spindles. To address the problem of fluff accumulation over the sensors, algorithms are defined in such a way that if the sensor (14a, 14b) is continuously turned "on" for more than one peg tray movement, the entire operations are stopped and showing the error message "sensors blocked permanently". To avoid fluff accumulation problem, Capacitance sensors can also be used. They will sense only bobbin tubeseven when the fluff is accumulated in sensors .

According to this invention, new method of controlling tube loading apparatus with sensors and algorithms have been developed, in considering all the possible situations in a ring spinning auto doffer tube loading apparatus.

WE CLAIM:

1. An improved method of controlling tube loading apparatus of an auto doffer ring spinning machine comprising: tube catching zone (A), tube delivering zone (B) and tube loading zone (C), wherein plurality of sensors (13,14, 14a, 14b, 15a, 15b) are arranged at specific locations.

2. The improved method of controlling tube loading apparatus of an auto doffer ring spinning machine as claimed in claim 1, wherein the tube loading process is performed by a control unit, based on the signals of sensors (13, 14,14a, 14b, 15a, 15b) and algorithm.

3. The improved method of controlling tube loading apparatus of an auto doffer ring spinning machine as claimed in claim 1, wherein the delivery of bobbin tube (4) into the funnel (9) is sensed by sensor (13 )

4. The improved method of controlling tube loading apparatus of an auto doffer ring spinning machine as claimed in claim 1, wherein the loading of bobbin tube (4) on the peg is sensed by sensor (14)

5. The improved method of controlling tube loading apparatus of an auto doffer ring spinning machine as claimed in claim 1, wherein if the sensor (13) senses the bobbin tube (4) and the sensor (14) not senses the bobbin tube (4), the operation of the tube loader is stopped as per the algorithm.

6. The improved method of controlling tube loading apparatus of an auto doffer ring spinning machine as claimed in claim 1, wherein if the sensor (13) not senses the bobbin tube (4) and the sensor (14) also not senses the bobbin tube (4), delivery of bobbin tube (4) into the funnel (9) is executed as per the algorithm.

7. The improved method of controlling tube loading apparatus of an auto doffer ring spinning machine as claimed in claim 1, wherein the loading of bobbin tube (4) on the pegs (11a, 11b) in upright position is sensed by sensors (14a, 14b)

8. The improved method of controlling tube loading apparatus of an auto doffer ring spinning machine as claimed in claim 1, wherein the proper seating of bobbin tube (4) on the stem (17) of the pegs (11a, 11b) is sensed by sensors (15a, 15b)

9. The improved method of controlling tube loading apparatus of an auto doffer ring spinning machine as claimed in claim 1, wherein if sensors (14a, 14b,) are continuously on for more than one peg tray movement, the operation of the tube loader is stopped as per the algorithm.

10. The improved method of controlling tube loading apparatus of an auto doffer ring spinning machine as claimed in claim 1, wherein said sensors (13, 14, 14a, 14b, 15a, 15b) are capacitance type.

11. The improved process of tube loading apparatus of an auto doffer ring spinning machine comprising:

a reciprocating bobbin carrier (3) having recess to catch the bobbin tube (4) delivered from the storage chamber (2), the forward movement of the bobbin carrier (3) makes the bobbin tube (4) slides over the rest plates (6a, 6b) and axially shifts the bobbin tube (4) in the direction of smaller end ,the axially shifted bobbin tube (4) engages with the swap plates for loading the bobbin tubes (4) on the peg (11,11a, 11b), said apparatus is provided with sensors (13,14,14a, 14b, 15a, 15b) associated with control unit and algorithm.