YARN WINDING DEVICE AND PACKAGE DECELERATING METHOD
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a control 5 carried
out when decelerating a package in a yarn winding device
including a yarn storage device.
2. Description of the Related Art
10 Conventionally, there is known a yarn winding device
adapted to wind a yarn from a yarn storage device to form
a package while temporarily storing the yarn unwound from
a yarn supplying bobbin in the yarn storage device. The
yarn winding device including the yarn storage device can
15 continue to form the package even when the yarn joining
operation is carried out. WO 2012/127939 A1 discloses this
type of yarn winding device.
WO 2012/127939 A1 discloses a yarn winding device
having a configuration of rotating the package by rotating
20 a winding drum (contact roller) brought into contact with
the package. The yarn winding device carries out a control
of changing a rotation speed of a winding drum based on a
storage amount of the yarn storage device. Specifically,
the yarn winding device lowers the rotation speed of the
25 winding drum when the storage amount of the yarn storage
device is smaller than or equal to a predetermined amount
to lower the rotation speed of the package or to stop the
rotation of the package. Such a control is carried out to
prevent the yarn stored in the yarn storage device from
30 running out.
Similarly to WO 2012/127939 A1, JP H7-187506 A
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discloses a yarn winding device having a configuration of
rotating the package by rotating a yarn guiding drum
(contact roller) brought into contact with the package.
The yarn winding device carries out a control of causing
a slip between the yarn guiding drum and the package 5 e when
lowering the rotation speed of the package. Such a control
is carried out to prevent ribbon winding (yarn newly wound
into the package is overlapped on the already wound yarn).
In the yarn winding device including the yarn storage
10 device as described in WO 2012/127939 A1, a large slip
occurs between the contact roller and the package when the
rotation speed of the contact roller is rapidly lowered.
When a large slip occurs, the yarn is not traversed in
accordance with the operation of the traverse device, and
15 the yarn may fall off from the end face of the package
(stitching). When the package is rotated at high speed or
the package is heavy, the inertia force of the rotating
package becomes large and hence a large slip easily occurs.
When the rotation speed of the contact roller is
20 gradually lowered, a great amount of yarn is unwound from
the yarn storage device before the rotation speed of the
package reaches the target speed, and the storage amount
of the yarn storage device is greatly reduced. Therefore,
when gradually lowering the rotation speed of the contact
25 roller, the package needs to be frequently stopped to ensure
the storage amount of the yarn storage device. However,
if the package is frequently stopped, the winding
efficiency is lowered, and furthermore, the yarn falls off
from the end face of the package and is wound around the
30 winding bobbin when the package is stopped, and thus yarn
breakage may occur. Therefore, it is not preferable to
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gradually lower the rotation speed of the contact roller
without resistance to inertia.
The yarn winding device of JP H7-187506 A has a
configuration of intentionally causing the slip of the
package. JP H7-187506 A does not disclose 5 the
configuration including the yarn storage device.
BRIEF SUMMARY OF THE INVENTION
The present invention has been made in view of the
10 above circumstances, and a main object thereof is to provide
a configuration of decelerating a package in a short period
of time while suppressing a slip of the package in a yarn
winding device including a yarn storage device.
The problems to be solved by the present invention
15 are as described above, and the means and effects for
solving such problems will be described next.
According to a first aspect of the present invention,
a yarn winding device having the following configuration
is provided. Specifically, the yarn winding device
20 includes a yarn supplying section, a yarn storage device,
a package forming section, and a control section. The yarn
supplying section is adapted to supply a yarn. The yarn
storage device is adapted to pull out the yarn from the yarn
supplying section and temporarily store the yarn. The
25 package forming section is adapted to pull out the yarn from
the yarn storage device and wind the yarn around a winding
bobbin to form a package. The control section is adapted
to control the package forming section. The package
forming section includes a package supporting section, a
30 package rotation detecting section, a contact roller, and
a roller drive source. The package supporting section is
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adapted to rotatably support the package. The package
rotation detecting section is adapted to detect a rotation
amount of the package. The contact roller is adapted to
rotate while making contact with the package supported by
the package supporting section to rotate the package. 5 The
roller drive source is adapted to rotatably drive the
contact roller. The control section carries out a
deceleration control of decelerating the contact roller
while adjusting such that a difference in peripheral speeds
10 of the package and the contact roller is smaller than or
equal to a predetermined value in a state where the yarn
is connected between the yarn storage device and the package
forming section and in a state where the contact roller is
brought into contact with the package based on a detection
15 result of the package rotation detecting section and a
rotation speed of the contact roller.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side view of a winding unit
20 arranged in an automatic winder according to an embodiment
of the present invention;
FIG. 2 is a front view illustrating a configuration
of the vicinity of a winding section;
FIG. 3 is a flowchart illustrating a process of
25 controlling a rotation of a traverse drum based on a storage
amount of a yarn storage device;
FIG. 4 is a flowchart illustrating a preliminary
process of a deceleration control, and a process
immediately after the deceleration control is started;
30 FIG. 5 is a flowchart illustrating a process carried
out after the deceleration control is started; and
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FIG. 6 is a graph illustrating an example of a time
change in peripheral speeds of a package and a traverse drum
when the deceleration control is carried out.
DETAILED 5 DESCRIPTION OF PREFERRED EMBODIMENTS
An embodiment of the present invention will be
described below. First, an outline of an automatic winder
(yarn winding device) will be described with reference to
FIGS. 1 and 2. The automatic winder has a configuration
10 in which a plurality of winding units 2 are arranged in a
row. The automatic winder includes a machine management
device (not illustrated) for intensively managing the
winding units 2 and a blower box (not illustrated) including
a compressed air source and a negative pressure source.
15 As illustrated in FIG. 1, the winding unit 2 includes
a control section 50, a yarn supplying bobbin supporting
section (yarn supplying section) 7, and a winding section
(package forming section) 8 as main components. The
winding unit 2 is configured to unwind a yarn (spun yarn)
20 20 of a yarn supplying bobbin 21 supported by the yarn
supplying bobbin supporting section 7, and wind the unwound
yarn 20 into a package 30. In the following description,
upstream and downstream when seen in a travelling direction
of the yarn are simply referred to as “upstream” and
25 “downstream”, respectively.
The control section 50 is configured by a hardware
such as a CPU, a ROM, and a RAM (not illustrated), and
software such as a control program stored in the RAM. With
the cooperative operation of the hardware and the software,
30 each section of the winding unit 2 is controlled. The
control section 50 of each winding unit 2 is able to
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communicate with the machine management device. The
operation of the plurality of winding units 2 in the
automatic winder thus can be intensively managed in the
machine management device.
The yarn supplying bobbin supporting section 7 hold5 s
the yarn supplying bobbin 21 in a substantially upright
state. Furthermore, the yarn supplying bobbin supporting
section 7 can discharge the empty yarn supplying bobbin 21.
A magazine type bobbin supplying device 26 is arranged on
10 a front side of the winding unit 2. The bobbin supplying
device 26 includes a rotary magazine part 27. The magazine
part 27 is configured to be able to hold a plurality of spare
yarn supplying bobbins 21. The bobbin supplying device 26
intermittently rotatably drives the magazine part 27 to
15 supply a new yarn supplying bobbin 21 to the yarn supplying
bobbin supporting section 7.
The winding section 8 includes a cradle 23 configured
to detachably attach the winding bobbin 22, and a traverse
drum (contact roller) 24 adapted to traverse the yarn 20
20 and to drive the winding bobbin 22.
As illustrated in FIG. 2, the cradle 23 includes a
pair of left and right arms swingable with a swing shaft
43 as a center, the swing shaft 43 being arranged parallel
to a rotational axis of the traverse drum 24 and with a
25 predetermined spacing with the traverse drum 24. An
increase in a yarn layer diameter of the package 30
accompanying the winding of the yarn 20 can be absorbed by
the swinging of the cradle 23.
A swing angle sensor (package yarn amount detecting
30 section) 46 adapted to detect a swing angle of the cradle
23 is attached to the swing shaft 43. The swing angle sensor
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46 includes, for example, a rotary encoder, and outputs the
swing angle of the cradle 23 to the control section 50. The
control section 50 can calculate a package diameter of the
package 30 based on the swing angle of the cradle 23 acquired
5 from the swing angle sensor 46.
Rotation holders (package supporting sections) 44,
45 are rotatably attached to the distal end of the arm of
the cradle 23. The rotation holders 44, 45 are arranged
to face each other. The winding bobbin 22 is attached so
10 as to be sandwiched between the two rotation holders 44,
45.
A package brake 80 for applying brake force to the
rotation of the package 30 is arranged in proximity to the
rotation holder 44. The package brake 80 includes a piston
15 housing 81, and a brake piston 82.
The piston housing 81 is incorporated at a distal end
portion of the cradle 23, and the brake piston 82 is
air-tightly fitted into the interior of the piston housing
81. The brake piston 82 is slidable with respect to the
20 piston housing 81, and is slidable with respect to a shaft
44a that rotates with the rotation holder 44.
The piston housing 81 is continuous with an
electromagnetic valve (not illustrated) controlled by the
control section 50 to switch between supply and stop of a
25 flow of compressed air into an internal space of the piston
housing 81. According to such a configuration, the
rotation holder 44 can freely rotate with respect to the
brake piston 82 in a state where the compressed air is not
supplied to the interior of the piston housing 81.
30 When the compressed air is supplied to the interior
of the piston housing 81, the advancing brake piston 82
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moves, thus generating a friction resistance with respect
to the rotation of the rotation holder 44. Thus, the
rotation of the winding bobbin 22 (package 30) is controlled.
The package brake is not limited to the pneumatic
configuration described above, and may have a 5 configuration
of applying brake force to the rotation of the rotation
holder 44 by hydraulic pressure or electromagnetic force.
A package rotation sensor (package rotation
detecting section) 47 is attached to a distal end portion
10 on an opposite side of the cradle 23. The package rotation
sensor 47 is adapted to detect the rotation amount of the
winding bobbin 22 (package 30) attached to the cradle 23.
The package rotation sensor 47 outputs a pulse signal to
the control section 50 each time the package 30 is rotated
15 by a predetermined angle. The control section 50 can
calculate the rotation speed of the package 30 by measuring
the number of pulses per time.
The traverse drum 24 is arranged to face the winding
bobbin 22. The traverse drum 24 is rotatably driven by a
20 traverse drum drive motor (roller drive source) 41
illustrated in FIG. 2. The presence/absence of rotation,
the rotation speed, and the like of the traverse drum drive
motor 41 are controlled by the control section 50. When
the traverse drum 24 is rotatably driven, the winding bobbin
25 22 and the package 30 are rotated accompanying the rotation
of the traverse drum 24. The yarn 20 stored in the yarn
storage device 19, to be described later, thus can be wound
into the package 30.
A traverse groove 24a illustrated in FIG. 2 is formed
30 on an outer peripheral surface of the traverse drum 24, and
the yarn 20 can be traversed at a predetermined width by
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the traverse groove 24a. According to such a configuration,
the yarn 20 can be wound around the winding bobbin 22 while
traversing, and the package 30 having a predetermined shape
can be formed.
Furthermore, a traverse drum rotation sensor 42 5 is
attached to the traverse drum 24. The traverse drum
rotation sensor 42 is configured as, for example, a rotary
encoder, and outputs the pulse signal to the control section
50 each time the traverse drum 24 rotates a predetermined
10 angle. The control section 50 can calculate the rotation
speed of the traverse drum 24 by measuring the number of
pulses per time.
In the winding unit 2, an unwinding assisting device
10, a lower yarn blow-up section 11, a gate type tension
15 applying device 12, an upper yarn catching section 13, a
yarn joining device 14, a yarn trap 15, a cutter 16, a yarn
monitoring device 17, an upper yarn pull-out section 18,
and the yarn storage device 19 are arranged in this order
from the yarn supplying bobbin supporting section 7 toward
20 the winding section 8 in the yarn travelling path between
the yarn supplying bobbin supporting section 7 and the
winding section 8.
The unwinding assisting device 10 brings a movable
member 10a into contact with a balloon formed at the upper
25 part of the yarn supplying bobbin 21 when the yarn 20 unwound
from the yarn supplying bobbin 21 is swung. The size of
the balloon thus can be appropriately controlled, and the
unwinding of the yarn 20 can be assisted.
The lower yarn blow-up section 11 is an air sucker
30 device arranged between the yarn supplying bobbin
supporting section 7 and the yarn joining device 14, and
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feeds the lower yarn from the yarn supplying bobbin 21
toward the yarn joining device 14 when replacing the yarn
supplying bobbin 21.
The gate type tension applying device 12 applies a
predetermined tension on the travelling yarn 20. The 5 gate
type tension applying device 12 of the present embodiment
is a gate type tension applying device in which movable comb
teeth are arranged with respect to fixed comb teeth. The
movable comb teeth can be swung by a rotary solenoid so that
10 the movable comb teeth are engaged with or released from
the fixed comb teeth. In place of the gate type tension
applying device 12, for example, a disc type tension
applying device may be arranged.
The upper yarn catching section 13 is arranged
15 between the yarn joining device 14 and the yarn supplying
bobbin supporting section 7. The upper yarn catching
section 13 is connected to a negative pressure source (not
illustrated), and is able to generate a suction airflow at
the time of the yarn joining operation.
20 The yarn trap 15 is arranged between the yarn joining
device 14 and the yarn storage device 19. A distal end of
the yarn trap 15 is formed as a tubular member, and is
arranged close to the travelling path of the yarn 20. The
yarn trap 15 is connected to the negative pressure source
25 (not illustrated) and generates a suction airflow at the
distal end to suck and remove contaminants such as fly waste
attached to the travelling yarn 20.
The yarn monitoring device 17 is configured to detect
a yarn defect such as a slub by monitoring the yarn thickness
30 of the yarn 20. When a yarn defect is detected, the yarn
monitoring device 17 transmits a signal instructing the
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cutting and the removal of the relevant yarn defect to the
cutter 16. The cutter 16 is arranged in proximity to the
yarn monitoring device 17 to immediately cut the yarn 20
in response to the signal.
The yarn joining device 14 joins the 5 disconnected
lower yarn from the yarn supplying bobbin 21 and upper yarn
from the yarn storage device 19 after the yarn defect is
detected by the yarn monitoring device 17 and the yarn 20
is cut by the cutter 16, after the yarn 20 unwound from the
10 yarn supplying bobbin 21 is broken, after the yarn supplying
bobbin 21 is replaced, and the like. The yarn joining
device 14 may be a type that uses fluid such as compressed
air or a mechanical-type.
The upper yarn pull-out section 18 is an air sucker
15 device arranged immediately upstream of the yarn storage
device 19, and is configured to feed the upper yarn from
the yarn storage device 19 toward the yarn guiding pipe 36
with compressed air.
When carrying out the yarn joining operation, the
20 upper yarn from the yarn storage device 19 is fed to the
yarn guiding pipe 36 by the upper yarn pull-out section 18.
The yarn guiding pipe 36 discharges the fed upper yarn from
the lower end portion. The yarn discharged by the yarn
guiding pipe 36 is sucked by the upper yarn catching section
25 13. When the upper yarn is sucked by the upper yarn catching
section 13, the upper yarn is taken out from a slit (not
illustrated) formed along the longitudinal direction of the
yarn guiding pipe 36 and is guided to the yarn joining device
14.
30 When carrying out the yarn joining operation, on the
other hand, the lower yarn blow-up section 11 feeds the
13 / 39
lower yarn toward the upper side. The lower yarn is sucked
by the yarn trap 15. The lower yarn is thereby guided to
the yarn joining device 14. The yarn joining device 14
carries out the yarn joining operation on the guided upper
yarn and lower yarn. The disconnected yarns can be 5 joined
in the above manner.
The yarn storage device 19 is configured to
temporarily store the yarn 20 unwound from the yarn
supplying bobbin 21. As illustrated in FIG. 1, the yarn
10 storage device 19 includes a storage roller 61, a storage
roller drive motor 62, and an annular member 63 as main
components.
The storage roller 61 is formed as a substantially
cylindrical member, and is configured to store the yarn 20
15 by winding the yarn 20 around the outer peripheral surface
thereof. The storage roller drive motor 62 is configured
to rotatably drive the storage roller 61 with a center axis
line thereof as the center. The operation of the storage
roller drive motor 62 is controlled by the control section
20 50.
Since a prescribed amount of the yarn 20 is stored
in the yarn storage device 19, even if the unwinding of the
yarn 20 from the yarn supplying bobbin 21 is interrupted
for some reason (e.g., when carrying out the yarn joining
25 operation), the winding unit 2 can wind the yarn 20 stored
in the yarn storage device 19. Thus, even if the unwinding
of the yarn 20 is interrupted, the winding of the yarn 20
to the package 30 can be continued.
The annular member 63 is arranged in proximity to the
30 end on the downstream side of the storage roller 61. The
yarn 20 stored in the yarn storage device 19 is pulled out
14 / 39
toward the downstream through a space between the annular
member 63 and the surface of the storage roller 61. With
the above configuration, an appropriate tension can be
applied on the yarn 20 unwound from the storage roller 61,
and hence the unwinding of the yarn 20 from the yarn s5 torage
device 19 can be stabilized.
A lower limit sensor 64 and an upper limit sensor 65
are attached in proximity to the storage roller 61. The
lower limit sensor 64 detects whether or not the amount of
10 yarn 20 greater than or equal to a predetermined lower limit
amount is stored on the storage roller 61. The amount of
yarn 20 greater than or equal to the predetermined lower
limit amount is the yarn amount required until the control
section 50 controls the rotation speed of the traverse drum
15 24 or the storage roller 61 and the storage amount of the
storage roller 61 starts to increase when the amount of yarn
is less than the lower limit amount detected by the lower
limit sensor 64, and is appropriately determined by the yarn
type and the like.
20 The upper limit sensor 65 detects whether or not the
amount of yarn 20 greater than or equal to a predetermined
upper limit amount is stored on the storage roller 61. The
detection results of the lower limit sensor 64 and the upper
limit sensor 65 are output to the control section 50. The
25 lower limit sensor 64 and the upper limit sensor 65
configure a storage amount detecting section.
Next, a description will be made on a control of
adjusting the storage amount of the storage roller 61 by
controlling the rotation speed of the traverse drum 24 with
30 reference to FIG. 3.
First, the control section 50 determines whether or
15 / 39
not there is a possibility that the storage amount of the
yarn storage device 19 is zero (S101). This determination
is based on whether or not the storage amount of the yarn
storage device 19 is smaller than or equal to the lower limit
amount based on the detection result of the lower 5 limit
sensor 64, for example. When determining that there is a
possibility the storage amount of the yarn storage device
19 is zero, the control section 50 decelerates the traverse
drum drive motor 41 and stops the traverse drum 24 to prevent
10 the storage amount of the yarn storage device 19 from being
zero (S102).
When the traverse drum 24 is decelerated as described
above, slip (hereinafter referred to as package slip) may
occur between the traverse drum 24 and the package 30. In
15 the present embodiment, since the traverse drum 24 is
decelerated by carrying out the deceleration control
described below, the package slip can be suppressed.
Since the winding unit 2 includes the yarn storage
device 19, the control section 50 stops the traverse drum
20 24 in a state where the yarn 20 is connected between the
yarn storage device 19 and the winding section 8.
Furthermore, the control section 50 stops the traverse drum
24 with the traverse drum 24 and the package 30 in contact
with each other and without separating the traverse drum
25 24 from the package 30.
When determining that there is no possibility (or
there is low possibility) that the storage amount of the
yarn storage device 19 is zero in the determination of step
S101, the control section 50 determines whether or not the
30 storage amount of the yarn storage device 19 is greater than
or equal to an upper limit amount based on the detection
16 / 39
result of the upper limit sensor 65 (S103).
If the yarn 20 is not detected by the upper limit
sensor 65, the control section 50 determines that the
storage amount of the yarn storage device 19 is smaller than
the upper limit amount. In this case, the reduction of 5 f the
storage amount of the yarn storage device 19 needs to be
prevented, and thus the control section 50 rotates the
traverse drum 24 at a first rotation speed, which is a
relatively low speed (S104). When lowering the rotation
10 speed of the traverse drum 24 to the first rotation speed,
the control section 50 carries out the deceleration control
to be described later.
When determining that the yarn 20 is detected by the
upper limit sensor 65 in the determination of step S103,
15 the control section 50 determines that the storage amount
of the yarn storage device 19 is greater than or equal to
the upper limit amount. In this case, the storage amount
of the yarn storage device 19 is sufficient, and hence the
control section 50 rotates the traverse drum 24 at a second
20 rotation speed, which is a relatively high speed (S105).
The control section 50 stops the rotation of the traverse
drum 24 or changes the rotation speed based on the storage
amount of the yarn storage device 19, and then again carries
out the processes of step S101 and subsequent steps. Thus,
25 the storage amount can be adjusted by controlling the
traverse drum 24 in accordance with the storage amount of
the yarn storage device 19.
Next, a description will be made on the deceleration
control carried out by the control section 50 with reference
30 to FIGS. 4 to 6.
The control section 50 calculates the rotation speed
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(peripheral speed of the package 30) of the package 30 of
a predetermined period, and a rotation speed of the traverse
drum 24 (peripheral speed of the traverse drum 24) before
carrying out the deceleration control (S201). The
rotation speed of the package 30 is calculated based on 5 the
detection result of the package rotation sensor 47. The
rotation speed of the traverse drum 24 is calculated based
on the detection result of the traverse drum rotation sensor
42. The rotation speed of the traverse drum 24 may be
10 calculated based on the command value of the control section
50. The predetermined period is arbitrary, and for example,
is one cycle of a disturb control.
Next, the control section 50 calculates a reference
rotation ratio based on the acquired rotation speed of the
15 package 30 and the rotation speed of the traverse drum 24.
The reference rotation ratio is a reference value for
estimating the package slip described above. Specifically,
the control section 50 first calculates an average value
of the rotation speeds of the package 30 and the traverse
20 drum 24 in the predetermined period. A ratio (reference
rotation ratio) of the average rotation speed of the package
30 and the average rotation speed of the traverse drum 24
(S202) is then calculated and updated.
Before carrying out the deceleration control, the
25 package slip greater than the package slip within a
tolerable range generated for the driven rotation does not
occur (peripheral speed is substantially equal). Thus, it
can be assumed that, when the ratio of the rotation speeds
of the package 30 and the traverse drum 24 matches the
30 reference rotation ratio after the start of the
deceleration control, the package slip does not occur. In
18 / 39
the package 30, the diameter increases with the winding of
the yarn 20, and thus the peripheral speed becomes larger
with the advancement of the winding even at the same
rotation speed. In view of this, the reference rotation
ratio is periodically calculated and continuously 5 updated
before carrying out the deceleration control in the present
embodiment.
The control section 50 determines whether or not the
starting condition of the deceleration control is satisfied
10 while carrying out the process of updating the reference
rotation ratio (S203). As described above, when the
storage amount of the yarn storage device 19 is reduced,
the starting condition of the deceleration control is
satisfied. For example, the starting condition of the
15 deceleration control is satisfied even in a case where the
yarn joining operation cannot be carried out. The case
where the yarn joining operation cannot be carried out
includes a case where a trouble occurs in the yarn joining
device 14, a case where the control section 50 and the yarn
20 joining device 14 cannot communicate, a case where the yarn
supplying bobbin supporting section 7 does not support the
yarn supplying bobbin 21, and the like. In such cases, the
yarn joining operation cannot be carried out, and hence the
storage amount of the yarn storage device 19 cannot be
25 increased. Furthermore, even in the case where the yarn
joining operation can be carried out, the deceleration
control is carried out, and the winding of the package 30
may be continued at the low speed until the yarn joining
operation is completed.
30 When determining that the starting condition of the
deceleration control is satisfied, the control section 50
19 / 39
stops the update of the reference rotation ratio, and
outputs a set value of the deceleration of the traverse drum
24 (reduction amount of rotation speed or peripheral speed
per unit time) (S204). The set value may be a value input
by the operator in advance, or may be a value stored 5 d in
advance in the control section 50, and the like.
In the process of step S204, calculation can be
performed based on the package diameter and the like instead
of using the value set in advance. The package diameter
10 is calculated based on the detection result of the swing
angle sensor 46. The control section 50 reduces the initial
value of the deceleration as the package diameter is great
(i.e., gradually reduces the rotation speed). The inertia
force is greater as the package diameter is greater, and
15 thus the package slip easily occurs. The initial value of
the deceleration may be continuously changed depending on
the package diameter, and may be changed in a step-wise
manner.
The control section 50 then controls the traverse
20 drum drive motor 41 using the output set value of the
deceleration, to start the deceleration of the traverse
drum 24 (S205). Next, the control section 50 calculates
a slip amount of the package from a difference in the
peripheral speeds of the package 30 and the traverse drum
25 24 based on the reference rotation ratio. The control
section 50 determines whether or not the calculated package
slip amount is greater than or equal to an upper limit amount
(upper limit slip amount) set in advance (S206). When the
calculated package slip amount is smaller than the upper
30 limit slip amount, in particular, the control section 50
does not carry out the control of changing the deceleration.
20 / 39
When the calculated package slip amount is greater than or
equal to the upper limit slip amount, the control section
50 detects which one of the peripheral speeds of the package
30 and the traverse drum 24 is greater (S207).
Immediately after the deceleration 5 on control, the
package 30 may not follow deceleration of the traverse drum
24, and the package slip may occur. In this case, the
peripheral speed of the package 30 is slower than that of
the traverse drum 24. Therefore, in this case (i.e., Yes
10 in S207), the control section 50 reduces the deceleration
of the traverse drum 24 (more gradually decelerates the
traverse drum 24, S208).
Next, the control section 50 determines whether or
not the deceleration of the traverse drum 24 is smaller than
15 the lower limit amount defined in advance (S209). When the
deceleration of the traverse drum 24 is greater than or
equal to the lower limit amount, the control section 50
determines whether or not the rotation speed of the traverse
drum 24 has reached the target rotation speed (e.g., 0,
20 first rotation speed, second rotation speed) (S211). When
determining that the rotation speed of the traverse drum
24 has not reached the target rotation speed, the control
section 50 again carries out the processes of step S206 and
the subsequent steps.
25 When the control section 50 carries out the process
of step S208 over several times, the deceleration of the
traverse drum 24 is lowered. The deceleration of the
traverse drum 24 thus may become lower than the lower limit
amount. When the deceleration of the traverse drum 24 is
30 lowered to an amount smaller than the lower limit amount,
time is required to stop the traverse drum 24 and the storage
21 / 39
amount of the yarn storage device 19 may be greatly reduced.
Thus, in this case (i.e., Yes in step S209), the control
section 50 activates the package brake 80 (S210). Thus,
even if the package 30 cannot follow the deceleration of
the traverse drum 24, the package 30 can be more ra5 pidly
decelerated.
When the package brake 80 is activated, the
peripheral speed of the package 30 is greatly reduced, and
hence the peripheral speed of the package 30 may become
10 smaller than the peripheral speed of the traverse drum 24.
In this case (i.e., No in S207), the control section 50
increases the deceleration of the traverse drum 24 (more
rapidly decelerates the traverse drum 24, S212).
An upper limit amount is set in advance for the
15 deceleration of the traverse drum 24, and the control
section 50 determines whether or not the deceleration of
the traverse drum 24 has reached the upper limit amount of
the deceleration of the traverse drum 24 (S213). When the
deceleration of the traverse drum 24 exceeds the upper limit
20 amount and determination is made that the package brake 80
is under activation (S214), the control section 50 releases
the package brake 80 (S215). Thereafter, the control
section 50 determines whether or not the rotation speed of
the traverse drum 24 has reached the target rotation speed
25 (S211). When the rotation speed of the traverse drum 24
has not reached the target rotation speed, the control
section 50 carries out the processes of S206 and the
subsequent steps. Therefore, the activation and release
of the package brake 80 may be repeated.
30 By repeatedly carrying out the above control, the
traverse drum 24 can be decelerated in a short period of
22 / 39
time while adjusting such that the difference in the
peripheral speeds of the traverse drum 24 and the package
30 (i.e., package slip amount) becomes smaller than or equal
to a predetermined value. Furthermore, when the storage
amount of the yarn storage device 19 is increased after 5 the
rotation speed of the traverse drum 24 has reached the
target rotation speed, the control section 50 again resumes
the rotation of the traverse drum 24 or accelerates the
rotation to a new target rotation speed.
10 Next, a description will be briefly made on the change
in the peripheral speeds of the package 30 and the traverse
drum 24 when the deceleration control is carried out, using
the graph with reference to FIG. 6.
As described above, the control section 50 calculates
15 and updates the reference rotation ratio (S202). In the
example illustrated in FIG. 6, the control section 50
updates the reference rotation ratio calculated using a
predetermined period (time T1’ to time T2’) to the reference
rotation ratio obtained using the subsequent period (time
20 T1 to time T2).
Thereafter, the starting condition of the
deceleration control is assumed to be satisfied at time T3.
In this case, the reference rotation ratio obtained in the
latest predetermined period (time T1 to time T2) is used.
25 First, the package 30 cannot follow the deceleration of the
traverse drum 24, and thus the peripheral speed is greater
in the package 30. Thus, the peripheral speed of the
traverse drum 24 is lowered by carrying out the process of
step S208.
30 Thereafter, the control section 50 activates the
package brake 80 at the timing (time T4) at which the
23 / 39
deceleration of the traverse drum 24 becomes smaller than
the lower limit amount (S210). The package 30 is thereby
rapidly decelerated. The package brake 80 is released at
the timing (time T5) at which the deceleration of the
package 30 exceeds the deceleration of the traverse 5 drum
24 (S207). Thereafter, the rotation speed of the traverse
drum 24 reaches the target rotation speed, and the
deceleration control is completed.
As described above, the automatic winder of the
10 present embodiment includes the yarn supplying bobbin
supporting section 7, the yarn storage device 19, the
winding section 8, and the control section 50. The yarn
supplying bobbin supporting section 7 can supply the yarn
20. The yarn storage device 19 winds and temporarily stores
15 the yarn 20 from the yarn supplying bobbin 21 supported by
the yarn supplying bobbin supporting section 7. The
winding section 8 pulls out the yarn 20 from the yarn storage
device 19, and winds the yarn 20 around the winding bobbin
22 to form the package 30. The control section 50 controls
20 the winding section 8. The winding section 8 includes the
rotation holders 44, 45, the package rotation sensor 47,
the traverse drum 24, and the traverse drum drive motor 41.
The rotation holders 44, 45 rotatably support the package
30. The package rotation sensor 47 detects the rotation
25 amount of the package 30. The traverse drum 24 rotates
while making contact with the package 30 supported by the
rotation holders 44, 45 to rotate the package 30. The
traverse drum drive motor 41 rotatably drives the traverse
drum 24. The control section 50 carries out the
30 deceleration control of decelerating the traverse drum 24
while adjusting such that the difference in the peripheral
24 / 39
speeds of the package 30 and the traverse drum 24 becomes
smaller than or equal to a predetermined value in a state
where the yarn 20 is connected between the yarn storage
device 19 and the winding section 8 and in a state where
the package 30 and the traverse drum 24 are brought 5 into
contact with each other based on the detection result of
the package rotation sensor 47 and the rotation speed of
the traverse drum 24.
The package slip can be suppressed without gradually
10 decelerating the traverse drum 24. Therefore, the
reduction in the storage amount of the yarn storage device
19 can be suppressed while preventing the occurrence of
stitching.
In the automatic winder of the present embodiment,
15 the control section 50 carries out the deceleration control
and stops the traverse drum 24 with the yarn 20 connected
between the yarn storage device 19 and the winding section
8, and the traverse drum 24 and the package 30 brought into
contact with each other.
20 Thus, even when stopping the package 30, the package
slip (furthermore, the occurrence of stitching) can be
prevented.
Furthermore, in the automatic winder of the present
embodiment, the control section 50 resumes the winding of
25 the yarn 20 to the package supported by the rotation holders
44, 45 after stopping the traverse drum 24.
The occurrence of the stitching thus can be prevented
by stopping the package 30 with the deceleration control
of the present invention, and thus the winding of the
30 package 30 can be resumed without any problem.
In the automatic winder of the present embodiment,
25 / 39
the control section 50 carries out the deceleration control
when the amount of yarn 20 stored in the yarn storage device
19 becomes smaller than a predetermined amount (lower limit
amount of the lower limit sensor 64).
The package slip can be suppressed even 5 when
recovering the reduced storage amount.
In the automatic winder of the present embodiment,
the control section 50 calculates a reference value
(reference rotation ratio) of a difference in the
10 peripheral speeds of the package 30 and the traverse drum
24 based on the rotation speed of the traverse drum 24 and
the detection result of the package rotation sensor 47 in
a predetermined period before the start of the deceleration
control, and carries out the deceleration control using the
15 reference rotation ratio.
Thus, the package slip amount during the deceleration
control can be easily estimated by using the ratio of the
rotation speeds of the package 30 and the traverse drum 24
of before the deceleration control (i.e., before the
20 occurrence of the package slip).
The automatic winder of the present embodiment
includes the swing angle sensor 46 adapted to detect the
amount of the yarn 20 wound into the package 30. The control
section 50 may determine an initial value of the
25 deceleration of the deceleration control in view of the
detection result of the swing angle sensor 46.
Thus, the initial value of the deceleration can be
determined in view of the magnitude of the inertia force
of the package 30, and thus the package slip can be more
30 reliably suppressed.
The automatic winder of the present embodiment
26 / 39
includes the package brake 80 that makes contact with the
winding bobbin 22 and applies brake force on the package
30. The control section 50 activates the package brake 80
based on the deceleration of the traverse drum 24 to
5 decelerate the package 30.
The rotation speed of the package 30 thus can be
forcibly lowered, and hence the rotation speed of the
package 30 can be brought close to a desired value in a short
period of time.
10 The preferred embodiment of the present invention has
been described above, but the above-described
configuration may be modified as below.
In the above-described embodiment, the initial value
of the deceleration is determined based on the package
15 diameter at the start of the deceleration control, but the
initial value may, for example, be determined based on the
package rotation speed at the start of the deceleration
control. Specifically, since the inertia force becomes
larger as the rotation speed of the package 30 is faster,
20 and the package slip easily occurs, the initial value of
the deceleration is preferably reduced (i.e., gradually
decelerates the traverse drum 24). In view of the package
diameter and the rotation speed of the package 30, not only
the initial value, but also the amount of change in the
25 deceleration may be controlled.
In the above-described embodiment, the traverse drum
drive motor 41 is controlled by the control section 50 for
carrying out a versatile control, but may be controlled by
a motor control section arranged separately from the
30 control section 50. In the above-described embodiment,
the deceleration control is carried out by the control
27 / 39
section 50 arranged for each winding unit 2, but the process
carried out by the deceleration control may be partially
or entirely carried out by the machine control device.
In the above-described embodiment, the yarn amount
of the package 30 is detected by the swing angle sensor 5 sor 46
adapted to detect the swing angle of the cradle 23, but the
yarn amount of the package 30 may be detected with a sensor
adapted to detect the length of the wound yarn 20.
In the above-described embodiment, the traverse drum
10 rotation sensor 42 and the package rotation sensor 47 have
a configuration of outputting the pulse signal
corresponding to the rotation to the control section 50,
but the rotation speed may be calculated and output to the
control section 50.
15 In the above-described embodiment, an example of
supplying the yarn supplying bobbin 21 by the magazine type
bobbin supplying device 26 has been described, but the yarn
winding device including the tray type bobbin supplying
device may be adopted.
20 The configuration of the present invention is not
limited to the automatic winder, and can also be applied
to other types of yarn winding devices including the yarn
storage device and the contact roller.
In the above-described embodiment, the control
25 section 50 activates the package brake 80 based on the
deceleration of the traverse drum 24 to decelerate the
package 30, but this is not the sole case. When the amount
of yarn stored in the yarn storage device 19 becomes smaller
than or equal to the lower limit amount as detected by the
30 lower limit sensor 64 configuring the storage amount
detecting section, the control section 50 determines that
28 / 39
there is a possibility the storage amount of the yarn
storage device 19 is zero, and activates the package brake
80 and decelerates and stops the package 30 to prevent the
storage amount of the yarn storage device 19 from being zero.
In this case, preventing the storage of the yarn 5 storage
device 19 from being zero is prioritized over the control
of the difference in the peripheral speeds of the traverse
drum 24 and the package 30. Thus, the difference in the
peripheral speeds of the traverse drum 24 and the package
10 30 (package slip amount) may become greater than or equal
to the upper limit slip amount. When the package slip
amount becomes greater than or equal to the upper limit slip
amount, the control section 50 suddenly stops the package
30 by the package brake 80 and activates the alarm warning
15 at the same time, and suggests the possibility of the
occurrence of stitching to the operator. The operator thus
can find the occurrence of the stitching at an early stage,
unwind the yarn in which the stitching has occurred, and
rewind the yarn into a package without the stitching.
20 Furthermore, when the winding of the package is
stopped as the amount of yarn stored in the yarn storage
device 19 becomes smaller than or equal to the lower limit
amount as detected by the lower limit sensor 64 configuring
the storage amount detecting section, the amount of yarn
25 stored in the yarn storage device 19 becomes smaller than
or equal to the lower limit amount when resuming the winding
the next time. In this case, when the next winding
operation is started, that is, when the winding of the yarn
to the package and the winding of the yarn 20 from the yarn
30 supplying bobbin 21 by the yarn storage device 19 are
started, the winding speed of the yarn to the package is
29 / 39
set to low speed (e.g., 200 to 300 m/min) until the amount
of yarn stored in the yarn storage device 19 becomes greater
than or equal to the lower limit amount. The deficiency
of storage yarn caused by the winding of the yarn to the
package 5 thus can be prevented.
Thus, the slip that occurs between the contact roller
and the package can be suppressed without gradually
decelerating the contact roller. Therefore, the storage
amount of the yarn storage device can be increased while
10 preventing occurrence of stitching.
In the above-described yarn winding device, the
control section preferably carries out the deceleration
control to stop the contact roller in a state where the yarn
is connected between the yarn storage device and the package
15 forming section and in a state where the contact roller and
the package are brought into contact with each other.
Thus, even when stopping the package, the slip
(furthermore, the occurrence of stitching) that occurs
between the contact roller and the package can be prevented.
20 In the above-described yarn winding device, after
stopping the contact roller, the control section preferably
resumes the winding of the yarn to the package supported
by the package supporting section.
Thus, the occurrence of the stitching can be
25 prevented by stopping the package with the deceleration
control of the present invention, whereby the winding of
the package can be resumed without causing any problems in
terms of quality.
In the above-described yarn winding device, the
30 control section preferably carries out the deceleration
control when the amount of yarn stored in the yarn storage
30 / 39
device is smaller than a predetermined amount.
The slip that occurs between the contact roller and
the package thus can be suppressed even when recovering the
reduced storage amount.
In the above-described yarn winding device, 5 the
control section preferably calculates a reference value of
a difference in peripheral speeds of the package and the
contact roller based on the rotation speed of the contact
roller and the detection result of the package rotation
10 detecting section in a predetermined period before start
of the deceleration control, and carries out the
deceleration control using the reference value.
In other words, since a diameter of the package
changes according to the winding amount, a slip amount
15 cannot be accurately obtained only by the rotation speed
of the package and the rotation speed of the contact roller.
In this regard, the slip amount during the deceleration
control can be easily estimated by using the rotation speeds
of the package and the contact roller before the
20 deceleration control (before the occurrence of slip).
The above-described yarn winding device preferably
has the following configuration. Specifically, the yarn
winding device includes a package yarn amount detecting
section adapted to detect the amount of yarn wound into the
25 package. The control section determines a set value of the
deceleration control in view of the detection result of the
package yarn amount detecting section.
Thus, the diameter and the weight of the package can
be calculated based on the amount of yarn wound into the
30 package, and hence the set value (initial value, control
parameter, or the like) can be determined in view of the
31 / 39
magnitude of the inertia force of the package. Therefore,
the slip that occurs between the contact roller and the
package can be more reliably suppressed.
The above-described yarn winding device preferably
has the following configuration. Specifically, the 5 yarn
winding device further includes a package brake adapted to
make contact with the winding bobbin or the package and
apply brake force to the package. The control section
activates the package brake based on the deceleration of
10 the contact roller to decelerate the package.
The rotation speed of the package thus can be forcibly
lowered, and hence the rotation speed of the package can
be brought close to a desired value in a short period of
time.
15 The above-described yarn winding device further
includes a package brake adapted to make contact with the
winding bobbin or the package and apply brake force to the
package, wherein the control section activates the package
brake to decelerate the package when the storage amount
20 detecting section detects that the amount of yarn wound
around the storage roller is smaller than or equal to a
predetermined amount.
The yarn stored in the yarn storage device thus can
be prevented from running out.
25 The control section calculates a difference in
peripheral speeds of the package and the contact roller
based on the rotation speed of the contact roller and the
detection result of the package rotation detecting section
while activating the package brake and decelerating the
30 package when the storage amount detecting section detects
that the amount of yarn wound around the storage roller is
32 / 39
smaller than or equal to a predetermined amount, and
immediately stops the rotation of the package by the package
brake and notifies an alarm warning when the difference in
the peripheral speeds is greater than or equal to a
5 predetermined value.
The operator thus can find the occurrence of the
stitching at an early stage and can unwind the yarn in which
the stitching occurred and rewind the yarn to a package
without stitching.
10 In the above-described yarn winding device, the yarn
supplying section is a yarn supplying bobbin supporting
section adapted to support a yarn supplying bobbin around
which a yarn spun by a spinning machine is wound, and the
contact roller is a traverse drum provided with a traverse
15 groove for traversing a yarn wound into the package.
Thus, although the surface of the package may be
damaged if a large slip occurs between the traverse drum
and the package, such damage can be prevented by carrying
out the deceleration control of the present invention.
20 The above-described yarn winding device preferably
has the following configuration. Specifically, the yarn
winding device includes a yarn joining device arranged
between the yarn supplying section and the yarn storage
device, and adapted to join a disconnected yarn when the
25 yarn is disconnected. The control section performs the
deceleration control when detecting that the yarn joining
operation by the yarn joining device is not possible.
If the yarn joining operation is not possible, the
yarn of the yarn storage device may run out shortly.
30 Therefore, by carrying out the deceleration control as
described above, the storage amount of the yarn storage
33 / 39
device can be increased while suppressing the slip that
occurs between the contact roller and the package.
According to a second aspect of the present invention,
a package decelerating method is provided as follows.
Specifically, the package decelerating method includes 5 a
package rotation detecting step, and a decelerating step.
In the package rotation detecting process, a rotation
amount of a package formed by winding a yarn around a winding
bobbin with a package forming section is detected. In the
10 decelerating process, the contact roller is decelerated
while adjusting such that a difference in peripheral speeds
of the package and the contact roller is smaller than or
equal to a predetermined value in a state where the yarn
is connected between the package forming section and a yarn
15 storage device, which is adapted to wind the yarn from a
yarn supplying section and temporarily store the yarn, and
in a state where the package and the contact roller are
brought into contact with each other based on a detection
result of the package rotation detecting process and a
20 rotation speed of the contact roller adapted to rotate while
making contact with the package to rotate the package.
Thus, the package can be decelerated while
suppressing the slip that occurs between the contact roller
and the package without gradually decelerating the contact
25 roller. Therefore, the storage amount of the yarn storage
device can be increased while preventing the occurrence of
stitching.

WE CLAIM:
1. A yarn winding device comprising:
a yarn supplying section adapted to supply a yarn;
a yarn storage device adapted to pull out the 5 e yarn
from the yarn supplying section and temporarily store the
yarn ;
a package forming section adapted to pull out the yarn
from the yarn storage device and wind the yarn around a
10 winding bobbin to form a package ; and
a control section adapted to control the package
forming section,
wherein the package forming section includes
a package supporting section adapted to
15 rotatably support the package,
a package rotation detecting section adapted
to detect a rotation amount of the package,
a contact roller adapted to rotate while making
contact with the package supported by the package
20 supporting section to rotate the package, and
a roller drive source adapted to rotatably
drive the contact roller , characterized in that
the control section carries out a deceleration
control of decelerating the contact roller while adjusting
25 such that a difference in peripheral speeds of the package
and the contact roller is smaller than or equal to a
predetermined value in a state where the yarn is connected
between the yarn storage device and the package forming
section and in a state where the package and the contact
30 roller are brought into contact with each other based on
a detection result of the package rotation detecting
35 / 39
section and a rotation speed of the contact roller.
2. The yarn winding device according to claim 1,
characterized in that
the control section carries out the 5 deceleration
control to stop the contact roller in a state where the yarn
is connected between the yarn storage device and the package
forming section and in a state where the contact roller and
the package are brought into contact with each other.
10
3. The yarn winding device according to claim 1 or
2, characterized in that
after stopping the contact roller , the control
section resumes the winding of the yarn to the package
15 supported by the package supporting section.
4. The yarn winding device according to any one of
claims 1 to 3, characterized in that
the yarn storage device includes a storage roller
20 adapted to wind and store the yarn, and
a storage amount detecting section adapted to detect
an amount of yarn wound around the storage roller , and
the control section carries out the deceleration
control when the storage amount detecting section detects
25 that the amount of yarn stored in the yarn storage device
is smaller than a predetermined amount.
5. The yarn winding device according to any one of
claims 1 to 4, characterized in that
30 the control section calculates a reference value of
a difference in peripheral speeds of the package and the
36 / 39
contact roller based on the rotation speed of the contact
roller and the detection result of the package rotation
detecting section in a predetermined period before start
of the deceleration control, and carries out the
deceleration 5 control using the reference value.
6. The yarn winding device according to any one of
claims 1 to 5, characterized by further comprising
a package yarn amount detecting section adapted to
10 detect the amount of yarn wound into the package ,
wherein the control section determines a set value
of the deceleration control in view of the detection result
of the package yarn amount detecting section.
15 7. The yarn winding device according to any one of
claims 1 to 6, characterized by further comprising
a package brake adapted to make contact with the
winding bobbin or the package and to apply brake force to
the package ,
20 wherein the control section activates the package
brake based on deceleration of the contact roller to
decelerate the package.
8. The yarn winding device according to claim 4,
25 characterized by further comprising
a package brake adapted to make contact with the
winding bobbin or the package and to apply brake force to
the package ,
wherein the control section activates the package
30 brake to decelerate the package when the storage amount
detecting section detects that the amount of yarn wound
37 / 39
around the storage roller is smaller than or equal to a
predetermined amount.
9. The yarn winding device according to claim 8,
5 characterized in that
the control section calculates a difference in
peripheral speeds of the package and the contact roller
based on the rotation speed of the contact roller and the
detection result of the package rotation detecting section
10 while activating the package brake and decelerating the
package when the storage amount detecting section detects
that the amount of yarn wound around the storage roller is
smaller than or equal to a predetermined amount, and
immediately stops the rotation of the package by the package
15 brake and produces an alarm warning when the difference in
the peripheral speeds is greater than or equal to a
predetermined value.
10. The yarn winding device according to any one of
20 claims 1 to 9, characterized in that
the yarn supplying section is a yarn supplying bobbin
supporting section adapted to support a yarn supplying
bobbin around which a yarn spun by a spinning machine is
wound, and
25 the contact roller is a traverse drum provided with
a traverse groove for traversing a yarn wound into the
package.
11. The yarn winding device according to any one of
30 claims 1 to 10, characterized by further comprising:
a yarn joining device arranged between the yarn
38 / 39
supplying section and the yarn storage device, and adapted
to join a disconnected yarn when the yarn is disconnected;
and
the control section performs the deceleration
control when detecting that the yarn joining operation 5 by
the yarn joining device is not possible.
12. A package decelerating method comprising:
a package rotation detecting step of detecting a
10 rotation amount of a package formed by winding a yarn around
a winding bobbin with a package forming section; and
a decelerating step of decelerating the contact
roller characterized by adjusting such that a difference
in peripheral speeds of the package and the contact roller
15 is smaller than or equal to a predetermined value in a state
where the yarn is connected between the package forming
section and a yarn storage device, which is adapted to wind
the yarn from a yarn supplying section and temporarily store
the yarn , and in a state where the package and the contact
20 roller are brought into contact with each other based on
a detection result of the package rotation detecting step
and a rotation speed of the contact roller adapted rotate
while making contact with the package to rotate the package.