Description:TECHNICAL FIELD
The present disclosure relates to a package transfer system and a package transfer method.

BACKGROUND
Conventionally, a package transfer system is known to receive a package discharged from each of a plurality of yarn winding units and transfer the package to a predetermined stop position (for example, see Japanese Unexamined Patent Publication No. 2008-230834). This system includes a transfer conveyor configured to transfer packages along a transfer path to a stop position via each of the yarn winding units. A deceleration start position is set on the transfer path between the most downstream position in the row of the yarn winding units and the stop position. If a package is not detected within a range from the deceleration start position to the stop position, a conveyor drive control unit increases the transfer speed of the transfer conveyor from the normal transfer speed.

SUMMARY
In the conventional system described above, the normal transfer speed is the speed at which the posture of the package is not disordered even if the transfer conveyor is abruptly stopped from the transfer speed. On the other hand, in transferring packages in a textile machine such as a yarn winding unit, the maximum transfer weight is a product of the maximum weight per package and the number of units (number of spindles of the machine). In recent years, the number of units tends to increase, and there is a need for increasing the capacity of the motor that is the drive unit of the transfer conveyor. However, in a normal package collection operation, it is rare to transfer the number of packages as many as that of the units. Thus, with conventional systems, it has been difficult to operate the drive unit in an efficient manner.
The present disclosure describes a package transfer system and a package transfer method capable of improving the transfer efficiency of a conveyor, by operating the drive unit in an efficient manner.
A package transfer system according to one aspect of the present disclosure includes: a plurality of yarn winding units each forming a package; a conveyor being arranged in the vicinity of the yarn winding units, having a transfer direction at least in an arrangement direction of the yarn winding units, and configured to temporarily accumulate the package discharged from the yarn winding units and transfer the package to a discharge area; a drive unit configured to drive the conveyor; a storage unit configured to store transfer information related to weight of the package placed on the conveyor and/or a location of the package; and a control unit configured to determine the transfer speed of the conveyor based on the transfer information and control the drive unit based on the determined transfer speed of the conveyor.
According to this package transfer system, the transfer speed of the conveyor is determined by the control unit, on the basis of the transfer information related to the weight of the package placed on the conveyor. For example, the conveyor can be driven at a relatively low speed when the transfer weight is high, and the conveyor can be driven at a relatively high speed when the transfer weight is low. Thus, the drive unit can be operated in an efficient manner, thereby improving the transfer efficiency of the conveyor.
The transfer information may be information related to at least one of the total weight of the packages placed on the conveyor, the number of packages placed on the conveyor, the number of times the packages are doffed after a previous operation of the conveyor, the load of the drive unit, the density of the packages on the conveyor, and the location of the package placed on the conveyor. In this case, the transfer information more accurately reflects the weight or location of the package transferred by the conveyor. Thus, the control unit can appropriately determine the transfer speed of the conveyor.
The storage unit may store the maximum weight that is the product of the number of yarn winding units and the heaviest weight of the package that can be formed by each of the yarn winding units when the number of packages placed on the conveyor corresponds to the total number of yarn winding units. When the transfer information matches the maximum weight, the control unit may cause the conveyor to run at the minimum speed within the variable range in the transfer speed of the conveyor. The size of the transfer device can be further optimized by causing the conveyor to run at the minimum speed according to the maximum weight. In the present specification, the "variable range of the transfer speed of the conveyor" means the range of transfer speed when the conveyor is transferring a package, and does not include a state when the conveyor is decelerating to a stop and a state when the conveyor is stopped (that is, zero speed).
The conveyor may include a deceleration sensor arranged on the downstream side of the yarn winding units in the transfer direction of the conveyor, and a terminal sensor arranged on the downstream side of the deceleration sensor in the transfer direction. The control unit may drive the conveyor at a confirmation speed equal to the minimum speed, to confirm the presence of a package between the deceleration sensor and the terminal sensor. The presence of the package can be confirmed with certainty, by driving the conveyor at the confirmation speed equal to the minimum speed. When the transfer speed is determined on the basis of the transfer information, it may not be possible to identify the location of the package with respect to the transfer direction of the conveyor. At the time immediately after the transfer is started, the package can be transferred more safely, by confirming the presence of the package at the confirmation speed.
The conveyor may include a deceleration sensor arranged on the downstream side of the yarn winding units in the transfer direction, and a terminal sensor arranged on the downstream side of the deceleration sensor in the transfer direction. The control unit may drive the conveyor at the minimum speed within the variable range of the transfer speed of the conveyor, to confirm the presence of a package between the deceleration sensor and the terminal sensor. The presence of the package can be confirmed with certainty, by driving the conveyor at the confirmation speed equal to the minimum speed. When the transfer speed is determined on the basis of the transfer information, it may not be possible to identify the location of the package with respect to the transfer direction of the conveyor. At the time immediately after the transfer is started, the package can be transferred more safely, by confirming the presence of the package at the confirmation speed.
The transfer information may be information related to weight, and the control unit may decrease the transfer speed with an increase in the weight of the package placed on the conveyor. In this case, it is possible to cause the conveyor to run at the transfer speed according to the transfer weight.
The transfer information may be information related to weight, and the conveyor may include a deceleration sensor arranged on the downstream side of the yarn winding units in the transfer direction and a terminal sensor arranged on the downstream side of the deceleration sensor in the transfer direction. The control unit may drive the conveyor at a confirmation speed that changes according to the weight of the package placed on the conveyor, to confirm the presence of a package between the deceleration sensor and the terminal sensor. By changing the confirmation speed used to confirm the presence of a package according to the weight of the package, the package can be transferred more safely while improving the transfer efficiency of the package.
The storage unit may store a plurality of division ranges classified into a plurality of divisions related to the transfer information, and speed information indicating the transfer speed defined by associating with each of the division ranges. The control unit may determine the transfer speed by referring to the speed information and selecting the transfer speed associated with the division range to which the transfer information belongs, based on the transfer information. In this case, by referring to the speed information, the control unit can appropriately determine the transfer speed through a relatively simple control.
The conveyor may include an operation unit configured to start transfer on the conveyor. The operation unit is operated to start the transfer on the conveyor. Hence, it is possible to start the transfer regardless of the state (number or density) of the package placed on the conveyor.
The control unit may change the transfer speed according to the weight of the package and the location of the package on the conveyor, the control unit preferentially using the location of the package over the weight of the package in controlling the transfer speed. For example, depending on the interval between the adjacent packages or the location of each package, there may be a case when acceleration or deceleration is not desirable. When the location of the package is preferentially used, a smooth transfer is possible on the whole.
The conveyor may include a belt part forming a transfer path longer than the total unit length in which the yarn winding units are installed in the transfer direction, and the belt part may be driven by one unit of the drive unit. In this case, the structure of the transfer device is simple.
As another aspect of the present disclosure, a package transfer method may be provided. It is a package transfer method in a package transfer system including: a conveyor being arranged in the vicinity of a plurality of yarn winding units, having a transfer direction at least in an arrangement direction of the yarn winding units, and configured to temporarily accumulate a package discharged from the yarn winding units and transfer the package to a discharge area; and a drive unit configured to drive the conveyor, the package transfer method including, when controlling the drive unit to cause the conveyor to run, determining the transfer speed of the conveyor based on transfer information related to weight of the package placed on the conveyor and/or a location of the package.
According to the package transfer method, the transfer speed of the conveyor is determined on the basis of the transfer information related to the weight of the package placed on the conveyor. For example, the conveyor can be driven at a relatively low speed when the transfer weight is high, and the conveyor can be driven at a relatively high speed when the transfer weight is low. Thus, the drive unit can be operated in an efficient manner, thereby improving the transfer efficiency of the conveyor.
According to some aspects of the present disclosure, the drive unit can be operated in an efficient manner, thereby improving the transfer efficiency of the conveyor.

BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a yarn winder to which a package transfer system according to an embodiment of the present disclosure is applied;
FIG. 2 is a block diagram illustrating a functional configuration of the package transfer system;
FIG. 3 is a flowchart illustrating a process executed in the package transfer system;
FIG. 4 is a diagram illustrating a relation between the estimated weight and transfer speed in the drive control of a conveyor;
FIG. 5A and FIG. 5B are diagrams each illustrating an example of the drive control of the conveyor; and
FIG. 6A is a plan view illustrating an arrangement example of packages when the transfer is started, and FIG. 6B and FIG. 6C are plan views each illustrating an arrangement example of packages during the transfer.

DETAILED DESCRIPTION
Hereinafter, an embodiment of the present disclosure will be described with reference to the accompanying drawings. In the description of the drawings, the same reference numerals denote the same components, and the repetitive description thereof will be omitted.
As illustrated in FIG. 1, a spinning machine (yarn winder) 1 includes a plurality of spinning units (yarn winding units) 2, a doffing truck 3, and a package transfer system 100 configured to transfer and collect a package P discharged from each of the spinning units 2. For example, the spinning units 2 are arranged in a line. For example, each spinning unit 2 produces a fiber bundle by drafting slivers (fiber bundles), produces a yarn by twisting the fiber bundle with a swirling air flow, and forms the package P by winding the yarn around a bobbin B. The doffing truck 3 can move along the arrangement direction of the spinning units 2. When a fully loaded package P is formed in a certain spinning unit 2, the doffing truck 3 discharges the fully loaded package P from the spinning unit 2, and supplies an empty bobbin B to the spinning unit 2.
The package transfer system 100 includes a conveyor 10 configured to transfer a plurality of the packages P placed on a transfer surface 11a in a transfer direction D, a drive unit 20 configured to drive the conveyor 10, and a control device 30 configured to drive the conveyor 10 by controlling the drive unit 20. As illustrated in FIG. 1 and FIG. 2, the conveyor 10 is arranged in the vicinity of the spinning units 2. For example, the transfer direction D of the conveyor 10 is parallel to the arrangement direction of the spinning units 2. Moreover, in the present specification, a "transfer device" means both or one of the conveyor 10 and the drive unit 20.
The conveyor 10 includes one belt part (transfer unit) 11 extending endlessly, a pulley 12 provided on a first end of the belt part 11, a pulley 14 provided on a second end of the belt part 11, and an operation unit 13 provided on an appropriate position operable by an operator. The transfer surface 11a is the surface of the belt part 11. For example, the belt part 11 forms a transfer path 10X longer than the total unit length L in which the spinning units 2 are installed. The pulley 12 is located on the upstream side of the most upstream spinning unit 2 among the spinning units 2. The pulley 14 is located on the downstream side of the most downstream spinning unit 2 among the spinning units 2. The first end of the belt part 11 provided with the pulley 12 is the upstream end of the transfer path 10X. The second end of the belt part 11 provided with the pulley 14 is the downstream end of the transfer path 10X. The transfer path 10X is a path from the upstream end to the downstream end of the conveyor 10. In the present specification, unless otherwise specified, the terms "upstream" and "downstream" are based on the transfer direction D of the conveyor 10.
For example, in the conveyor 10, the pulley 12 is a drive pulley and the pulley 14 is a driven pulley. The pulley 12 and pulley 14 rotate around a horizontal rotating shaft perpendicular to the transfer direction D. In addition to the above, the conveyor 10 may also include other members such as frames, shafts, V-belts, rubber bushes, other elastic members, and the like. As the configuration of the conveyor 10, any other configuration may be employed.
For example, the drive unit 20 is an electric motor. An output shaft of the drive unit 20 is connected to the pulley 12. The drive unit 20 is controlled by the control device 30, and causes the belt part 11 of the conveyor 10 to circulate (move). In other words, the belt part 11 is driven by one unit of the drive unit 20. The drive unit 20 causes the conveyor 10 to run in the transfer direction D, thereby transferring the package P placed on the transfer surface 11a. In the present specification, "to cause the conveyor 10 to run" or the "conveyor 10 runs" means that the belt part 11 is circulating (moving).
A package collection unit 16 for collecting the package P is provided on the downstream end of the conveyor 10. The package collection unit 16 is a portion for collecting the package P transferred by the conveyor 10. A terminal position P0 and a deceleration start position P2 are set on the downstream side of the conveyor 10. The terminal position P0 and the deceleration start position P2 are set on the transfer surface 11a. The terminal position P0 is set in the vicinity of the downstream end of the transfer path 10X. Each package P is transferred up to the terminal position P0. When each package P arrives at the terminal position P0, the conveyor 10 stops driving, and the package P is collected by the package collection unit 16. That is, the conveyor 10 stops when each package P arrives at the terminal position P0. In the package collection unit 16, the package P may be manually picked up by the operator, or the package P may be automatically picked up by a collection device (not illustrated).
For example, the operation unit 13 includes a button, a lever, or the like operated by the operator, and switches or the like. The operation unit 13 is operated to cause the conveyor 10 to start transferring the package P. Moreover, the operation unit 13 is operated to cause the conveyor 10 to stop transferring the package P. In this manner, in the package transfer system 100, the transfer does not start on the basis of the placement status of the package P on the conveyor 10 and the like, but the transfer starts according to the operation of the operation unit 13. The operation unit 13 may be a touch operation unit provided on a touch panel display or a monitor such as a liquid crystal display.
In the package transfer system 100, the operation unit 13 is operated at an appropriate timing to start transferring and collecting the package P. Consequently, the downstream processes can be advantageously and easily coped with. For example, if the processing in the downstream process is proceeding fast, the package P can be collected at any time by operating the operation unit 13. In the conventional systems, the transfer sometimes starts only when the number of packages P on the conveyor reach a certain number. Compared to the conventional control such as the above, the control in the package transfer system 100 is advantageous in terms of transfer efficiency.
In the package transfer system 100, the control device 30 can change the transfer speed of the conveyor 10. More specifically, the rotation speed of the drive unit 20 per unit time can be controlled and changed by the control device 30. For example, the drive unit 20 includes an inverter, and can change the rotation speed per unit time by changing the frequency. The variable control of transfer speed by the drive unit 20 may be implemented by other known configurations in addition to the inverter.
In the conveyor 10, the package P is transferred at a predetermined (variable) transfer speed. However, when the package P is detected at the deceleration start position P2, the transfer speed of the conveyor 10 is decelerated. For example, the transfer speed after the package P is detected at the deceleration start position P2 may be the minimum speed (minimum speed Vmin, which will be described below) within the variable range of the transfer speed of the conveyor 10 when the conveyor 10 transfers the package P. The "variable range of the transfer speed of the conveyor 10" means the range of transfer speed when the conveyor 10 is transferring the package P, and for example, means the speed range illustrated in FIG. 4 (which will be described below).
On the side of the belt part 11, a terminal sensor 17 is installed at a position corresponding to the terminal position P0, and a deceleration sensor 18 is installed at a position corresponding to the deceleration start position P2. The deceleration start position P2 is located on the downstream side of a most downstream position P1 in the row of the spinning units 2, and is also located on the upstream side of the terminal position P0. That is, the conveyor 10 includes the deceleration sensor 18 arranged on the downstream side of the spinning units 2 in the transfer direction D, and the terminal sensor 17 arranged on the downstream side of the deceleration sensor 18 in the transfer direction D.
The terminal sensor 17 and the deceleration sensor 18 each transmits a detection signal to a drive control unit 35 of the control device 30. For example, during transfer, the drive control unit 35 may also determine whether the non-detection time during which the package P is not detected by the deceleration sensor 18 exceeds the time required for transferring the package P from the deceleration start position P2 to the terminal position P0 at the current transfer speed.
For example, the distance from the deceleration start position P2 to the terminal position P0 can be determined on the basis of the transfer speed. When the package P is detected by the deceleration sensor 18 at the deceleration start position P2, the control device 30 decelerates the conveyor 10. Moreover, when the package P is detected by the terminal sensor 17 at the terminal position P0, the control device 30 stops the conveyor 10 to prevent the package P from falling. Therefore, the distance described above is the distance that can allow the conveyor 10 to decelerate from the transfer speed (maximum speed) at the deceleration start position P2 to the minimum speed at the terminal position P0. The acceleration during deceleration (in this case, the acceleration is negative with respect to the transfer direction D) may be constant or may vary. When the acceleration changes, the distance described above may vary depending on how the acceleration changes. The "minimum speed" is the speed at which the package P can be stopped at the terminal position P0 without falling, in the deceleration control toward a stop. In other words, when the package P is detected by the terminal sensor 17 at the terminal position P0, the control device 30 stops the conveyor 10 from the minimum speed.
In the package transfer system 100, when the conveyor 10 starts transferring the package P, the presence of the package P between the deceleration start position P2 and the terminal position P0 (that is, between the deceleration sensor 18 and the terminal sensor 17) is confirmed. When the conveyor 10 starts transferring the package P, one or more packages P that may be present between the deceleration start position P2 and the terminal position P0, may be the packages P that may have remained after the previous collection operation.
Next, a configuration according to the drive control of the conveyor 10 will be described. The control device 30 can communicate with the drive unit 20 by wired or wireless communication. As illustrated in FIG. 2, the control device 30 includes a transfer information acquisition unit 31, a weight estimation unit (control unit) 32, a storage unit 33, a transfer speed determination unit 34, and the drive control unit (control unit) 35. The control device 30 may be formed of one or more computers. The control device 30 includes a processor such as a CPU (Central Processing Unit), a main storage unit, an auxiliary storage unit, a communication control unit, an input device, and an output device. For example, the main storage unit includes a ROM (Read Only Memory), a RAM (Random Access Memory), and the like. For example, the auxiliary storage unit includes a hard disk or a flash memory, and in general, stores a larger amount of data than the main storage unit. The auxiliary storage unit stores a computer program for causing at least one computer to function as the control device 30. For example, the communication control unit includes a network card or a wireless communication module.
Each functional component of the control device 30 is implemented by causing the processor or the main storage unit to read a computer program and execute the computer program. The transfer information acquisition unit 31 acquires transfer information related to the weight of the package P placed on the conveyor 10. For example, the transfer information is information related to at least one of the total weight of the packages P placed on the conveyor 10, the number of packages P placed on the conveyor 10, the number of times the packages P are doffed after the previous collection operation of the conveyor 10, and the load of the drive unit 20.
For example, when the total weight of the packages P placed on the conveyor 10 is used as the transfer information, for example, a weight scale (measuring device) is provided on the conveyor 10. The transfer information acquisition unit 31 acquires information related to the weight of the package P from this weight scale. For example, when the number of packages P placed on the conveyor 10 is used as the transfer information, the transfer information acquisition unit 31 acquires a discharge signal of the package P from the doffing truck 3 or a discharge signal of the package P from each spinning unit 2, and adds up (accumulates) the number of times the discharge signal is discharged, after the previous collection operation. When the number of times the packages P are doffed after the previous collection operation is used as the transfer information, the transfer information acquisition unit 31 also acquires a discharge signal of the package P from the doffing truck 3, and adds up (accumulates) the number of times the discharge signal is discharged, after the previous collection operation.
For example, when the number of packages P placed on the conveyor 10 is used as the transfer information, the number of times the packages P are detected by the terminal sensor 17 (or another sensor corresponding thereto) needs to be counted. This is because not all packages P remaining on the conveyor 10 are necessarily collected at the previous collection time. Therefore, when the number of packages P is used as the transfer information, the difference is obtained by subtracting the number of times the packages P are detected by the terminal sensor 17 from the number of packages P, and the difference needs to be added to the number of packages P in the next transfer information. If all the packages P placed on the conveyor 10 are always picked up by the operator, there is no need to count the number of times the packages P are detected.
For example, when the load of the drive unit 20 is used as the transfer information, the operation unit 13 obtains the motor current at the minimum speed within the variable range of the transfer speed of the conveyor 10 (minimum speed Vmin, which will be described below). For this purpose, the control device 30 is electrically connected to the drive unit 20 and can obtain motor current. For example, up to a certain period of time t1 illustrated in FIG. 5A and FIG. 5B, the conveyor 10 is driven at the minimum speed. The current value is obtained before reaching the certain period of time t1. The motor output (W) may also be obtained instead of the motor current, as the load (transfer information) of the drive unit 20.
The storage unit 33 stores the transfer information obtained by the transfer information acquisition unit 31. In addition to the transfer information, for example, the storage unit 33 also stores a maximum weight of the packages P that can be transferred by the conveyor 10 (hereinafter, the weight will be called “the maximum weight of the packages P”). For example, the maximum weight of the packages P is the product of the total number of the spinning units 2 and the heaviest weight (package weight) of the package P that can be formed by each spinning unit 2 when the number of packages P placed on the conveyor 10 corresponds to the total number of the spinning units 2. The heaviest weight (package weight) of the package P is the maximum capacity of the spinning machine 1. That is, the heaviest weight (package weight) of the package P is the capacity of the device that is taken into account at the time of designing, and is the weight of the package P when the package P is formed by a specific type of yarn at a specific winding length. Alternatively, for example, the maximum weight of the packages P may be the number corresponding to the total number of the spinning units 2. In reality, the unit weight of the package P differs depending on the lot. However, it is possible to assume that the unit weight of the package P has reached the heaviest weight (package weight) of the package P.
The weight estimation unit 32 obtains the weight of the package P placed on the conveyor 10 on the basis of the acquired transfer information. The weight estimation unit 32 may also estimate the weight of the package P placed on the conveyor 10 on the basis of the acquired transfer information. For example, if a weight scale (measuring device) is provided on the conveyor 10, and the weight of the package P is used as the transfer information, the weight estimation unit 32 may directly use the acquired weight value as the estimated weight. In this case, it is possible to say that the estimated weight is the measured weight. When the number of packages P placed on the conveyor 10 and/or the number of times the packages P are doffed after the previous collection operation of the conveyor 10 are used as the transfer information, the weight estimation unit 32 calculates the estimated weight of the packages P on the conveyor 10 by multiplying the weight of one package P by the number of packages P or the number of times the packages P are doffed. The weight of one package P used in this case may be the weight calculated on the basis of the weight per unit length of the yarn wound around the package P and the length of the yarn wound around the package P. Alternatively, the unit weight of the fully loaded package P may also be used to simplify the calculation. The weight estimation unit 32 stores the relation (for example, conversion formula and the like) between the current value of the motor current at the minimum speed of the conveyor 10 (minimum speed Vmin, which will be described below) and the package P on the conveyor 10. When the load of the drive unit 20 is used as the transfer information, the weight estimation unit 32 uses this relation to calculate the estimated weight of the package P on the conveyor 10. Two or more types of information among the four types of information described above may be used in combination. In this case, the calculation method of the estimated weight can be appropriately combined by obtaining an average value and the like.
The transfer speed determination unit 34 determines the transfer speed of the conveyor 10 on the basis of the estimated weight of the package P on the conveyor 10. The transfer speed determination unit 34 determines (changes) the transfer speed at regular intervals, after the conveyor 10 starts transferring the package P. For this purpose, for example, the storage unit 33 stores the relation (for example, conversion formula and the like) between the estimated weight and the transfer speed. The storage unit 33 stores speed information indicating the transfer speed defined according to the transfer information. The storage unit 33 may also store speed information indicating the transfer speed defined in stages according to the transfer information. The transfer speed relative to the weight of the package P may be stored in a table format. That is, the storage unit 33 may store a plurality of division ranges classified into a plurality of divisions related to the transfer information that is classified into a plurality of divisions, and speed information indicating the transfer speed defined by associating with each of the division ranges. The transfer speed determination unit 34 determines the transfer speed by referring to the speed information and selecting the transfer speed associated with the division range to which the acquired transfer information belongs, on the basis of the transfer information.
For example, as illustrated in FIG. 4, the transfer speed of the conveyor 10 may decrease with an increase in the estimated weight. The transfer speed of the conveyor 10 has an appropriate variable range according to the selected drive unit 20 and the like. For example, the variable range of the transfer speed is in the range between the minimum speed Vmin or more and the maximum speed Vmax or less. In the example illustrated in FIG. 4, the maximum speed Vmax corresponds to the minimum weight Wmin, and the minimum speed Vmin corresponds to the maximum weight Wmax (maximum weight of the packages P). The transfer speed of the conveyor 10 is changed in a stepless manner according to the estimated weight. The minimum speed Vmin is not zero, but has a positive value.
In the variable control of the transfer speed by the control device 30, the transfer speed need not gradually change according to the estimated weight as illustrated in FIG. 4, but the transfer speed may also change in stages according to the estimated weight. That is, the transfer speed may vary in multiple stages according to the transfer information. The transfer speed of the conveyor 10 may change in a linear manner (linearly) according to the estimated weight. The relation of the transfer speed according to the estimated weight may be different from that described above.
The drive control unit 35 controls the drive unit 20 so as the conveyor 10 runs at the transfer speed determined by the transfer speed determination unit 34. That is, the transfer speed determination unit 34 and the drive control unit 35 change the transfer speed of the conveyor 10 on the basis of the transfer information obtained by the transfer information acquisition unit 31.
Next, with reference to FIG. 3, the drive control of the conveyor 10 in the package transfer system 100 will be described. First, the operation unit 13 is operated to supply a transfer start signal to the control device 30 (step S01). Next, the transfer information acquisition unit 31 acquires transfer information (step S02). Next, the weight estimation unit 32 estimates the transfer weight on the conveyor 10 (step S03). Between step S02 and step S03, the transfer speed determination unit 34 may drive the conveyor 10 for a certain period of time at the confirmation speed equal to the minimum speed Vmin, to confirm the presence of the package P between the deceleration start position P2 and the terminal position P0. During this period, when the package P is detected at the terminal position P0, the conveyor 10 is stopped. The certain period of time t1 may be set equal to or greater than the time required for the belt part 11 to move the distance from the deceleration start position P2 to the terminal position P0 at the minimum speed Vmin. The certain period of time t1 may be shorter than the time required for the belt part 11 to move the distance from the deceleration start position P2 to the terminal position P0. If the package P is placed in the vicinity of the downstream side of the deceleration start position P2, such a short certain period of time t1 may be set from the viewpoint of efficiency.
The weight estimation unit 32 calculates the estimated weight on the basis of the transfer information using the method described above. Moreover, the transfer speed determination unit 34 determines the transfer speed of the conveyor 10 (step S04). The transfer speed determination unit 34 determines the transfer speed on the basis of the transfer information and the speed information stored in the storage unit 33. The transfer speed obtained at step S04 is the speed for transferring the package P that is located at the most downstream position known by the system, to the deceleration start position P2.
For example, at step S04, if the estimated weight from the transfer information matches the maximum weight Wmax, the transfer speed of the conveyor 10 is set to the minimum speed Vmin. The drive control unit 35 controls the drive unit 20 so as the conveyor 10 runs at the transfer speed determined by the transfer speed determination unit 34 (step S05). If the maximum weight of the packages P is the number corresponding to the total number of spinning units 2 as described above, the maximum weight Wmax is simply the number of spinning units 2 (the weight factor is excluded). When the number of packages P placed on the conveyor 10 matches the number of spinning units 2 (that is, the number corresponding to the total number of spinning units 2), the transfer speed of the conveyor 10 is set to the minimum speed Vmin.
For example, the control device 30 executes steps S02 to S05 described above at regular intervals, from when a transfer start signal is supplied (step S01) to when a transfer end signal is supplied (step S06). For example, the regular interval is every time a certain number of packages P are discharged, or at every certain time. Moreover, if the package P is not detected at the terminal position P0, the control device 30 may execute steps S02 and S03 to estimate (reacquire) the weight again. For example, the control device 30 can obtain the distance of the successive packages P on the basis of the space between the spinning units 2. The control device 30 drives the conveyor 10 while the packages P are continuously detected. However, if the package P is not detected, the control device 30 may estimate (reacquire) the weight again.
In the present embodiment, for example, as illustrated in FIG. 5A, the transfer speed may be changed once when the certain period of time t1 has passed from when the transfer is started. Moreover, as illustrated in FIG. 5B, the transfer speed may be changed to increase gradually after the certain period of time t1 has passed from when the transfer is started. In FIG. 5A and FIG. 5B, only the transfer speed of the package P (speed for transferring the package P located at the most downstream position to the deceleration start position P2) is illustrated, and the deceleration of the conveyor 10 (deceleration to a stop) triggered by the detection of the package P by the deceleration sensor 18 is omitted.
Returning to FIG. 3, at the stage when all the packages P on the conveyor 10 are collected, the operation unit 13 is operated to supply a transfer end signal to the control device 30 (step S06). Then, the drive control unit 35 stops the conveyor 10 by controlling the drive unit 20. Through the series of processes described above, the drive control (transfer control) of the conveyor 10 is executed by the control device 30. When the transfer end operation is performed by the operation unit, the doffing truck 3 can perform doffing. In the package transfer system 100, a period of time from the start of transfer to the end of transfer corresponds to one transfer (that is, one collection operation).
The operation unit 13 need not be operated to end the transfer of the conveyor 10. The transfer end operation by the operation unit 13 may not be required. When the belt part 11 has moved the length corresponding to the total unit length L of the spinning units 2 (see FIG. 1), the control device 30 may end the transfer by assuming that all packages P have been picked up. Alternatively, the control device 30 may count the number of packages P discharged by the doffing truck 3 (discharge number), drive the conveyor 10 until the accumulated number of packages P that have passed the deceleration start position P2 (or the most downstream position P1) reaches the discharge number, and end the transfer after the last package P has reached the most downstream position P1. According to these controls, the transfer end operation is not required.
Depending on the operator, a predetermined working time (for example, an hour) may be set in advance. In such a case, when the working time has elapsed, the operation unit 13 is operated to end the transfer.
According to the package transfer system 100 of the present embodiment, the transfer speed of the conveyor 10 can be changed by the transfer speed determination unit 34 and the drive control unit 35, on the basis of the transfer information related to the weight of the package P placed on the conveyor 10. For example, the conveyor 10 can be driven at a relatively low speed when the transfer weight is high, and the conveyor 10 can be driven at a relatively high speed when the transfer weight is low. Thus, the drive unit 20 can be operated in an efficient manner, thereby improving the transfer efficiency of the conveyor 10. Moreover, it is possible to prevent the size of the transfer device (for example, a capacity of the drive unit 20, the belt part 11, and the like) from becoming excessive, and reduce the size of the transfer device compared to that of the conventional systems.
Originally, in the spinning machine 1, the timing at which the package P is fully loaded in each spinning unit 2 varies, because the spinning machine 1 is stopped to wait for the doffing truck 3 (wait for an AD) at the first start-up and the like, and is stopped by a red light. Moreover, when the conveyor 10 is in operation, the doffing operation cannot be carried out even if the package P is fully loaded, and a waiting time can occur. According to the package transfer system 100 of the present embodiment, the package P can be collected in a short period of time. Accordingly, the working hours of the operator can be reduced. Moreover, by determining the reference speed (upper limit value) such as a certain speed or less if the mount weight is large, the capacity of the drive unit 20 can be reduced. Furthermore, even when the package P with the maximum weight is placed on the conveyor, the package P can still be transferred.
Still furthermore, according to the package transfer system 100, the transfer information is information related to at least one of the total weight of the packages P placed on the conveyor 10, the number of packages P placed on the conveyor 10, the number of times the packages P are doffed after the previous operation of the conveyor 10, and the load of the drive unit 20. Thus, the transfer information more accurately reflects the weight of the package P transferred by the conveyor 10. Thus, the transfer speed determination unit 34 and the drive control unit 35 can appropriately determine the transfer speed of the conveyor 10.
When the transfer information matches the maximum weight Wmax, the transfer speed determination unit 34 and the drive control unit 35 causes the conveyor 10 to run at the minimum speed Vmin. The size of the transfer device can be further optimized, by causing the conveyor 10 to run at the minimum speed Vmin according to the maximum weight Wmax.
The transfer speed determination unit 34 and the drive control unit 35 cause the conveyor 10 to run at the confirmation speed equal to the minimum speed Vmin, to confirm the presence of the package P between the deceleration sensor 18 and the terminal sensor 17. The presence of the package P can be confirmed with certainty, by causing the conveyor 10 to run at the confirmation speed equal to the minimum speed Vmin. When the transfer speed is determined on the basis of the transfer information, it may not be possible to identify the location of the package P with respect to the transfer direction D of the conveyor 10. For example, there may be a case when the operator places the package P on an appropriate position while the conveyor 10 is stopped. When the package P placed by the operator is located in the vicinity of the terminal sensor 17, the package P may pass the terminal sensor 17 if the transfer speed is relatively high. Therefore, at the time immediately after the transfer is started, the package P can be transferred more safely, by confirming the presence of the package P at the confirmation speed.
On the basis of the transfer information, the weight estimation unit 32 obtains the weight of the package P placed on the conveyor 10, and the transfer speed determination unit 34 decreases the transfer speed with an increase in the obtained weight. Consequently, it is possible to cause the conveyor 10 to run at the transfer speed according to the transfer weight.
The storage unit 33 stores the division ranges classified into divisions related to the transfer information and the speed information (for example, information in a table format) indicating the transfer speed defined by associating with each of the division ranges. The transfer speed determination unit 34 determines the transfer speed by referring to the speed information and selecting the transfer speed associated with the division range to which the acquired transfer information belongs, on the basis of the transfer information. In this case, by referring to the speed information, the transfer speed determination unit 34 can appropriately determine the transfer speed through a relatively simple control. For example, if the transfer speed relative to the weight of the package P is stored in a table format, the control becomes simpler.
In the conveyor 10, the operation unit 13 is operated to cause the conveyor 10 to start transferring the package P. Thus, it is possible to start the transfer, regardless of the state (number or density) of the package P placed on the conveyor 10.
The conveyor includes the belt part 11 forming the transfer path 10X longer than the total unit length L of the spinning units 2 (see FIG. 1), and the belt part 11 is driven by one unit of the drive unit 20. With this configuration, the structure of the transfer device is simplified.
While the embodiment of the present disclosure has been described above, the present invention is not limited to the embodiment described above.
The transfer information may be information related to the location of the package P placed on the conveyor 10. In this case, the transfer speed determination unit 34 and the drive control unit 35 change the transfer speed according to the location of the package P on the conveyor 10. Specifically, the transfer speed determination unit 34 and the drive control unit 35 may change the transfer speed according to the distance between the deceleration sensor 18 or the terminal sensor 17 and the package P located at the most downstream. Consequently, the transfer efficiency is improved. Alternatively, the transfer speed determination unit 34 and the drive control unit 35 may take the interval between the package P located at the most downstream and the subsequent package P located upstream of the package P, and the acceleration time of transfer speed into consideration, and if the acceleration time is shorter than a predetermined acceleration time, may not change the transfer speed. That is, the conveyor 10 need not be accelerated. Consequently, because the frequency of acceleration and deceleration is reduced, the load on the drive unit 20 will be reduced. The life of the drive unit 20 can be extended. By controlling the speed according to the location of the package P, the control device 30 can appropriately determine the transfer speed of the conveyor 10, while taking the location of the package P into consideration.
Moreover, the transfer speed determination unit 34 and the drive control unit 35 may change the transfer speed according to the weight of the package P and the location of the package P on the conveyor 10. In this case, the transfer speed determination unit 34 and the drive control unit 35 may preferentially use the location of the package P over the weight of the package P in controlling the transfer speed. That is, in controlling the transfer speed, the interval between the adjacent packages P or the location of each package P may be preferentially used over the weight of the package P. There may be a case when acceleration or deceleration is not desirable. When the location of the package is preferentially used, a smooth transfer is possible on the whole.
For example, if the package P located at the most downstream is a predetermined distance away from the deceleration start position P2, the transfer speed determination unit 34 may set the speed faster than the speed defined by the normal transfer information. Moreover, the transfer information acquisition unit 31 may manage the successive packages P as a group, on the basis of a discharge signal of the package P from the doffing truck 3, and the transfer speed determination unit 34 may recalculate the transfer speed when the group changes.
Furthermore, when at least one package P passes the deceleration start position P2 and the conveyor 10 decelerates to a stop, the control device 30 may take the location of each package P into consideration. For example, as illustrated in FIG. 6A, a package PA and a package PB are approaching the deceleration start position P2. Next, as illustrated in FIG. 6B, when the package PA is picked up and the package PB is detected by the deceleration sensor 18, the conveyor 10 is driven at the minimum speed Vmin. Next, as illustrated in FIG. 6C, no package P is detected by the deceleration sensor 18 before the package PB is detected by the terminal sensor 17. In this situation, when the package PB is collected, in the normal control in which the location of each package P is not taken into consideration, the conveyor 10 is accelerated to the speed faster than the minimum speed Vmin. However, there may be a case when the distance between a package PC and the deceleration sensor 18 is halfway distance. In this case, the "halfway distance" is defined by the acceleration of the conveyor 10. Consequently, as soon as the conveyor 10 is accelerated, the conveyor 10 is controlled to the minimum speed Vmin again. Thus, in this case, from the viewpoint of energy saving and preventing the package P from falling, the control device 30 may maintain the minimum speed Vmin without accelerating the conveyor 10.
Moreover, two conveyors may be provided for the total unit length L in which the multiple yarn winding units are installed. For example, the two conveyors are arranged in the transfer direction D. In this case, the transfer path of the package P is formed by the two conveyors, that is, by the two belt parts. That is, two drive units may be provided in the transfer path of the package P. The speed control by the control device 30 may also be performed by estimating (or measuring) the transfer weight of each of the packages P (at two locations) placed on each conveyor. According to this configuration, the package P can also be collected from the conveyor at the upstream side, thereby allowing what is called front packing. In more detail, in the section from the deceleration start position P2 to the terminal position P0, the conveyor 10 is often driven at the minimum speed Vmin. Therefore, by separating the conveyors on the upstream side of the deceleration start position P2, the effect of the front packing is increased. However, in this case, a sensor is required to stop (or decelerate) the conveyor on the upstream side. For example, a sensor may be provided on the most downstream position P1 and separate the conveyors.
The operation unit 13 need not necessarily be operated to start the transfer. For example, when the package collection unit 16 is a package packing device or the like, the transfer may be started when the device is ready.
In the conveyor 10, the operation unit 13 may be omitted. Alternatively, one or both of the terminal sensor 17 and the deceleration sensor 18 may be omitted. Even in such a case, it may be possible to cause the conveyor 10 to run at the confirmation speed equal to the minimum speed Vmin, only for the certain period of time t1. When one or both of the terminal sensor 17 and the deceleration sensor 18 are omitted or the like, the operator may operate the operation unit 13 to stop and start driving the conveyor 10.
Moreover, between step S02 and step S03, the conveyor 10 need not be run at a low speed to confirm the presence of the package P between the deceleration start position P2 and the terminal position P0, and the control device 30 may sequentially perform step S02 to step S05 immediately after the transfer is started.
The control unit may also drive the conveyor 10 at the confirmation speed that changes according to the weight of the package P placed on the conveyor 10, to confirm the presence of the package P between the deceleration sensor 18 and the terminal sensor 17. For example, the control unit increases (speeds up) the confirmation speed with a decrease in the weight of the package P placed on the conveyor 10. The package P placed on the conveyor 10 hardly rolls with a decrease in the weight of the package P. Hence, it is possible to increase the confirmation speed. “The weight of the package P” may be the weight of only the package P located at the most downstream of the conveyor 10.
An example will be described in which two or more types of information among the four types of transfer information described above are used in combination. As described above, for example, the transfer information is information related to at least one of the total weight of the packages P placed on the conveyor 10, the number of packages P placed on the conveyor 10, the number of times the packages P are doffed after the previous collection operation of the conveyor 10, the load of the drive unit 20, the density of the packages P on the conveyor 10, and the location of the package P placed on the conveyor 10. For example, the control device 30 obtains the weight of the package P placed on the conveyor 10. Moreover, the control device 30 obtains the weight on the basis of the number of packages P placed on the conveyor 10. Then, the control device 30 calculates the average value of the weight obtained by the two methods, and sets the average value as the weight of the package P. The example has been described in which the average value is calculated using the first method and second method among the four types of transfer information. However, the example is not limited thereto. The average value may be calculated using any one of the four methods and any one of the other methods, or the average value may be calculated using three or more methods among the four methods. To change the transfer speed according to both of the weight of the package P and the location of the package P on the conveyor 10, the control device 30 may control the transfer speed using the weight of the package P and the location of the package P in parallel (equally). For example, the control device 30 may determine the reference speed on the basis of the weight information, and if the distance of the package P (distance away from the deceleration sensor 18 toward the upstream side) is far, the distance may be added to the reference speed.
In the embodiment described above, the control unit drives the conveyor 10 at the confirmation speed equal to the minimum speed Vmin applicable when the transfer information matches the maximum weight Wmax. However, the minimum speed within the variable range of the transfer speed of the conveyor 10 may be set regardless of whether the transfer information matches the maximum weight Wmax. The maximum weight Wmax may not be stored in the storage unit 33. Even in such a case, the control unit may drive the conveyor 10 at the minimum speed (this may be set appropriately) within the variable range of the transfer speed of the conveyor 10, to confirm for the presence of the package P between the deceleration sensor 18 and the terminal sensor 17.
In the embodiment described above, in one transfer, the transfer speed can be changed at least once after the certain period of time t1 has passed from when the transfer is started. However, the form (transfer control) is not limited thereto. Once the transfer speed of the conveyor is determined on the basis of the transfer information, the control unit may maintain the transfer speed. That is, one transfer speed may be determined per transfer. The transfer speed may be changed according to the change in the transfer information, every time the package P transferred by the conveyor 10 is collected.
When the transfer speed of the conveyor is determined on the basis of the transfer information, the control unit may determine the acceleration to the transfer speed, on the basis of the weight of the package P located at the most downstream of the conveyor 10. For example, the storage unit 33 stores the division ranges classified into divisions related to the weight of the package P and the correction value (for example, information in a table format) of the acceleration defined by associating with each of the division ranges. The transfer speed determination unit 34 determines the acceleration to the transfer speed, by adding or subtracting the correction value of the acceleration associated with the division range to which the acquired weight belongs, with respect to the reference acceleration. Moreover, the control unit may increase the acceleration of the conveyor 10, with an increase in the distance of the package P located at the most downstream of the conveyor 10 from the deceleration sensor 18 or the terminal sensor 17 to the upstream side. To decelerate the conveyor 10 (when the conveyor 10 is decelerated from the confirmation speed described above to zero speed), the control unit may increase the deceleration with a decrease in the weight of the package P placed on the conveyor 10.
The yarn winder may include the spinning units 2 arranged in two rows, and the conveyor 10 may be arranged between the two rows of spinning units 2 opposite to each other.
, Claims:We claim:

1. A package transfer system (100), comprising:
a plurality of yarn winding units (2) each forming a package (P);
a conveyor (10) being arranged in a vicinity of the yarn winding units (2), having a transfer direction (D) at least in an arrangement direction of the yarn winding units (2), and configured to temporarily accumulate the package (P) discharged from the yarn winding units (2) and transfer the package (P) to a discharge area;
a drive unit (20) configured to drive the conveyor (10);
a storage unit (33) configured to store transfer information related to weight of the package (P) placed on the conveyor (10) and/or a location of the package (P); and
a control unit (34, 35) configured to determine a transfer speed of the conveyor (10) based on the transfer information and control the drive unit (20) based on the determined transfer speed of the conveyor (10).

2. The package transfer system (100) as claimed in claim 1, wherein the transfer information is information related to at least one of total weight of the package (P) placed on the conveyor (10), number of the package (P) placed on the conveyor (10), number of times the package (P) is doffed after a previous operation of the conveyor (10), a load of the drive unit (20), density of the package (P) on the conveyor (10), and a location of the package (P) placed on the conveyor (10).

3. The package transfer system (100) as claimed in claim 2, wherein
the storage unit (33) stores maximum weight that is a product of number of the yarn winding units (2) and heaviest weight of a package (P) that is able to be formed by each of the yarn winding units (2) when the number of the package (P) placed on the conveyor (10) corresponds to total number of the yarn winding units (2), and
when the transfer information matches the maximum weight, the control unit (34, 35) causes the conveyor (10) to run at a minimum speed within a variable range in the transfer speed of the conveyor (10).

4. The package transfer system (100) as claimed in claim 3, wherein
the conveyor (10) includes a deceleration sensor (18) arranged on a downstream side of the yarn winding units (2) in the transfer direction (D), and a terminal sensor (17) arranged on a downstream side of the deceleration sensor (18) in the transfer direction (D), and
the control unit (34, 35) drives the conveyor (10) at a confirmation speed equal to the minimum speed, to confirm a presence of the package (P) between the deceleration sensor (18) and the terminal sensor (17).

5. The package transfer system (100) as claimed in claim 1 or 2, wherein
the conveyor (10) includes a deceleration sensor (18) arranged on a downstream side of the yarn winding units (2) in the transfer direction (D), and a terminal sensor (17) arranged on a downstream side of the deceleration sensor (18) in the transfer direction (D), and
the control unit (34, 35) drives the conveyor (10) at a minimum speed within a variable range of the transfer speed of the conveyor (10), to confirm a presence of the package (P) between the deceleration sensor (18) and the terminal sensor (17).

6. The package transfer system (100) as claimed in one of claims 1 to 5, wherein
the transfer information is information related to weight, and
the control unit (34, 35) decreases the transfer speed with an increase in the weight of the package (P) placed on the conveyor (10).

7. The package transfer system (100) as claimed in claim 1 or 2, wherein
the transfer information is information related to weight,
the conveyor (10) includes a deceleration sensor (18) arranged on a downstream side of the yarn winding units (2) in the transfer direction (D), and a terminal sensor (17) arranged on a downstream side of the deceleration sensor (18) in the transfer direction (D), and
the control unit (34, 35) drives the conveyor (10) at a confirmation speed that changes according to the weight of the package (P) placed on the conveyor (10), to confirm a presence of the package (P) between the deceleration sensor (18) and the terminal sensor (17).

8. The package transfer system (100) as claimed in one of claims 1 to 7, wherein
the storage unit (33) stores a plurality of division ranges classified into a plurality of divisions related to the transfer information, and speed information indicating the transfer speed defined by associating with each of the division ranges, and
the control unit (34, 35) determines the transfer speed by referring to the speed information and selecting the transfer speed associated with the division range to which the transfer information belongs, based on the transfer information.

9. The package transfer system (100) as claimed in one of claims 1 to 8, wherein the conveyor (10) includes an operation unit configured to start transfer on the conveyor (10).

10. The package transfer system (100) as claimed in one of claims 1 to 9, wherein the control unit (34, 35) changes the transfer speed according to the weight of the package (P) and the location of the package (P) on the conveyor (10), the control unit (34, 35) preferentially using the location of the package (P) over the weight of the package (P) in controlling the transfer speed.

11. The package transfer system (100) as claimed in one of claims 1 to 10, wherein
the conveyor (10) includes a belt part (11) forming a transfer path longer than a total unit length (L) in which the yarn winding units (2) are installed in the transfer direction (D), and
the belt part (11) is driven by one unit of the drive unit (20).

12. A package transfer method in a package transfer system (100) including: a conveyor (10) being arranged in a vicinity of a plurality of yarn winding units (2), having a transfer direction (D) at least in an arrangement direction of the yarn winding units (2), and configured to temporarily accumulate a package (P) discharged from the yarn winding units (2) and transfer the package (P) to a discharge area; and a drive unit (20) configured to drive the conveyor (10), the package transfer method, comprising
when controlling the drive unit (20) to cause the conveyor (10) to run, determining a transfer speed of the conveyor (10) based on transfer information related to weight of the package (P) placed on the conveyor (10) and/or a location of the package (P).