YARN ACCUMULATING DEVICE AND YARN WINDING DEVICE PROVIDED WITH THE
SAME
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a yarn accumulating device
adapted to accumulate a yarn, and a yarn winding device provided
with the yarn accumulating device.
2. Description of the Related Art
WO 2011/040545 discloses an automatic winder adapted to
rewind a yarn unwound from a yarn supplying bobbin while removing
a yarn defect such as slub to form a package. The automatic winder
of WO 2011/040545 includes various devices such as a yarn joining
device, a yarn accumulating device, and the like between the yarn
supplying bobbin and a package winding section adapted to wind the
yarn. The yarn joining device joins the yarn from the package and
the yarn from the yarn supplying bobbin at the time of replacing
the yarn supplying bobbin, after performing yarn cutting operation
to remove the yarn defect, and after occurrence of an unexpected
yarn breakage. The yarn accumulating device includes a rotating
yarn accumulating roller (rotating accumulating drum), and
temporarilyaccumulatesthe yarnthatisnotyetwoundintoapackage
by winding the yarn around the yarn accumulating roller.
In the above automatic winder, during the winding of the yarn
by the package winding section, the yarn accumulating roller of
the yarn accumulating device arranged between the yarn supplying
bobbin and the package winding section winds the yarn unwound from
the yarn supplying bobbin, and unwinds the yarn wound around the
yarn accumulating roller towards the package winding section. The
yarn accumulating roller rotates with a prescribed amount of yarn
wound therearound. The rotation of the yarn accumulating roller
is stopped when performing yarn joining operation by the yarn
joiningdevice. At the time ofthe yarn joining operation, although
2 / 25
the yarn is not supplied from the yarn supplying bobbin, since a
@ prescribed amount of yarn is accumulated in the yarn accumulating
roller, the yarn of the yarn accumulating roller is unwound and
wound by the package winding section. In this manner, the winding
of the yarn by the package winding section is continuously carried
out without being stopped even at the time of the yarn joining
operation.
The yarnaccumulatingdevice ofWO2011/040545 adopts amethod
of accumulating the yarn by winding the yarn around the rotating
yarn accumulating roller. If the winding speed of the package
I winding section is large, the yarn accumulated in the yarn
I accumulating device quickly runs out during the yarn joining
operation, and hence the yarn accumulating amount of the yarn
accumulating device is desirably large. However, the amount of
yarn that can be accumulated in the yarn accumulating device is
proportional to the size (outer diameter and length) of the yarn
accumulating roller. That is, the yarn accumulating roller needs
to be large in order to increase the yarn accumulating amount, which
consequently increases the inertia moment ofthe yarn accumulating
roller. In this case, it becomes difficult to quickly control the
I rotation of the roller, for example, the yarn accumulating roller
cannotbepromptlystoppedwhenstartingtheyarnjoiningoperation.
Alternatively, a large motor can be adopted to rotationally drive
the yarn accumulating roller, but this greatly increases the cost
and is also disadvantageous in terms of energy consumption.
1 BRIEF SUMMARY OF THE INVENTION
I An object of the present invention is to reduce a weight of
I the yarnaccumulating roller and realize a quickrotationalcontrol
I
of the yarn accumulating roller.
A yarn accumulating device according to a first aspect of the
invention relates to a yarn accumulating device for accumulating
a yarn, and the yarn accumulating device includes a cylindrical
yarn accumulating roller around which the yarn is wound by being
3 / 25
rotated, the yarn accumulating roller being formed of a non-metal
@ material having a smaller specific weight than that of iron.
According to the present invention, since the cylindrical
yarn accumulating roller is formed of a non-metal material having
a smaller specific weight than that of iron, the weight of the yarn
accumulating roller can be reduced compared to when being formed
of ametal material. Therefore, a prompt rotational control ofthe
yarn accumulating roller can be carried out without enlarging the
motor.
In the following, the present invention is illustrated with
more detail with regard to an embodiment disclosed in the enclosed
drawings.
Figure 1 is a side view of a winding unit of an automatic winder
according to the present invention;
figure 2 is a side view of a yarn accumulating device according
to the invention;
figure 3 is a cross sectional view in a plain including an axis
center ofthe yarn accumulating roller according tothe invention;
figure 4 is an enlarged cross-sectional view of an outer peripheral
portion of the yarn accumulating roller of figure 3; and
figure 5 is a flow chart showing the control of the package winding
operation including the yarn joining operation performed by the
unit control section according to the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
An embodiment of the pre%ent invention will be described below.
The present embodiment is an example in which the present invention
is applied to an automatic winder including a plurality of winding
units (yarn winding devices), adapted to wind a yarn unwound from
a yarn supplying bobbin to form a winding package. The automatic
winder has a configuration in which the plurality of winding units,
each forming one package, is arranged in a line in one direction.
FIG. 1 is a side view of one winding unit of the automatic winder.
As illustratedin FIG. 1, eachwindingunit lincludes abobbin
supplying device 2, a yarn supplying section 3, a package winding
section 4, and a unit control section 5 for controlling each section
of the winding unit 1. With the yarn supplying bobbin 8 supplied
from the bobbin supplying device 2 being held by the yarn supplying
section 3, the winding unit 1 winds a spun yarn Y unwound from the
yarn supplying bobbin 8 around a winding tube 6 while traversing
the spun yarn Y by the package winding section 4 to form a package
P of a predetermined shape.
The bobbin supplying device 2 includes a rotary magazine 10
capable of holding an extra supply of yarn supplying bobbins 8.
When the magazine 10 is intermittently rotated, one yarn supplying
bobbin 8 is dropped diagonally so that the yarn supplying bobbin
8 is supplied to the yarn supplying section 3.
The yarn supplying section 3 holds the yarn supplying bobbin
8 ina replaceablemanner. Specifically, the yarn supplyingbobbin
8 supplied from the bobbin supplying device 2 is held in a
substantially upright state by a bobbin holding tool (not
illustrated) inserted to a lower end of the yarn supplying bobbin
8. When the yarn of the yarn supplying bobbin 8 is all unwound
and the yarn supplying bobbin 8 becomes empty, the yarn supplying
section 3 can flip up the yarn supplying bobbin 8 by a springboard
11 to discharge the yarn supplying bobbin 8 outside the yarn
supplying section 3.
5 / 25
15, a lower yarn blow-up device 16, a tension applying device 17,
an upper yarn catching device 18, a yarn j o i n i n g d e v i c e 19, a yarn
t r a p 2 0 , a c l e a r e r 2 1 , andayarnaccumulatingdevice 22 a r e arranged
i n t h i s order from the yarn supplying s e c t i o n 3.
The unwinding a s s i s t i n g device 15 lowers a t u b e body 30, which
covers anupper e n d o f t h e yarn supplyingbobbin 8, withadvancement
t
i n the unwinding of the yarn Y t o r e g u l a t e bulging (balloon) of
the y a r n y d u r i n g t h e unwindingandstabilizethe unwindingtension.
I The lower yarn blow-up device 16 is connected t o a compressed
a i r source (not i l l u s t r a t e d ) , and is configured t o generate an
upward a i r f l o w a t the time of the yarn joining operation t o blow
up a lower yarn Y2 from the yarn supplying bobbin 8 towards the
yarn joining device 19.
The tension applying device 17 is adapted t o apply a
predeterminedtension on t h e t r a v e l l i n g yarn Y. The tension device
17 may be, f o r example, a gate-type which includes fixed comb t e e t h
and movable comb t e e t h movably arranged with respect t o the fixed
comb t e e t h .
The upper yarn catching device 18 is connected t o a negative
pressure source (not i l l u s t r a t e d ) , and is adapted t o generate a
suction a i r f l o w d u r i n g t h e yarn j o i n i n g o p e r a t i o n t o suck and catch
an upper yarn Y 1 from the yarn accumulating device 22 guided by
a guide member 32, t o be described l a t e r . ~ The yarn t r a p 20 is connected t o the negative pressure source
, (not i l l u s t r a t e d ) , and catches the lower yarn Y2 blown up by the ~
lower yarn blow-up device 16 a t the time of t h e yarn joining
operation.
The yarn joining device 19 j o i n s the lower yarn Y2 from the
yarn supplying bobbin 8 and the upper yarn Y 1 from the winding s i d e
(yarn accumulating device 22) a t the time of r e p l a c i n g the yarn
supplying bobbin 8, a f t e r yarn cut c a r r i e d out when the c l e a r e r
21, described l a t e r , d e t e c t s a yarn d e f e c t , or a f t e r yarn breakage
during the unwinding of the yarn from the yarn supplying bobbin
8. The yarn j o i n i n g d e v i c e 19 may be the yarn joining device 19
( a i r s p l i c e r ) including an untwisting nozzle adapted t o untwist
the yarn end of the upper yarn Y 1 and the yarn end of the lower
yarn Y2, and a t w i s t i n g nozzle adapted t o apply a whirling a i r f l o w
on the untwisted yarn ends t o t w i s t the yarn ends t o g e t h e r .
The c l e a r e r 21 (yarn d e f e c t d e t e c t i n g device) is arranged on
the yarn t r a v e l l i n g path between the yarn supplying s e c t i o n 3 and
the yarn accumulating device 22, and d e t e c t s a yarn d e f e c t such
as slub of the yarn Y t r a v e l l i n g through the yarn t r a v e l l i n g path.
The c l e a r e r 21 is provided with a c u t t e r 31 (yarn c u t t i n g s e c t i o n )
adapted t o c u t t h e yarn when t h e c l e a r e r 21 d e t e c t s t h e yarn d e f e c t .
The s u b s t a n t i a l l y t u b u l a r guide member 32 is arranged on the
s i d e of the yarn joining device 19 between the upper yarn catching
device 18 and the yarn accumulating device 22 so a s t o circumvent
a l i n e a r yarn t r a v e l l i n g path during t h e normal winding.
Furthermore, a s l i t 32a is formed over the e n t i r e length of the
guide member 32 i n a s i d e wall ( l e f t s i d e i n the f i g u r e ) of the
I
guide member 32.
I
I A t the t i m e of the yarn j o i n i n g o p e r a t i o n , the upper yarn Y 1
from the yarn accumulating device 22 is p u l l e d o u t by an upper yarn
I pull-out device 42 of the yarn accumulating device 22, t o be
I described l a t e r , and fed t o the guide member 32, and the yarn end
of the upper yarn Y 1 is passed through the guide member 32 t o be
~ caught by the upper yarn c a t c h i n g d e v i c e 18. Furthermore, when the
1 yarn is pulled by the upper yarn catching device 18, the yarn is
p u l l e d o u t t o the outside of the guide member 32 from the s l i t 32a
and guided t o the yarn joining device 19. The lower yarn Y2 from
theyarnsupplyingbobbin 8 isblownupwardbytheloweryarnblow-up
I device 16. Moreover, the blown-up yarn is caught and pulled by the
I
yarn t r a p 20 t o be guided t o the yarn joining device 19. After the
upper yarn Y 1 and the lower yarn Y2 a r e set i n the yarn joining
device 19 i n t h i s manner, the yarn joining device 19 j o i n s the upper
yarn Y 1 and the lower yarn Y2.
7 / 25
A l t h o u g h n o t i l l u s t r a t e d , the yarn joining device 1 9 i n c l u d e s
@ a c u t t e r adapted t o cut the ends of the guided upper yarn Y 1 and
the lower yarn Y2. The yarn d e f e c t i n the upper yarn Y 1 is removed
a t the t i m e of the c u t t i n g operation performed by the c u t t e r i n
the yarn j o i n i n g o p e r a t i o n when t h e yarn d e f e c t is d e t e c t e d . A f t e r
t h e c u t t i n g operation, the yarn ends of the upper yarn Y 1 and the
lower yarn Y2 a r e joined.
I n t h e present embodiment, a device group such as the lower
yarn blow-up device 16, the upper yarn c a t c h i n g d e v i c e 1 8 , the yarn
joining device 19, the yarn t r a p 20, the c l e a r e r 21, and t h e c u t t e r
31 corresponds t o a "yarn d e f e c t removing device" i n the invention
of the p r e s e n t a p p l i c a t i o n , which d e t e c t s and removes the yarn
d e f e c t from t h e t r a v e l l i n g yarn Y.
The yarn accumulating device 22 is arranged between the yarn
joining device 19 and the package winding s e c t i o n 4 . The yarn
accumulating device 22 temporarily accumulates the yarn Y t h a t is
not yet wound by the package winding s e c t i o n 4 . The d e t a i l s on the
s t r u c t u r e of the yarn accumulating device 22 w i l l be described
l a t e r .
The package winding s e c t i o n 4 (winding s e c t i o n ) includes a
c r a d l e 33 which has a p a i r of c r a d l e arms f o r r o t a t a b l y and
detachably supporting the winding tube 6, and a t r a v e r s e drum 34
which can make contact with the surface of the winding tube 6
supported by the c r a d l e 33 or the surface of a package P formed
on the winding tube 6. The package winding s e c t i o n 4 is configured
such t h a t , by r o t a t i n g t h e t r a v e r s e drum 34 by a drum d r i v i n g motor
(not i l l u s t r a t e d ) with the t r a v e r s e drum 34 making contact with
the winding tube 6 ( o r t h e s u r f a c e of the package P ) , the winding
tube 6 i s r o t a t e d (accompanying r o t a t i o n ) accompanyingthe r o t a t i o n
of t h e t r a v e r s e drum 34 while t r a v e r s i n g the yarn unwound from the
yarn accumulating device 22, t o thereby form the package P on the
outer periphery of the winding tube 6.
In the present embodiment, since the yarnaccumulatingdevice
22 adapted t o accumulate the yarn Y is arranged between the yarn
8 / 25
supplying section 3 and the package winding section 4, the package a? winding section 4 can wind the yarn accumulated in the yarn
accumulating device 22 and the winding of the package P can be
continued even if the unwinding of the yarn from the yarn supplying
bobbin 8 is interrupted for some reason (e-g., during the yarn
joining operation by the yarn joining device 19).
The unit control section 5 (control section) is configured
byaCPU (Central Processing Unit) whichis anarithmeticprocessing
unit, a ROM (Read-Only Memory) which stores programs executed by
the CPU and data used in the program, a RAM (Random Access Memory)
which temporarily stores the data during the execution of the
program, a n d a n i n p u t / o u t p u t i n t e r f a c e for inputting andoutputting
data from and to outside. The unit control section 5 controls the
operationofeachdevice oftheabove-describedwindingunitlbased
on a command sent from a machine control device (not illustrated),
which performs the overall control of the automatic winder.
Next, the yarn accumulating device 22 will be described in
detail. F I G . 2 is a side view of the yarn accumulating device 22.
As illustrated in F I G . 1 and F I G . 2, the yarn accumulating device
22 includes a cylindrical yarn accumulating roller 40 around which
the yarn is wound by rotating, a roller driving motor 41 which
rotatably drives the yarn accumulating roller 40, and an upper yarn
pull-out device 42 which pulls out the yarn end of the yarn wound
around the yarn accumulating roller 40 at the time of the yarn
joining operation.
As will be specifically described later, the yarn
accumulating roller 40 is formed of a resin material R. As
illustrated in F I G . 2, the yarn accumulating roller 40 is rotatably
supported on the machine of the winding unit 1 with an axis C1,
which is slightly tilted with respect to a horizontal direction,
as a center. Tapered portions 40a, 40b, whose diameter becomes
larger towards the end, are formed at both axial ends of the yarn
accumulating roller 40, respectively. The portion between the two
tapered portions 40a, 40b is a cylindrical portion 40c having a
9 / 25
constant diameter, and the yarn Y is wound around the cylindrical @ portion 40c. The yarn Y wound around the cylindrical portion 40c
is prevented from falling off by the two tapered portions 40a, 40b
at both ends.
FIG. 3 is a cross-sectional view in a plane including an axis
center of the yarn accumulating roller 40. A wall portion 40d is
formed inside the cylindrical yarn accumulating roller 40, and a
metal coupling member 48 is attached to the wall portion 40d. A
rotation shaft 41a of the roller driving motor 41 is coupled to
the coupling member 48. The roller driving motor 41 is a position
controllable motor such as a DC brushless motor, a stepping motor,
a servo motor, and the like, and can rotatably drive the yarn
accumulating roller 40 in both directions. Since the yarn
accumulating roller 40 formed of the resin material R and the
rotation shaft 41a of the roller driving motor 41 are coupled by
the metal coupling member 48 having high strength, the portion
coupled with the roller driving motor 41 is less likely to break
when the torque of the roller driving motor 41 is applied.
A guide tube 43 which constitutes one part of the upper yarn
pull-out device 42, to be described later, is arranged in proximity
to the tapered portion 40a on the basal end side of the yarn
accumulating roller 40. One end of the guide tube 43 is arranged
close to the surface of the yarn accumulating roller 40. At the
time of the normal winding, the yarn from the yarn supplying bobbin
8 is guided to the tapered portion 40a on the basal end side of
the yarn accumulating roller 40 through the guide tube 43.
When the yarn accumulating roller 40 is rotated in one
direction, the yarn Y guided to the tapered portion 40a on the basal
end side of the yarn accumulating roller 40 by the guide tube 43
is sequentially wound while pushing up the previous yarn layer from
the basal end side (left side in the figure) of the cylindrical
portion 40c. As a result, the yarn that is already wound around
the yarn accumulating roller 40 is pushed by the newly wound yarn,
and is sequentially fed towards the distal end side. The yarn Y
10 / 25
is thus spirally aligned and orderly wound from the basal end side
C) on the outer peripheral surface of the cylindrical portion 40c of
the yarn accumulating roller 40.
Meanwhile, the yarn Y wound around the yarn accumulating
roller 40 is pulled out from the tapered portion 40b on the distal
end side (right side in the figure) of the yarn accumulating roller
40, and is fed downstream (towards the package winding section 4) .
At the tapered portion 40b on the distal end side, the yarn on the
yarn accumulating roller 40 is pulled out towards the downstream
through a pull-out guide 44, which is positioned on an extended
line of the center axis C1 of the yarn accumulating roller 40.
A rubber annular member 45 such as a rubber band, an 0 ring,
or the like is attached to the distal end of the cylindrical portion
40c of the yarn accumulating roller 40 (boundary portion with the
distal end side tapered portion 40b). The yarn wound around the
yarnaccumulating roller 40is passedbetweenthe yarnaccumulating
roller 40 and the annular member 45 to be unwound, whereby an
appropriate tension is applied on the unwinding yarn. The annular
member 45 is prevented from falling off from the yarn accumulating
roller 40 by the tapered portion 40b on the distal end side of the
yarn accumulating roller 40.
As described above, in the present embodiment, the yarn
accumulating roller 40 is formed of the resin material R which is
a non-metal material. As the resin material R for forming the yarn
accumulating roller 40, if it is a thermoplastic resin, ABS resin
(specific weight: 1.0) (copolyrneric synthetic resin of
Acrylonitrile (specific weight: 0.6), Butadiene (specific weight:
1.0) , and Styrene (specific weight 1.0) ) or a polycarbonate
(specificweight: 1.2), whichexcels inmoldabilitymaybe suitably
used. If it is a thermosetting resin, phenol resin (specific
weight: 1.25t01.5)~u nsaturatedpolyester resin (specificweight:
1.1 to 1.46), epoxy resin (specific weight: 1.1 to 1.2), and the
like may be suitably used. Including the above examples, the resin
material Rhas a significantly low specific weight compared tothe
11 / 25
i r o n - b a s e d m e t a l m a t e r i a l such as s t a i n l e s s s t e e l ( s p e c i f i c weight:
@ 7 . 7 ) . and thus the weight of the yarn accumulating r o l l e r 40 can
be g r e a t l y reduced compared t o the case where the yarn accumulating
r o l l e r 40 is formed of a metal m a t e r i a l .
Furthermore, t h e yarn accumulating r o l l e r 40 may be formed
of a f i b e r reinforced r e s i n (FRP) i n which r e i n f o r c e d f i b e r is
contained i n the thermosetting r e s i n . For example, a g l a s s f i b e r
reinforced r e s i n (GFRP) i n which g l a s s f i b e r is contained i n the
above-describedphenolresinandthelike, a c a r b o n f i b e r r e i n f o r c e d
r e s i n (CFRP) which contains carbon f i b e r , and the l i k e may be used.
By forming the yarn accumulating r o l l e r 40 from a f i b e r reinforced
r e s i n , h i g h s t r e n g t h c a n b e e n s u r e d i n a d d i t i o n t o f u r t h e r reduction
inweight o f t h e yarn accumulating r o l l e r 40. Moreover, a v i b r a t i o n
damping e f f e c t can be obtained by the r e i n f o r c e d f i b e r .
The yarn accumulating r o l l e r 40 can be molded through a
general molding method using a d i e . With the thermoplastic r e s i n ,
the yarn accumulating r o l l e r 40 can be e a s i l y molded by i n j e c t i o n
molding. With t h e thermosetting r e s i n , the yarn accumulating
r o l l e r 40 can be molded by t r a n s f e r molding, compression molding,
or injectionmolding. I f the thermosetting r e s i n suchas the phenol
r e s i n is used, the shrink produced a t the time of molding by the
d i e is reduced. Since the phenol r e s i n h a s a l o w t h e r m a l c o n t r a c t i o n
r a t e , t h e accuracy of the surface of the d i e becomes the accuracy
of the r e s i n surface as is, and thus the yarn accumulating r o l l e r
40 having a very small surface roughness can be molded.
In the present embodiment, as i l l u s t r a t e d i n FIG. 3, t h e m e t a l
coupling member 48 f o r coupling the yarn accumulating r o l l e r 40
with t h e r o l l e r d r i v i n g m o t o r 4 1 i s a t t a c h e d t o t h e yarnaccumulating
r o l l e r 40. In such a case, the yarn accumulating r o l l e r 40 is
p r e f e r a b l y molded by i n s e r t molding. That is, the metal coupling
member 48 is attached i n advance t o the i n t e r i o r of the d i e f o r
molding the yarn accumulating r o l l e r 40, and t h e r e s i n m a t e r i a l
R is then i n j e c t e d i n t o the d i e t o i n t e g r a l l y form the yarn
accumulating r o l l e r 40 and the coupling member 48. In t h i s case,
12 / 25
the p o s i t i o n a l accuracy of the coupling member 48 and the yarn
accumulating r o l l e r 40 t o be molded with the d i e becomes higher
by s e t t i n g the d i e with t h e coupling member 48 as a reference.
Since t h e r e s i n m a t e r i a l Rgenerallyhaslowhardness compared
t o the metal m a t e r i a l , s c r a t c h e s and deformation may occur on the
o u t e r s u r f a c e o f t h e y a r n a c c u m u l a t i n g r o l l e r 40 f o r m e d o f t h e r e s i n
material R depending on the wound yarn Y. Furthermore, abrasion
may occur when the wound yarn Y is rubbed a g a i n s t the o u t e r s u r f a c e
of the yarn accumulating r o l l e r 40. Thus, the outer surface of the
yarn accumulating r o l l e r 40 may be covered with a p r o t e c t i v e l a y e r
H. Accordingly, the deformation, s c r a t c h e s , abrasion, or the l i k e
caused by the winding of the yarn a r e suppressed from occurring
on the outer surface of the yarn accumulating r o l l e r 40 formed of
t h e r e s i n m a t e r i a l R, whereby t h e d u r a b i l i t y is improved.
The m a t e r i a l of the p r o t e c t i v e l a y e r H is not p a r t i c u l a r l y
l i m i t e d , b u t the m a t e r i a l e x c e l l i n g i n corrosion r e s i s t a n c e and
abrasion r e s i s t a n c e is p r e f e r a b l y used. Examples of the m a t e r i a l
include hard chrome p l a t i n g , DLC (Diamond-like Carbon), and the
l i k e . The covering method may include p l a t i n g (wet p l a t i n g ) ,
deposition (PVD, CVD, o r t h e l i k e ) , painting, thermal spraying,
and the l i k e . A t h i n metal film manufactured i n a d i f f e r e n t s t e p
may be laminated t o the surface of the yarn accumulating r o l l e r
40.
Fromtheviewpointofpreventing s c r a t c h e s a n d t h e l i k e caused
by the wound yarn Y, the p r o t e c t i v e l a y e r H is p r e f e r a b l y arranged
a t l e a s t o n t h e t a p e r e d p o r t i o n s 40a, 4 0 b a n d t h e c y l i n d r i c a l p o r t i o n
40c, on which the yarn Y is wound, of the o u t e r s u r f a c e of the yarn
accumulating r o l l e r 40. However, fromthe viewpoint of p r o t e c t i n g
the e n t i r e yarn accumulating r o l l e r 40, the outer surface of the
yarn accumulating r o l l e r 40 may be e n t i r e l y covered with the
p r o t e c t i v e l a y e r H. In p a r t i c u l a r , i n the case of p l a t i n g , the
p r o t e c t i v e l a y e r H can be e a s i l y formed over the e n t i r e surface
of the yarn accumulating r o l l e r 40. Furthermore, i n the case of
p l a t i n g , it is g e n e r a l l y e a s i e r t o form the p l a t e d l a y e r e n t i r e l y
W / 25
A case of forming the protective layer H by plating will be
describedbywayofexample. FIG. 4 is anenlarged cross-sectional
view of an outer peripheral portion of the yarn accumulating roller
40 of FIG. 3. First, the outer surface of the yarn accumulating
roller 40 formed of the resin material R is etched to form
irregularities on the outer surface, and then a catalyst having
high reducing ability such as Pd and Sn is added. Then, the yarn
accumulating roller 40 added with the catalyst is immersed in a
chemical plating solution to carry out non-electrolytic plating,
thereby forming a base layer 61, which has nickel or copper as the
maincomponent, ontheouter surfaceofthe yarnaccumulatingroller
40. The electrolytic plating thus can be carried out by forming
the base layer 61 having conductivity on the outer surface of the
yarn accumulating roller 40. Then, a metal plated layer 60 having
chromium as the main component is formed as the protective layer
H on the base layer 61 by the electrolytic plating. In the above
configuration, the term "main component" refers to a component
havingthe highestweightratio among the components of eachlayer.
It shouldbenotedthat, regardless ofthe presence or absence
of coating by the protective layer H described above, the physical
processing such as blast processing, buffing, and the like may be
performed on the outer surface of the yarn accumulating roller 40,
as necessary.
Returning to FIG. 2, an upper limit sensor 46 for detecting
that the amount of yarn Y on the yarn accumulating roller 40 is
greater than or equal to a predetermined upper limit amount, and
a lower limit sensor 47 for detecting that the amount of yarn Y
is smaller than a predetermined lower limit amount are arranged
in proximity of the outer peripheral surface of the cylindrical
portion 40c of the yarn accumulating roller 40. The detection
results of the upper limit sensor 46 and the lower limit sensor
47 are sent to the unit control section 5. Based on the detection
14 / 25
results of the sensors 46, 47, the unit control section 5 controls
the roller driving motor 41 such that the yarn accumulating amount
(winding amount) of the yarn accumulating roller 40 is within a
range between the upper limit amount and the lower limit amount.
Each of the upper limit sensor 46 and the lower limit sensor 47
corresponds to a "yarn amount detecting section" in the invention
of the present application.
The upper yarn pull-out device 42 is a device for pulling out
the yarn end of the yarn from the yarn accumulating device 22 (upper
yarn Y1) to perform the yarn joining operation by the yarn joining
device 19 at the time of replacement of the yarn supplying bobbin
8, after the cutting of the yarn, or after the yarn breakage when
the yarn defect is detected. The upper yarn pull-out device 42
includes the guide tube 43 mentioned above. A yarn passage 50 and
a nozzle 51 connected to the yarn passage 50 are formed inside the
guide tube 43. One endoftheguide tube 43 facesthe taperedportion
40a on the basal end side of the yarn accumulating roller 40, and
the above-described guide member 32 is arranged at the other end
of the guide tube 43 with its opening at the upper end facing the
guide tube 43. The nozzle 51is connectedtoa compressedair source
52, and an electromagnetic valve 53 that opens and closes by the
s i g n a l f r o m t h e u n i t c o n t r o l s e c t i o n 5 i s a r r a n g e d b e t w e e n t h e n o z z l e
51 and the compressed air source 52.
At the time of the normal winding, the yarn Y unwound from
the yarn supplying bobbin 8 is passed through the yarn passage 50
of the guide tube 43 and guided to the surface of the yarn
accumulating roller 40. At the time ofthe yarn joining operation,
the electromagnetic valve 53 is switched from close to open, and
the compressed air is supplied from the nozzle 51 into the yarn
passage 50, so that the airflow directed from the yarn accumulating
roller 40 towards the guide member 32 is generated in the yarn
passage 50. Under this state, when the yarn accumulating roller
40 is rotated in a direction opposite to the rotation at the time
of normal winding, the yarn Y on the yarn accumulating roller 40
15 / 25
is unwound from the basal end s i d e , and the yarn end thereof is
@ pulled i n t o the guide t u b e 43 by the a i r f l o w and f u r t h e r fed from
the guide tube 43 t o the guide member 32. The yarn end of the upper
yarn Y 1 fed t o the guide member 32 i n t h i s manner is guided t o and
caughtbytheabove-describedupperyarncatchingdevice18, whereby
the upper yarn Y 1 is fed t o the yarn joining device 19.
Next, the c o n t r o l of the package winding o p e r a t i o n i n c l u d i n g
the yarn j o i n i n g o p e r a t i o n performed by the u n i t c o n t r o l s e c t i o n
5 w i l l be described with reference t o a flowchart of FIG. 5. In
the following, i n p a r t i c u l a r , a s e r i e s of operations performedwhen
a yarn d e f e c t is detected during the package winding w i l l be
described.
When a yarn d e f e c t o f t h e t r a v e l l i n g yarn Y i s detected (S10)
by t h e c l e a r e r 21 while the package P is being wound, the yarn Y
is cut with the c u t t e r 31 (S11). The r o t a t i o n of the yarn
accumulating r o l l e r 40 is stopped (S12). However, t h e t r a v e r s e
drum 34 of the package winding s e c t i o n is not stopped. In other
words, the package winding s e c t i o n 4 unwinds and winds the yarn
Y wound around the yarn accumulating r o l l e r 40.
Then, the yarn joining device 19 performs the yarn joining
operation (S13). With respect t o the lower yarn Y2 from the yarn
supplying bobbin 8, t h e yarn end blown up by the lower yarn blow-up
device 16 i l l u s t r a t e d i n FIG. 1 is caught by t h e yarn t r a p 20 so
t h a t the lower yarn Y2 is guided t o the yarn joining device 19.
The upper yarn Y 1 is p u l l e d out by the upper yarn pull-out device
42 i l l u s t r a t e d i n FIG. 1 and FIG. 2, and the upper yarn Y 1 fed t o
the guide member 32 is caught by the upper yarn catching device
18 so t h a t the upper yarn Y 1 is guided t o the yarn joining device
19. The yarn joining device 19 j o i n s the guided lower yarn Y2 and
the upper yarn Y 1 . Then, the yarn j o i n i n g d e v i c e 19 removes the
yarn d e f e c t contained i n the upper yarn Y 1 upon joining the lower
yarn Y2 and the upper yarn Y 1 .
Since the yarn Y wound around the yarn accumulating r o l l e r
40 is unwound during the yarn j o i n i n g o p e r a t i o n , the amount of yarn
16 / 25
accumulated in the yarn accumulating roller 40 is reduced. When
@ the lower limit sensor 47 (see FIG. 2) of the yarn accumulating
device 22 detects that the amount of yarn accumulated in the yarn
accumulating roller 40 is less than a predetermined lower limit
value (S14: Yes) before the yarn joining operation is finished,
the winding speed of the package winding section 4 (rotation speed
of the traverse drum 34) is reduced to prevent the yarn Y of the
yarn accumulating roller 40 fromrunning out (S15). Alternatively,
the winding operation of the package winding section 4 may be
temporarily stopped.
After the yarn joining operation by the yarn joining device
I
I 19 is finished (S16: Yes), the yarn accumulating roller 40 is
re-accelerated to resume the unwinding of the yarn Y from the yarn
I supplying bobbin 8 (S17). If the winding speed of the package
1
I winding section 4 is reduced or the winding is stopped previously,
1 the winding speed is increased to a predetermined speed.
The yarn accumulating device 22 is arranged between the yarn
supplying section 3 and the package winding section 4. Thus, even
ina state inwhich the yarnYis not supplied fromthe yarn supplying
section 3 to the package winding section 4 at the time of removing
the yarn defect, the package winding section 4 winds the yarn
accumulated in the yarn accumulating device 22 to continuously
perform the winding operation of the package winding section 4.
When a state in which the amount of yarn of the yarn accumulating
device 22 is small is detected by the lower limit sensor 47, the
winding operation of the package winding section 4 may be stopped
or thewinding speedmaybe reducedtopreventthe yarnYaccumulated
in the yarn accumulating device 22 from running out.
In the present embodiment described above, the yarn
accumulating roller 40 of the yarn accumulating device 22 is formed
of a non-metal material, and the yarn accumulating roller 40 has
light weight. In particular, further reduction in weight of the
yarn accumulating roller 40 can be realized by forming the yarn
accumulating roller 40 with the resin material R. Therefore, the
17 / 25
quick rotational control of the yarn accumulating roller 40 can
C) be achieved without enlarging the roller driving motor 41.
Specifically, at the time of the yarn joining operation by
the yarn joining device 19, the yarn accumulating roller 40 can
bepromptlystopped. Furthermore, afterthe yarn joiningoperation
is finished, the yarn accumulating roller 40 can be promptly
re-accelerated. In the case where the amount of yarn accumulated
in the yarn accumulating roller 40 is required to be increased or
decreased during the package winding, the rotation speed of the
yarn accumulating roller 40 is to be changed. Such changing of the
rotation speed can also be promptly performed.
In the above embodiment, an example in which the yarn
accumulating roller 40 is formed of the resin material R has been
described, but the yarn accumulating roller 40 may be formed of
other non-metal materials. For example, the yarn accumulating
roller 40 may be formed of ceramics. Ceramics also has a smaller
specific weight compared to that of the metal material, and thus
the weight of the yarn accumulating roller 40 can be reduced. If
the yarn accumulating roller 40 is formed of ceramics, the hardness
of the outer surface of the yarn accumulating roller 40 becomes
high. Thus, the durability becomes sufficiently high even if the
protective layer H is not provided. However, since the ceramics
haslowtoughness, the protective layer H formedof rubber or resin
may be formed on the surface of the yarn accumulating roller 40
made of ceramics for the purpose of preventing cracks.
In addition, the carbon fiber reinforced carbon composite
material (CC material) may be used. Generally, the CC material is
producedbyalternatelyrepeatinga stepofcoveringa corematerial
of the carbon fiber with carbon resin such as phenol resin, and
a step of firing the same in vacuum at a temperature from 1000°C
to2000°Ctocarbonizethe resin. The specificweight ofthe general
CC material is 1.3 to 1.7.
The above embodiment is an example in which the present
invention is applied to the automatic winder for rewinding the yarn
@ of the yarn supplying bobbin while removing the yarn defect to form
a package, but the target of application of the present invention
is not limitedtothe automaticwinder. Inotherwords, the present
invention can be applied to the yarn winding device other than the
automatic winder as long as it is useful to install the yarn
accumulating device adapted to accumulate the yarn in the middle
of the yarn path from the yarn supplying section to the winding
section. For example, ina spinningdevice adaptedto spinandwind
the yarn, the present invention can be applied to an accumulating
roller adapted to temporarily wind and accumulate the yarn between
the spinning section and the winding section.
In accordance with a second aspect of the invention, in the
yarnaccumulatingdevice, thenon-metalmaterial is a resinmaterial.
According to the present invention, the weight of the yarn
accumulating roller can be further reduced.
In accordance with a third aspect of the invention, in the
yarn accumulating device, the yarn accumulating roller is formed
of a fiber reinforced resin in which reinforced fiber is contained
in the resin material. According to the present invention, high
strength can be ensured in addition to the reduction in weight of
the yarn accumulating roller.
In accordance with a fourth aspect of the invention, in the
yarn accumulating device, at least a portion, around which the yarn
is wound, of an outer surface of the yarn accumulating roller is
covered with a protective layer. According to the present
invention, since the portion around which the yarn is wound of the
yarn accumulating roller is covered with the protective layer,
deformation, scratches, abrasion, or the like causedbythe winding
of the yarn are suppressed from occurring at the outer surface of
the yarnaccumulating rollermade of resinmaterial, thus improving
durability.
In accordance with a fifth aspect of the invention, in the
yarn accumulating device, the yarn accumulating roller is formed
19 / 25
of the resin material, and a metal plated layer is applied as the
Q protective layer on the entire outer surface of the yarn
accumulating roller. According to the present invention, the
entire surface of the yarn accumulating roller is protected with
the plated layer serving as the protective layer. In the case of
plating, it is generally easier to form the plated layer on the
entire surface rather than forming the plated layer only on one
part of the base material.
In accordance with a sixth aspect of the invention, in the
yarn accumulating device, the yarn accumulating roller is formed
of ABS resin, the plated layer is a layer having chromium as a main
component, and a base layer having nickel or copper as a main
component is formed between the yarn accumulating roller and the
plated layer.
The ABS resin (copolymeric synthetic resin of Acrylonitrile,
Butadiene, and Styrene) has high moldability and is suited for
molding of the yarn accumulating roller. The chromiumplating has
high corrosion resistance and excels in hardness of the roller
surface and the improvement of the abrasion resistance. However,
it is difficult to form the chromium plating through electrolytic
plating on the surface of the ABS resin, which is an insulating
material. However, in the present invention, the chromiumplating
can be formed with electrolytic plating since the base layer having
nickel or copper as the main component that can be formed with
non-electrolytic plating or the like exists on the surface of the
ABS resin.
In accordance with a seventh aspect of the invention, in the
yarn accumulating device, the yarn accumulating roller is formed
of ceramics. According tothe present invention, the weight ofthe
yarnaccumulating roller canbe reduced since the yarnaccumulating
roller is formed of ceramics which is lighter in weight than the
metal material.
In accordance with an eighth aspect of the invention, in the
yarn accumulating device, a metal coupling member for coupling a
20 / 25
rotation shaft of a drive motor, which is adapted to rotate the
yarn accumulating roller, and the yarn accumulating roller is
attachedtothe yarn accumulating roller. According tothe present
invention, since the yarn accumulating roller made of a non-metal
material and the drive motor are coupled with the metal coupling
member having high strength, breakage is less likely to occur at
the coupling portion with the motor when the torque of the drive
motor is applied.
A yarn winding device according to a ninth aspect of the
invention includes a yarn supplying section; a winding section
adapted to wind a yarn supplied from the yarn supplying section;
the yarn accumulating device arranged between the yarn supplying
section and the winding section and adapted to accumulate the yarn
that is not yet wound around the winding section; and a yarn defect
removing device, which is arranged between the yarn supplying
section and the yarn accumulating device, and adapted to detect
and remove a defect of the travelling yarn.
According to the present invention, the yarn accumulating
device is arranged between the yarn supplying section and the yarn
defect removing device. Thus, even in a state in which the yarn
is not supplied from the yarn supplying section to the winding
section at the time of removing the yarn defect, the winding section
winds the yarn accumulated in the yarn accumulating device, and
hence the winding operation of the winding section can be
continuously carried out.
In accordance with a tenth aspect of the invention, in the
yarn winding device, the yarn defect removing device includes a
yarn defect detecting device adapted to detect the defect of the
travelling yarn, a yarn cutting section adapted to cut the yarn
whentheyarndefectisdetectedbythe yarndefectdetectingdevice,
and a yarn joining device adapted to join a yarn end from the yarn
accumulating device and a yarn end from the yarn supplying section
while removing the yarn defect after the yarn is cut by the yarn
cutting section.
21 / 25
In the present invention, when the yarn defect is detected
@ by the yarn defect detecting device, the yarn is first cut by the
yarn cutting section. Thereafter, the yarn joining device joins
the yarn end from the yarn accumulating device and the yarn end
from the yarn supplying section. Then, the yarn joining device
removes the yarn defect upon joining the yarn ends. During such
series of operations, the yarn is not supplied from the yarn
supplying section, but the winding section winds the yarn unwound
fromthe yarn accumulating roller of the yarn accumulating device,
so that the winding operation can be continued.
In accordance with an eleventh aspect of the invention, the
yarn winding device further includes: a control section adapted
to control a winding operation of the winding section and a yarn
accumulating operation of the yarn accumulating roller of the yarn
accumulating device; and a yarn amount detecting section adapted
to detect an amount of yarn accumulated in the yarn accumulating
device; wherein the control section stops rotation of the yarn
accumulating roller and controls the winding operation of the
winding section according to a detection result of the yarn amount
detecting section when the yarn is cut by the yarn cutting section.
In the present invention, when a state in which the amount
of yarn of the yarn accumulating device is small is detected by
the yarn amount detecting section, the winding operation of the
winding sectionis stoppedorthewindingspeedis reducedtoprevent
the yarn accumulated in the yarn accumulating device from running
out.

WE CLAIM
1. A yarn accumulating device for accumulating a yarn, the
device characterized by comprising:
a cylindrical yarn accumulating roller around which the yarn
is wound by being rotated, the yarn accumulating roller being formed
of a non-metal material having a smaller specific weight than that
of iron.
2. The yarn accumulating device according to claim 1, wherein
the non-metal material is a resin material.
3. The yarn accumulating device according to claim 2, wherein
the yarn accumulating roller is formed of a fiber reinforced resin
in which reinforced fiber is contained in the resin material.
4. The yarn accumulating device according to claim 2 or 3,
wherein at least a portion, around which the yarn is wound, of an
outer surface of the yarn accumulating roller is covered with a
protective layer.
5. The yarn accumulating device according to claim 4, wherein
the yarn accumulating roller is formed of the resin material ,
and
a metal plated layer is applied as the protective layer on
the entire outer surface of the yarn accumulating roller.
6. The yarn accumulating device according to claim 5, wherein
the yarn accumulating roller is formed of ABS resin,
the plated layer is a layer having chromium as a main component,
and
a base layer having nickel or copper as a main component is
formed between the yarn accumulating roller and the plated layer.
23/25
7. The yarn accumulating device according to claim 1, wherein
the yarn accumulating roller is formed of ceramics.
8. The yarn accumulating device according to any of claims
1 to 7, wherein
a metal coupling member for coupling a rotation shaft of a
drive motor, which is adapted to rotate the yarn accumulating roller ,
with the yarn accumulating roller is attached to the yarn
accumulating roller.
9. A yarn winding device comprising:
a yarn supplying section;
a winding section adapted to wind a yarn supplied from the
yarn supplying section; characterized in that
the yarn accumulating device according to any of claims 1 to
8 is arranged between the yarn supplying section and the winding
section and adapted to accumulate the yarn that is not yet wound
around the winding section; and that
a yarn defect removing device is arranged between the yarn
supplying section and the yarn accumulating device, and is adapted
to detect and remove a defect of the travelling yarn.
10. The yarn winding device according to claim 9, wherein
the yarn defect removing device includes
a yarn defect detecting device adapted to detect the
defect of the travelling yarn,
a yarn cutting section adapted to cut the yarn when the
yarn defect is detected by the yarn defect detecting device, and
a yarn joining device adapted to join a yarn end from
the yarn accumulating device and a yarn end from the yarn supplying
section while removing the yarn defect after the yarn is cut by
the yarn cutting section.
11. The yarn winding device according to claim 10,further
24/25
comprising:
^P a control section adapted to control a winding operation of
the winding section and a yarn accumulating operation of the yarn
accumulating roller of the yarn accumulating device; and
a yarn amount detecting section adapted to detect an amount
of yarn accumulated in the yarn accumulating device, wherein
the control section stops rotation of the yarn accumulating
roller and controls the winding operation of the winding section
according to a detection result of the yarn amount detecting section
when the yarn is cut by the yarn cutting section.
12. A yarn accumulating device for accumulating a yarn,
substantially as herein described with reference to accompanying
drawings and example.
13. A yarn winding device, substantially as herein described with
reference to accompanying drawings and example.