YARN WINDING DEVICE, AUTOMATIC WINDER, AND YARN WINDING
METHOD
BACKGROUND OF THE INVENTION
5 1. Field of the Invention
The present invention relates to a yarn winding
device, an automatic winder, and a yarn winding method.
2. Description of the Related Art
10 For example, JP 2002-128390 A discloses a yarn
winding device configured to wind a yarn into a package
by rotating, with a motor, a bobbin holder that supports
the package while traversing the yarn with a traverse
device.
15 In the yarn winding device of JP 2002-128390 A, in
order to keep a constant winding speed of the yarn, a
deceleration process is executed in which a rotation
speed of the package is reduced as a diameter of the
package is increased.
20 However, when winding is performed with a yarn
winding speed kept constant as in JP 2002-128390 A, a
problem of "surface collapse" may sometimes have
occurred in which a surface layer of the package
collapses, as the diameter of the package is increased
25 to some extent. Since a package in which the surface
collapse has occurred is to be a defective product, it
is required to suppress the surface collapse.
BRIEF SUMMARY OF THE INVENTION
30 The present invention has been made in view of the
above problem, and an object is to suppress surface
3
collapse of a package.
A yarn winding device according to the present
invention is a yarn winding device that rotates a package
while traversing a yarn to wind the yarn on the package.
5 The yarn winding device includes a control section
that accelerates a winding speed of the yarn to a winding
speed that has been set, and executes winding control of
winding the yarn at the winding speed. The control
section executes a deceleration mode for decelerating a
10 winding speed of the yarn when a diameter of the package
exceeds a predetermined diameter that is set before a
full winding diameter is reached.
A yarn winding method according to the present
invention is a yarn winding method for rotating a package
15 while traversing a yarn to wind the yarn on the package.
In the yarn winding method, a winding speed of the yarn
is decelerated when a diameter of the package exceeds a
predetermined diameter that is set before a full winding
diameter is reached.
20 The inventors of the present application have paid
attention to the following events as one of the causes
of the surface collapse. It is considered that, when a
yarn is wound while being traversed, the yarn is tightly
stretched (tension is high) at an end portion of a
25 package where the yarn is folded back, while the yarn
tends to have slackness (tension tends to decrease) at
a center portion of the package. As a diameter of the
package increases, a length of the yarn wound in one
traverse becomes longer, and the yarn becomes more likely
30 to have slackness. As a result, when the diameter of
the package increases to some extent, the yarn on a
4
surface layer of the package may float due to a
centrifugal force, to cause the surface collapse.
Based on such an event, in the present invention,
a winding speed of the yarn is decelerated when a
5 diameter of the package exceeds a predetermined diameter
that is set before a full winding diameter is reached.
Decelerating the yarn winding speed will accordingly
reduce a rotation speed of the package, which can reduce
a centrifugal force acting on the yarn on the surface
10 layer of the package. As a result, the surface collapse
of the package can be suppressed.
In the yarn winding device according to the present
invention, when a winding condition is set such that a
winding density of the package is 0.40 g/cm3 or less,
15 the control section desirably executes a deceleration
mode.
In order to produce a package suitable for dyeing,
so-called "soft winding" may be performed in which a
yarn is wound such that a winding density is lower than
20 that of a normal package (for example, 0.40 g/cm3 or
less). When the soft winding is performed, since tension
of the yarn wound around the package is lower than usual,
the surface collapse tends to occur due to an action of
a centrifugal force. Therefore, by automatically
25 applying the deceleration mode in the case of soft
winding, the surface collapse can be reliably suppressed.
In the yarn winding device according to the present
invention, in the deceleration mode, multiple
predetermined diameters are provided before the diameter
30 of the package reaches the full winding diameter.
Executing the deceleration mode can suppress the
5
surface collapse, but a production speed of the package
will be reduced. Therefore, by decelerating the winding
speed in multiple stages, it is possible to avoid a
sudden deceleration of the winding speed and suppress
5 reduction in the production speed of the package.
In the yarn winding device according to the present
invention, it is desirable that a traverse device for
traverse of the yarn and a drive device for rotation of
the package are individually provided, and the traverse
10 device and the drive device for rotation of the package
are synchronously controlled when the winding speed of
the yarn is decelerated during execution of the
deceleration mode.
According to such a configuration, since the
15 traverse speed and the rotation speed of the package can
be controlled independently, a degree of freedom in
setting a winding condition is high, which is suitable
for soft winding. Therefore, it is particularly
effective to apply the deceleration mode to such a yarn
20 winding device.
In the yarn winding device according to the present
invention, the traverse device is desirably an arm-type
traverse device that traverses the yarn with an arm that
reciprocatingly swings.
25 When an arm-type traverse device is adopted, a
drive device for rotation of the package is provided
separately from the traverse device. Therefore, as
described above, the degree of freedom in setting the
winding condition is high, which is suitable for soft
30 winding, and it is particularly effective to apply the
deceleration mode.
6
In the yarn winding device according to the present
invention, the drive device desirably rotates the
package directly.
When the package is directly rotated by the drive
5 device, a rotation speed of the package can be controlled
with high accuracy, which can improve accuracy of the
deceleration mode.
An automatic winder according to the present
invention is configured by arranging a plurality of any
10 of the above-described yarn winding devices.
According to such an automatic winder, it is
possible to suppress the surface collapse of the package
in each yarn winding device.
15 BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic configuration view of an
automatic winder according to the present embodiment;
FIG. 2 is a front view of a winding unit;
FIG. 3 is an enlarged front view of a winding
20 section;
FIG. 4 is a view schematically illustrating surface
collapse that has occurred in a package;
FIG. 5 is a flowchart showing an Example of a
deceleration mode; and
25 FIG. 6 is a graph showing changes in a yarn winding
speed in the Example.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Hereinafter, an example of an embodiment of the
30 present invention will be described with reference to
the drawings.
7
(Automatic winder)
FIG. 1 is a schematic configuration view of an
automatic winder according to the present embodiment.
As illustrated in FIG. 1, an automatic winder 1 has a
5 plurality of winding units 2 (corresponding to a yarn
winding device of the present invention) arranged in one
direction. On one side of a row formed by the plurality
of winding units 2, a machine control device 3 is
arranged. In this specification, as illustrated in FIG.
10 1, an arrangement direction of the plurality of winding
units 2 will be described as a horizontal direction.
The automatic winder 1 forms a package P by winding
a yarn Y unwound from a yarn supplying bobbin B in each
of the winding units 2. When the package P is completed
15 in one winding unit 2, a doffing device (not illustrated)
moves to the winding unit 2, collects the completed
package P, and newly sets an empty winding bobbin Q.
Operations of the plurality of winding units 2 and the
doffing device are controlled by the machine control
20 device 3.
The machine control device 3 is provided with a
setting section 4. An operator can set a winding
condition and the like in the plurality of winding units
2 via the setting section 4. The setting section 4 has
25 a display section 4a to display the winding condition
and the like, and an operation section 4b including a
plurality of input keys and the like for the operator to
input the winding condition and the like.
(Winding unit)
30 Next, a configuration of the winding unit 2 will
be described. FIG. 2 is a front view of the winding
8
unit 2. The winding unit 2 winds the yarn Y unwound
from the yarn supplying bobbin B around the winding
bobbin Q while traversing, to form the package P. The
winding unit 2 has a yarn supplying section 10, a yarn
5 processing section 20, a winding section 30, and a unit
control section 40 (corresponding to a control section
of the present invention). The unit control section 40
is electrically connected to the machine control device
3. The unit control section 40 controls operations of
10 the yarn supplying section 10, the yarn processing
section 20, and the winding section 30 on the basis of
the winding condition and the like sent from the machine
control device 3.
The yarn supplying section 10 is arranged at a
15 lower part of the winding unit 2, and gives instruction
to allow the yarn Y to be unwound from the yarn supplying
bobbin B. The yarn supplying section 10 includes a
bobbin holding section 11 that holds the yarn supplying
bobbin B, and an unwinding assisting device 12 that
20 assists in unwinding the yarn Y from the yarn supplying
bobbin B. The unwinding assisting device 12 has a
cylindrical body 13 that is placed over the yarn
supplying bobbin B from above. The cylindrical body 13
is lifted and lowered by a lifting device (not
25 illustrated). The unwinding assisting device 12
controls bulging (balloon) of the yarn Y during unwinding,
by lowering the cylindrical body 13 as the unwinding of
the yarn Y progresses, and stabilizes the tension of the
yarn Y.
30 The yarn processing section 20 is arranged between
the yarn supplying section 10 and the winding section 30
9
in a yarn travelling direction, and performs various
kinds of processing on the yarn Y supplied from the yarn
supplying section 10. The yarn processing section 20
includes a tension applying device 21 that applies a
5 predetermined tension to the travelling yarn Y, a yarn
joining device 22 that joins the yarn, a yarn clearer 23
that detects a yarn defect, a lower-yarn capturing and
guiding member 24, and an upper-yarn capturing and
guiding member 25.
10 When the yarn Y is divided in the winding unit 2,
the yarn joining device 22 joins a yarn (a lower yarn)
Y on the yarn supplying bobbin B side and a yarn (an
upper yarn) Y on the package P side. The yarn joining
by the yarn joining device 22 is performed, for example,
15 when a yarn defect is detected by the yarn clearer 23
and the yarn Y is cut by a cutter 23a, when yarn Y breaks
during winding of the yarn Y, when the yarn supplying
bobbin B is replaced as the yarn Y of the yarn supplying
bobbin B runs out, and the like.
20 When the yarn Y is divided, the lower-yarn
capturing and guiding member 24 captures the lower yarn
Y and guides the lower yarn Y to the yarn joining device
22. The lower-yarn capturing and guiding member 24 is
rotatable about a shaft 24a, and is rotationally driven
25 by a motor (not illustrated). The lower-yarn capturing
and guiding member 24 has, at a distal end portion
thereof, a suction section 24b that sucks and captures
a yarn end of the lower yarn Y. When the yarn Y is
divided, the upper-yarn capturing and guiding member 25
30 captures the upper yarn Y and guides the upper yarn Y to
the yarn joining device 22. The upper-yarn capturing
10
and guiding member 25 is rotatable about a shaft 25a,
and is rotationally driven by a motor (not illustrated).
The upper-yarn capturing and guiding member 25 has, at
a distal end portion thereof, a suction section 25b that
5 sucks and captures a yarn end of the upper yarn Y.
When the yarn is joined by the yarn joining device
22, the lower-yarn capturing and guiding member 24 guides
the lower yarn Y to the yarn joining device 22, and the
upper-yarn capturing and guiding member 25 guides the
10 upper yarn Y to the yarn joining device 22. Specifically,
after sucking and capturing a yarn end of the lower yarn
Y with the suction section 24b, the lower-yarn capturing
and guiding member 24 guides the lower yarn Y to the
yarn joining device 22 by rotating upward. Whereas, by
15 first rotating upward and positioning the suction
section 25b near the package P, the upper-yarn capturing
and guiding member 25 sucks and captures a yarn end of
the upper yarn Y attached to a surface of the package P
by the suction section 25b. Then, the upper-yarn
20 capturing and guiding member 25 rotates downward, to
guide the upper yarn Y to the yarn joining device 22.
The yarn joining device 22 connects the yarn end of the
lower yarn Y guided by the lower-yarn capturing and
guiding member 24 and the yarn end of the upper yarn Y
25 guided by the upper-yarn capturing and guiding member
25, to form one yarn Y.
The yarn clearer 23 constantly acquires
information on a thickness of the travelling yarn Y, and
detects, as a yarn defect, an abnormal portion where a
30 thickness included in the yarn Y is larger than a certain
value. The yarn clearer 23 is provided with the cutter
11
23a, and the cutter 23a immediately cuts the yarn Y when
a yarn defect is detected by the yarn clearer 23. A
portion of the yarn defect is removed by being sucked by
the suction section 25b of the upper-yarn capturing and
5 guiding member 25 when the yarn is joined thereafter.
The winding section 30 is arranged at an upper part
of the winding unit 2, and winds the yarn Y around the
winding bobbin Q to form the package P. The winding
section 30 includes a cradle 31 that supports the package
10 P (the winding bobbin Q), a contact roller 32 that comes
into contact with a peripheral surface of the package P,
and a traverse device 33 for traverse of the yarn Y.
FIG. 3 is an enlarged front view of the winding
section 30. The cradle 31 rotatably supports both end
15 portions of the package P (the winding bobbin Q). The
cradle 31 is provided with a rotary motor 34
(corresponding to a drive device of the present
invention) that rotationally drives the package P (the
winding bobbin Q). By directly rotating the package P
20 with the rotary motor 34, the yarn Y is wound around the
package P. The rotary motor 34 is provided with a
rotation sensor 35 that detects a rotation speed of the
rotary motor 34 (that is, a rotation speed of the package
P). The rotary motor 34 and the rotation sensor 35 are
25 electrically connected to the unit control section 40,
and driven synchronously with the traverse device 33
when the yarn Y is wound.
The contact roller 32 applies contact pressure to
the package P by coming into contact with the package P,
30 and adjusts a shape of the package P. When the package
P is rotationally driven by the rotary motor 34, the
12
contact roller 32 is driven to rotate by a frictional
force with the package P. The cradle 31 is configured
to be swingable in accordance with a change in a diameter
of the package P. This allows the contact pressure
5 applied to the package P by the contact roller 32 to be
kept substantially constant, even if the winding of the
yarn Y progresses and the diameter of the package P
increases. In the vicinity of the contact roller 32, a
roller rotation sensor 36 that detects a rotation speed
10 of the contact roller 32 is provided. The roller
rotation sensor 36 is electrically connected to the unit
control section 40.
The traverse device 33 includes: an arm 37 capable
of reciprocatingly swinging in a direction substantially
15 parallel to an axial direction (the horizontal
direction) of the winding bobbin Q; a traverse guide 38
attached to a distal end portion of the arm 37; and a
traverse motor 39 that swings and drives the arm 37. By
reciprocatingly swinging the arm 37 by the traverse motor
20 39, the yarn Y hung on the traverse guide 38 is traversed
in the axial direction of the winding bobbin Q. The
traverse motor 39 is electrically connected to the unit
control section 40.
In the winding unit 2 configured as described above,
25 the yarn Y is wound in accordance with the winding
condition set by the operator via the setting section 4
of the machine control device 3. The unit control
section 40 appropriately controls the rotary motor 34
and the traverse motor 39 to realize a way of winding
30 according to the winding condition. For example, when
the winding condition is set to form a soft-wound package
13
P suitable for dyeing, the traverse motor 39 is
controlled such that a traverse speed is higher than
that in production of a normal package P. Note that a
winding density of the normal package P is around 0.42
5 g/cm3, while a winding density of the soft-wound package
P is about 0.40 g/cm3 or less.
(Suppression of surface collapse)
When a diameter of the package P increases to some
extent in the process of winding the yarn Y with the
10 winding unit 2, as illustrated in FIG. 4, a phenomenon
called "surface collapse" may sometimes have occurred in
which the yarn Y at a center portion of the surface layer
of the package P is in a floating state. The surface
collapse is particularly remarkable when soft winding
15 with a low winding density is performed.
The inventors of the present application have paid
attention to the following events as one of the causes
of the surface collapse. It is considered that, when
the yarn Y is wound while being traversed, the yarn Y is
20 tightly stretched (tension is high) at an end portion of
the package P where the yarn Y is folded back, while the
yarn Y tends to have slackness (tension tends to
decrease) at a center portion of the package P. As a
diameter of the package P increases, a length of the
25 yarn Y wound in one traverse becomes longer, and the
yarn Y becomes more likely to have slackness. As a
result, when the diameter of the package P becomes large
to some extent, the yarn Y on the surface layer of the
package P may float due to a centrifugal force, to cause
30 the surface collapse. Based on such an event, in the
automatic winder 1 of the present embodiment, when a
14
diameter of the package P exceeds a predetermined
diameter that is set before a full winding diameter is
reached, the deceleration mode for decelerating a
winding speed of the yarn Y (a travelling speed of the
5 yarn Y) is executed. The deceleration mode will be
described below.
When soft winding is set, that is, when the winding
condition is set in which the winding density of the
package P is 0.40 g/cm3 or less, the unit control section
10 40 automatically executes the deceleration mode. While
the yarn Y is wound, a winding angle and a traverse range
are kept constant. Further, until the deceleration mode
is executed, a rotation speed of the package P is
controlled so that a winding speed of the yarn Y is kept
15 constant.
The unit control section 40 calculates a diameter
of the package P, on the basis of the rotation speed of
the package P detected by the rotation sensor 35 and the
rotation speed of the contact roller 32 detected by the
20 roller rotation sensor 36. Specifically, the unit
control section 40 calculates a peripheral speed of the
contact roller 32 (that is, a peripheral speed of the
package P) from the rotation speed and the diameter of
the contact roller 32. Then, the diameter of the package
25 P is calculated from the rotation speed and the
peripheral speed of the package P.
Note that the unit control section 40 may calculate
the diameter of the package P by another method. For
example, the unit control section 40 may calculate the
30 diameter of the package P on the basis of a travelling
speed of the yarn Y. Specifically, the travelling speed
15
of the yarn Y may be detected by the yarn clearer 23 or
a dedicated yarn speed sensor, and the diameter of the
package P may be calculated on the basis of a length of
the yarn Y wound around the package P so far.
5 FIG. 5 is a flowchart showing an Example of the
deceleration mode. FIG. 6 is a graph showing changes in
a yarn winding speed in the Example. The unit control
section 40 keeps a winding speed of the yarn Y at 1000
m/min until the deceleration mode is executed. When a
10 diameter of the package P calculated every predetermined
time exceeds 130 mm (YES in step S11), the unit control
section 40 controls the rotary motor 34 so as to
decelerate the winding speed of the yarn Y from 1000
m/min to 900 m/min (step S12). When decelerating the
15 winding speed of the yarn Y, it is desirable to gradually
reduce the speed as shown in FIG. 6.
Next, when the diameter of the package P exceeds
a predetermined diameter of 170 mm (YES in step S13),
the winding speed of the yarn Y is decelerated to 800
20 m/min (step S14). Hereinafter, similarly, when the
diameter of the package P exceeds a predetermined
diameter of 210 mm (YES in step S15), the winding speed
of the yarn Y is decelerated to 700 m/min (step S16),
and when the diameter of the package P further exceeds
25 a predetermined diameter of 250 mm (YES in step S17),
the winding speed of the yarn Y is decelerated to 600
m/min (step S18). As described above, in the
deceleration mode of the present Example, the winding
speed of the yarn Y is decelerated in multiple stages.
30 That is, multiple predetermined diameters are provided
before the diameter of the package reaches the full
16
winding diameter. After that, the winding speed of the
yarn Y is kept at 600 m/min until the winding of the
yarn Y ends. When the deceleration mode was actually
executed under such conditions, it was possible to
5 suppress the surface collapse that occurred when the
deceleration mode was not executed.
(Effect)
In the present embodiment, when a diameter of the
package P exceeds a predetermined diameter, the
10 deceleration mode for decelerating a winding speed of
the yarn Y is executed. Decelerating the winding speed
of the yarn Y will accordingly reduce a rotation speed
of the package P, which can reduce a centrifugal force
acting on the yarn Y on a surface layer of the package
15 P. As a result, the surface collapse of the package P
can be suppressed.
In the present embodiment, when a winding condition
in which a winding density of the package P is 0.40 g/cm3
or less is set, that is, a winding condition of soft
20 winding is set, the deceleration mode is executed. When
the soft winding is performed, since tension of the yarn
Y wound around the package P is lower than usual, the
surface collapse tends to occur. Therefore, by
automatically applying the deceleration mode in the case
25 of soft winding, the surface collapse can be reliably
suppressed.
In the deceleration mode of the present embodiment,
the winding speed of the yarn Y is decelerated in
multiple stages. Executing the deceleration mode can
30 suppress the surface collapse, but a production speed of
the package P will be reduced. Therefore, by
17
decelerating the winding speed in multiple stages, it is
possible to avoid sudden deceleration of the winding
speed and suppress reduction in the production speed of
the package P.
5 The winding unit 2 of the present embodiment is
individually provided with the traverse device 33 for
traverse of the yarn Y and the rotary motor 34 for
rotation of the package P. According to such a
configuration, since a traverse speed and a rotation
10 speed of the package P can be controlled independently,
a degree of freedom in setting a winding condition is
high, which is suitable for soft winding. Therefore, it
is particularly effective to apply the deceleration mode
to such a winding unit 2.
15 The traverse device 33 of the present embodiment
is an arm-type traverse device that traverses the yarn
Y by the arm 37 that reciprocatingly swings. When the
arm-type traverse device is adopted, the rotary motor 34
for rotation of the package P is provided separately
20 from the traverse device 33. Therefore, as described
above, the degree of freedom in setting the winding
condition is high, which is suitable for soft winding,
and it is particularly effective to apply the
deceleration mode.
25 The rotary motor 34 of the present embodiment
directly rotates the package P. When the package P is
rotated directly by the rotary motor 34, the rotation
speed of the package P can be controlled accurately,
which can improve accuracy of the deceleration mode.
30 (Other embodiments)
Alternative embodiments in which various
18
modifications are made on the above-described embodiment
will be described.
In the above-described embodiment, the
deceleration mode is executed when the soft winding is
5 performed in which the winding density of the package P
is 0.40 g/cm3 or less. However, it is also possible to
execute the deceleration mode under a winding condition
in which the winding density of the package P is greater
than 0.40 g/cm3.
10 In the above-described embodiment, the winding
speed of the yarn Y is decelerated in multiple stages in
the deceleration mode. However, a way of deceleration
of the winding speed in the deceleration mode can be
appropriately changed. For example, the winding speed
15 may be decelerated in one step alone, or the winding
speed may be continuously decelerated.
In the above-described embodiment, the traverse
device 33 is an arm-type traverse device, and the package
P is rotationally driven directly by the rotary motor
20 34. However, the specific configuration of the winding
unit 2 is not limited to this. For example, the traverse
device 33 is not limited to the arm-type traverse device,
but may be a belt-type traverse device in which a
traverse guide is attached to an endless belt that is
25 reciprocatingly driven. Further, the contact roller 32
may be rotationally driven directly by a motor, to drive
the package P to rotate. Further, a traverse drum
(having a traverse groove formed on a peripheral surface
of a drum) also having functions of the contact roller
30 32 and the traverse device 33 may be adopted.
In the above-described embodiment, the unit
19
control section 40 automatically executes the
deceleration mode in accordance with the winding
condition. However, for example, when a diameter of the
package P exceeds a predetermined diameter, an
5 instruction for the operator to manually execute the
deceleration mode may be displayed.

WE CLAIM
1. A yarn winding device (2) for rotating a
package (P) while traversing a yarn to wind the yarn
around the package (P), the yarn winding device (2)
5 comprising
a control section (40) that accelerates a winding
speed of a yarn to a winding speed that has been set,
and executes winding control of winding the yarn at the
winding speed,
10 wherein the control section (40) executes a
deceleration mode for decelerating a winding speed of
the yarn, when a diameter of the package (P) exceeds a
predetermined diameter that is set before a full winding
diameter is reached.
15
2. The yarn winding device (2) as claimed in claim
1, wherein the control section (40) executes the
deceleration mode when a winding condition is set in
which a winding density of the package (P) is 0.40 g/cm3
20 or less.
3. The yarn winding device (2) as claimed in claim
1 or 2, wherein, in the deceleration mode, multiple
predetermined diameters are provided before a diameter
25 of the package (P) reaches a full winding diameter.
4. The yarn winding device (2) as claimed in any
one of claims 1 to 3, wherein a traverse device (33) for
traverse of the yarn and a drive device for rotation of
30 the package (P) are individually provided, and the
traverse device (33) and the drive device for rotation
21
of the package (P) are synchronously controlled when a
winding speed of the yarn is decelerated during execution
of the deceleration mode.
5 5. The yarn winding device (2) as claimed in claim
4, wherein the traverse device (33) is an arm-type
traverse device (33) that traverses the yarn with an arm
that reciprocatingly swings.
10 6. The yarn winding device (2) as claimed in claim
4 or 5, wherein the drive device directly rotates the
package (P).
7. An automatic winder (1), wherein a plurality
15 of the yarn winding devices (2) as claimed in any one of
claims 1 to 6 are arranged.
8. A yarn winding method for rotating a package
(P) while traversing a yarn to wind the yarn, wherein
20 when a diameter of the package (P) exceeds a
predetermined diameter, a winding speed of the yarn is
decelerated.