Claims:I/We claim:

1. A yarn winding machine (1) comprising:
a yarn supplying section (11) capable of supplying a yarn;
a winding section (13) that performs winding operation to form a package (P) by winding onto a winding tube the yarn that has been supplied from the yarn supplying section (11);
a yarn joining section (32) that joins yarn ends when the yarn is disconnected between the yarn supplying section (11) and the winding section (13) in a yarn running direction;
an operation section (53) that can be operated by an operator; and
a control section (15), characterized in that
the winding section (13) includes
a cradle (41) that rotatably supports the package (P);
a rotary roller that rotates while being in contact with the package (P) that is supported by the cradle (41); and
a rotation detection section (45) that detects rotations of the package (P) and / or rotations of the rotary roller,
the yarn joining section (32) includes
a yarn joining device (34) that joins the yarn ends;
a catching member (36) that catches the yarn running in the yarn running direction on the winding section (13) and guides the yarn to the yarn joining device (34); and
catching detecting members (33, 44) that detect the yarn caught by the catching member (36), and
the control section (15)
executes a stop control to stop the yarn joining operation upon determining, based on the result of detection by the catching detecting members (33, 44), that it is impossible for the catching member (36) to normally capture the yarn on the winding section (13) side during the yarn joining operation, and
determines, based on the result of detection by the rotation detection section (45), whether the package (P) was rotated in a period between the execution of the stop control by the control section (15) and a restart operation performed by operation of the operation section (53), when the restart operation is performed by the operation section (53) after the stop control.

2. The yarn winding machine (1) as claimed in Claim 1, wherein the control section (15) causes the yarn joining section (32) to perform the yarn joining operation only when determining that the package (P) was rotated from an angle to which the package (P) had rotated in the period between the execution of the stop control by the control section (15) and the restart operation performed by operation of the operation section (53).

3. The yarn winding machine (1) as claimed in Claim 1 or 2, comprising a notifying section (14) that notifies information, wherein
when the control section (15) determines that the package (P) was not rotated in the period between the execution of the stop control by the control section (15) and the restart operation performed by operation of the operation section (53), the control section (15) causes the notifying section (14) to notify information that indicates that the package (P) was not rotated.

4. The yarn winding machine as claimed in Claim 3, wherein, at the same time as or immediately after the execution of the stop control, the control section (15) causes the notifying section (14) to notify information that indicates that work by an operator is required.

5. The yarn winding machine (1) as claimed in any one of Claims 1 to 4, comprising a storage section (15a) capable of storing information, wherein
the control section (15), upon determining that the package (P) was not rotated in the period between the execution of the stop control by the control section (15) and the restart operation performed by operation of the operation section (53), causes the storage section (15a) to store the information that indicates that the package (P) was not rotated.
, Description:BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a yarn winding machine.

2. Description of the Related Art
A winding unit (yarn winding machine) that forms a package by winding a yarn supplied from a yarn supplying bobbin (yarn supplying section) onto a rotating winding bobbin is disclosed in the Japanese Patent Application Laid-Open No. 2011-16631. The yarn winding machine includes a winding section that winds the yarn supplied from the yarn supplying section, a yarn processing section (yarn joining section) that joins yarns if the yarn supplied from the yarn supplying section to the winding section is disconnected before reaching the winding section, an operation panel that includes an alarm lamp (notifying section) and an operation switch (operation section), and a control section. The yarn joining section includes a splicer (hereinafter, "yarn joining device") that joins two yarns, a suction mouth that sucks and holds the yarn on the winding section side in a yarn running direction and guides the held yarn to the yarn joining device, and a suction mouth sensor that detects the yarn sucked and held by the suction mouth.
In this yarn winding machine, if, for some reason, the yarn is disconnected between the yarn supplying section and the winding section during a yarn winding operation, then the control section instructs the yarn joining section to perform a yarn joining operation. The yarn joining operation includes the operation of guiding the winding section side yarn, which is running in the yarn running direction, to the yarn joining device with the help of the suction mouth. Moreover, the control section determines, based on the result of yarn detection by the suction mouth sensor, whether a normal yarn joining operation is possible.
When the control section determines that the normal yarn joining operation is not possible, then it stops the yarn joining operation and displays on the notifying section, information that indicates the occurrence of an error. As an example of such error an end finding error can be thought of. The end finding error is a situation in which the suction mouth fails to suck and hold the yarn for reasons such as tight winding of the yarn in a package. When such an error occurs, an operator performs appropriately processing the yarn on the winding section side, so as to enable the suction mouth to suck and hold the yarn, and resumes the normal yarn joining operation by operating the operation section.
Thus, for a normal resumption of the yarn joining operation as explained above, the operator may have to take the necessary measures. In such a case, if, for example, a non-expert operator operates the operation section without performing the necessary work, then the yarn joining operation resumes without the yarn on the winding section side undergoing the appropriate processing. As a result, the yarn joining may fail and stop again, making it almost impossible to restart the yarn winding operation for a long time or even permanently, thereby lowering the utilization rate.

SUMMARY OF THE INVENTION
The purpose of the present invention is to assist the operator in performing the necessary work.
According to one aspect of the present invention, a yarn winding machine includes a yarn supplying section capable of supplying a yarn; a winding section that performs winding operation to form a package by winding onto a winding tube the yarn that has been supplied from the yarn supplying section; a yarn joining section that joins yarn ends when the yarn is disconnected between the yarn supplying section and the winding section in a yarn running direction; an operation section that can be operated by an operator; and a control section. The winding section includes a cradle that rotatably supports the package; a rotary roller that rotates while being in contact with the package that is supported by the cradle; and a rotation detection section that detects rotations of the package and / or rotations of the rotary roller. The yarn joining section includes a yarn joining device that joins the yarn ends; a catching member that catches the yarn running in the yarn running direction on the winding section and guides the yarn to the yarn joining device; and catching detecting members that detect the yarn caught by the catching member. The control section executes a stop control to stop the yarn joining operation upon determining, based on the result of detection by the catching detecting members, that it is impossible for the catching member to normally capture the yarn on the winding section side during the yarn joining operation, and determines, based on the result of detection by the rotation detection section, whether the package was rotated in a period between the execution of the stop control by the control section and a restart operation performed by operation of the operation section, when the restart operation is performed by the operation section after the stop control.
The above and other objects, features, advantages and technical and industrial significance of this invention will be better understood by reading the following detailed description of presently preferred embodiments of the invention, when considered in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of an automatic winder according to the present embodiment.
FIG. 2 is a block diagram showing an electrical configuration of the automatic winder.
FIG. 3 is a front view of a winding unit.
FIGS. 4A and 4B are explanatory drawings showing the operation of an upper-yarn catching and guiding section.
FIG. 5 is a drawing for explaining an upper yarn end finding error.
FIGS. 6A and 6B are drawings for explaining multiple end finding.
FIG. 7 is a flowchart showing controls involved in the processes that take place from occurrence a problem in an upper yarn to resumption of a yarn joining operation.

DETAILED DESCRIPTION
Exemplary embodiments of the present invention will be explained below. The horizontal direction on the paper on which FIG. 1 has been printed is referred to as a left-right direction. The direction orthogonal to left-right direction is referred to as an up-down direction (orthogonal direction). A direction orthogonal to both the left-right direction and the up-down direction is referred to as a front-back direction. Moreover, the direction in which a yarn Y runs is referred to as a yarn running direction.
Structural Outline of the Automatic Winder
First, a structural outline of an automatic winder 1 (yarn winding machine of the present invention) of the present embodiment is explained with reference to FIGS. 1 and 2. FIG. 1 is a front view of the automatic winder 1. FIG. 2 is a block diagram showing an electrical configuration of the automatic winder 1. The automatic winder 1 includes a plurality of winding units 2, a doffing device 3, and a main control device 4.
The winding units 2 are arranged in the left-right direction, and each of the winding units 2 winds the yarn Y pulled from a respective yarn supplying bobbin Bs onto a respective winding bobbin Bw (winding tube of the present invention) to form a respective package P. The doffing device 3 is arranged above the winding units 2. The doffing device 3 is supported so as to be movable in the left-right direction. Upon receiving a signal indicative of completion of winding (formation of package P completed) from a certain winding unit 2, the doffing device 3 travels to a position near the winding unit 2 to perform tasks such as removing the package P from the winding unit 2, mounting an empty winding bobbin Bw on the winding unit 2, and the like.
The main control device 4 is arranged on one side of the row of the winding units 2 (see FIG. 1). The main control device 4 is, for example, a computer device. The main control device 4 communicates with a unit controller 15 (see FIG. 2) of each of the winding units 2 and a not-shown control section of the doffing device 3, with which it is electrically connected. The main control device 4 includes a storage section 4a that stores therein various settings.
Winding Unit
Next, a structure of the winding unit 2 will be explained with reference to FIG. 3. FIG. 3 is a front view showing an outline of the winding unit 2.
As shown in FIG. 3, the winding unit 2 include a frame 10, a yarn supplying section 11, a yarn processing section 12, a winding section 13, a display section 14 (notifying section of the present invention), and the unit controller 15. In the winding unit 2, the yarn Y pulled from the yarn supplying section 11 is processed by the yarn processing section 12 and the yarn Y is wound by the winding section 13 (winding operation). Moreover, when a problem occurs in the winding unit 2, a predetermined information is displayed (notified) on the display section 14.
The frame 10 is a hollow member that extends lengthwise in the up-down direction. The various members constituting the winding unit 2 are attached to and supported by the frame 10.
The yarn supplying section 11 supplies the yarn Y while unwinding the yarn Y from the yarn supplying bobbin Bs. As shown in FIG. 3, the yarn supplying section 11 is arranged on the lowermost side of the winding unit 2. The yarn supplying section 11 includes a yarn supplying bobbin supporting member 21 and a yarn unwinding assisting device 22. The yarn supplying bobbin supporting member 21 supports the yarn supplying bobbin Bs substantially vertically. The yarn unwinding assisting device 22 regulates, with the help of a regulating cylinder 23, the bulge formed in the yarn Y when the yarn Y is being unwound from the yarn supplying bobbin Bs. The regulating cylinder 23 is movable in the downward direction as the amount of yarn on the yarn supplying bobbin Bs decreases in order to maintain the size of the bulge constant. Moreover, for example, a yarn feeler 24 is arranged above the yarn unwinding assisting device 22. The yarn feeler 24 detects the presence of the running yarn Y.
The yarn processing section 12 performs various processes on the yarn Y. As shown in FIG. 3, the yarn processing section 12 is arranged mid-way between the yarn supplying section 11 and the winding section 13 in the up-down direction. The yarn processing section 12 includes a tension applying device 31, a yarn joining mechanism 32 (yarn joining section of the present invention), and a yarn clearer 33.
The tension applying device 31 is a device that applies a predetermined amount of tension to the running yarn Y. The tension applying device 31 is arranged right above the yarn supplying section 11. An example of the tension applying device 31 is the so- called gate-type tension applying device. As shown in FIG. 3, a plurality of fixed gate members 31a and a plurality of movable gate members 31b are arranged alternately in the up-down direction. By adjusting the position of the movable gate members 31b in a horizontal direction, the predetermined amount of tension is applied to the yarn Y that runs between the fixed gate members 31a and the movable gate members 31b.
The yarn joining mechanism 32 is a mechanism that joins the yarn Y (lower yarn Y1) on the yarn supplying section 11 to the yarn Y (upper yarn Y2) on the winding section 13, when the yarn Y becomes noncontinuous (yarn Y is disconnected) between the yarn supplying section 11 and the winding section 13 in the yarn running direction. The situations where the yarn Y may become disconnected are, when the yarn Y is cut after a yarn defect is detected by the later-explained yarn clearer 33, when the yarn Y breaks while being wound into the package P, and at the time of replacing the yarn supplying bobbin Bs. The yarn joining mechanism 32 includes a yarn joining device 34, a lower-yarn catching and guiding member 35, and an upper-yarn catching and guiding member 36 (catching member of the present invention).
The yarn joining device 34 is a device that joins the lower yarn Y1 to the upper yarn Y2. The yarn joining device 34 is, for example, a splicer that intertwines both the yarn ends by the action of compressed air. The yarn joining device 34 blows the compressed air supplied from a not-shown compressed air supply source onto the lower yarn Y1 and the upper yarn Y2 to untangle the ends of both the yarns once, after which the yarns are joined again by blowing the compressed air onto the yarn ends to intertwine them with each other. Alternatively, the yarn joining device 34 can be a knotter that mechanically knots the lower yarn Y1 with the upper yarn Y2.
The lower-yarn catching and guiding member 35 is configured to catch the lower yarn Y1 on the yarn supplying bobbin Bs (upstream side in the yarn running direction) and guide the same to the yarn joining device 34. The lower-yarn catching and guiding member 35 is arranged on the lower side of the yarn joining device 34. The lower-yarn catching and guiding member 35 includes a pipe-shaped arm 35b that is rotatable around a shaft 35a, a sucking member 35c arranged at a tip end part of the arm 35b for sucking and catching the yarn end of the lower yarn Y1, and a motor 37 that causes the arm 35b to pivot up and/or down. The lower-yarn catching and guiding member 35 is connected to a not-shown suction source. The upper-yarn catching and guiding member 36 is configured to catch the upper yarn Y2 on the winding section 13 (downstream side in the yarn running direction) and guide the same to the yarn joining device 34. The upper-yarn catching and guiding member 36 is arranged on the upper side of the yarn joining device 34. The upper-yarn catching and guiding member 36 includes a transparent and pipe-shaped arm 36b that is rotatable around a shaft 36a, a sucking member 36c arranged at a tip end part of the arm 36b for sucking and catching a yarn end of the upper yarn Y2, and a motor 38 that causes the arm 36b to pivot up and/or down. The upper-yarn catching and guiding member 36 is connected to a not-shown suction source.
The yarn clearer 33 acquires information regarding thickness and the like of the running yarn Y and detects whether there is a yarn defect based on this information. The yarn clearer 33 is, for example, arranged on the upper side of the yarn joining device 34. The yarn clearer 33 includes a cutter 33a. When a yarn defect is detected by the yarn clearer 33, the cutter 33a immediately cuts the yarn Y. Also, the yarn clearer 33 outputs a detection signal to the unit controller 15.
The winding section 13 performs the winding operation. The winding operation includes winding the yarn Y on the winding bobbin Bw to form the package P. As shown in FIG. 3, the winding section 13 is arranged on the uppermost side of the winding unit 2. The winding section 13 includes a cradle 41 that rotatably holds the winding bobbin Bw, a traverse drum 42 (contact drum of the present invention), a drum driving motor 43 (see FIG. 2), and an upper yarn sensor 44. In the winding section 13, the drum driving motor 43 rotatably drives the traverse drum 42, which is in contact with the package P, which, in turn, is rotatably supported by the cradle 41; therefore, the package P rotates following the rotation of the traverse drum 42. Accordingly, when the traverse drum 42 is rotated, the yarn Y is wound onto the winding bobbin Bw.
The cradle 41 rotatably supports the winding bobbin Bw (package P). A rotation number sensor 45 (rotation detection section of the present invention), for example, a magnetic type sensor, capable of detecting rotations of the package P is provided near the cradle 41. The rotation number sensor 45 is electrically connected to the unit controller 15 (see FIG. 2). The rotation number sensor 45 transmits information regarding the rotation of the package P to the unit controller 15.
The traverse drum 42 is a cylindrical member whose axial direction is substantially parallel to the left-right direction. A traverse groove 42a for traversing the yarn Y is formed on an outer peripheral surface of the traverse drum 42. When the traverse drum 42 rotates, while the yarn Y is passed in the traverse groove 42a, the yarn Y is traversed within a predetermined width. Furthermore, the traverse drum 42 rotates in contact with an outer peripheral surface of the package P while traversing the yarn Y via the traverse groove 42a; therefore, the contact friction of the package P with the traverse drum 42 makes the package P to rotate following the rotation of the traverse drum 42. As a result, the package P is formed as the yarn Y is wound around the winding bobbin Bw in the course of traverse of the yarn Y.
The drum driving motor 43 is a motor that rotationally drives the traverse drum 42. The drum driving motor 43 rotationally drives the traverse drum 42 in a forward direction in which the yarn Y is wound around the package P and in a reverse direction in which the yarn Y is pulled from the package P. In a normal winding operation, the traverse drum 42 is driven in the forward direction to rotate the package P in the forward direction, thus winding the yarn Y onto the winding bobbin Bw. In contrast, in the yarn joining operation explained later, the traverse drum 42 is driven in the reverse direction.
The drum driving motor 43 includes, for example, a magnetic type rotation number sensor 46 (see FIG. 2) that detects the number of rotations of the traverse drum 42. The rotation number sensor 46 is electrically connected to the unit controller 15 (see FIG. 2) and transmits information regarding the rotation of the traverse drum 42 to the unit controller 15.
The upper yarn sensor 44 is, for example, a known optical sensor. The upper yarn sensor 44 detects the catching of the upper yarn Y2 by the sucking member 36c of the upper-yarn catching and guiding member 36.
The display section 14 displays information regarding the winding unit 2. As shown in FIG. 3, the display section 14 is provided on the front surface of the frame 10. The display section 14 includes a plurality of lamps 51, a text display section 52, and an operation button 53 (operation section of the present invention). The lamps 51 are used to notify the operator of the change in a state of the winding unit 2. The lamps 51 are, for example, LED lamps, and can output light of two colors - red and blue. The text display section 52 displays characters indicative of a specific state of the winding unit 2 and is arranged above the lamps 51. The text display section 52 is, for example, a seven-segment liquid crystal display of three digits. The operation button 53 is operated by the operator when restarting the yarn winding process when the yarn winding operation by the winding unit 2 is interrupted. The operation button 53 is arranged below the lamps 51 and is electrically connected to the unit controller 15.
The unit controller 15 (control section of the present invention) includes, for example, a CPU, a ROM, and a RAM (storage section 15a. See FIG. 2). The unit controller 15 controls each unit according to a computer program stored in the ROM by using the CPU. Specifically, the unit controller 15 receives signals from various units and sensors, such as the yarn clearer 33, the rotation number sensors 45, 46, and controls the yarn joining device 34, the motor 37, the motor 38, the drum driving motor 43, and the like. Moreover, the unit controller 15 outputs, via the main control device 4, a signal requesting the doffing device 3 to perform doffing.
In the winding unit 2 having the above configuration, the winding operation for forming the package P is performed as follows. That is, the unit controller 15 drives the drum driving motor 43 so as to rotate the traverse drum 42 in a state where the package P and the traverse drum 42 are in contact with each other; therefore, the contact friction of the package P with the traverse drum 42 makes the package P to rotate following the rotation of the traverse drum 42. Accordingly, the yarn Y pulled from the yarn supplying bobbin Bs is wound around the winding bobbin Bw to form the package P.
Details of Yarn Joining
Next, the yarn joining performed by the yarn joining device 34 and peripheral components thereof will be explained in detail. If, for example, during a winding operation, a yarn defect is detected by the yarn clearer 33, and the yarn Y is cut, the unit controller 15 controls each component of the winding unit 2 so as to suspend the winding operation. Furthermore, the unit controller 15 controls the yarn joining mechanism 32 and the like, so that the disconnected lower yarn Y1 and upper yarn Y2 are sucked and caught, the lower yarn Y1 and the upper yarn Y2 are guided to the yarn joining device 34 and the yarn joining is performed by the yarn joining device 34. Hereinafter, for simplifying the explanation, the series of operations related to the yarn joining (sucking, catching and guiding of yarn Y, and yarn joining by the yarn joining device 34) will be referred to as a yarn joining operation.
Details of the yarn joining operation will be explained with reference to FIGS. 4A and 4B. FIGS. 4A and 4B are explanatory drawings showing the operation performed by the upper-yarn catching and guiding member 36.
First, when the yarn Y is disconnected and the winding operation is temporarily stopped, the upper yarn Y2 is wound on the package P because the traverse drum 42 and the package P continue to rotate for a while due to inertia. Then, the unit controller 15 causes the sucking member 36c to position near the package P by pivoting the arm 36b of the upper-yarn catching and guiding member 36 in the upward direction. Accordingly, the unit controller 15 causes the sucking member 36c to suck and catch the upper yarn Y2 (suction operation. See FIG. 4A). Next, the unit controller 15, while controlling the drum driving motor 43 to temporarily drive the traverse drum 42 and the package P to rotate in the reverse direction, pivots the arm 36b in the downward direction. As a result, the upper yarn Y2 is guided to the yarn joining device 34 by the upper-yarn catching and guiding member 36 (See FIG. 4B) while being pulled from the package P.
Moreover, the unit controller 15, in a state in which the yarn end portion of the lower yarn Y1 is sucked and caught by the sucking member 35c of the lower-yarn catching and guiding member 35, controls the motor 37 (See FIG. 2) to cause the arm 35b of the lower-yarn catching and guiding member 35 to pivot in the upward direction so as to guide the lower yarn Y1 to the yarn joining device 34 (omitted in FIG). Then, the unit controller 15 controls the yarn joining device 34 to join the guided lower yarn Y1 and the upper yarn Y2. After the yarn joining operation is completed, the unit controller 15 controls each component of the winding unit 2 so as to restart the winding operation.
Problems Relating to Yarn Joining Operation
There are situations where the yarn joining operation fails due to, for example, a defect explained later. If the unit controller 15 determines that a problem has occurred in the yarn joining operation, the unit controller 15 causes the display section 14 to display a message prompting the operator to solve the problem, stops the operation of the winding unit 2, and waits for the operator to operate the operation button 53. That is, the yarn joining operation and the subsequent winding operation cannot restart until the operator operates the operation button 53 (restart operation).
Specific examples of problems related to the yarn joining operation (causes of failure in the yarn joining operation) will be explained with reference to FIG. 5 and FIGS. 6A and 6B. FIG. 5 is a drawing for explaining end finding error of the upper yarn Y2. FIGS. 6A and 6B are drawings for explaining multiple end finding.
First, the automatic end finding error will be explained. The automatic end finding error is a problem in which the upper yarn Y2 cannot be sucked and caught by the upper-yarn catching and guiding member 36 during the yarn joining operation. When a yarn end Ya (shown by a solid line in FIG. 5) is normally sucked and caught by the sucking member 36c, the upper yarn Y2 is sucked in the arm 36b (shown by a double-dashed line in FIG. 5), and the upper yarn Y2 that has been sucked into the arm 36b is detected by the upper yarn sensor, which is an optical sensor, 44 from a transparent window provided in the arm 36b. However, for example, when the yarn end Ya firmly sticks to the package P, or when the yarn end Ya falls on the end surface side of the package P, a problem where the yarn end Ya is not sucked and caught by the sucking member 36c may occur (end finding error). If, for example, the upper yarn Y2 is not detected by the upper yarn sensor 44 even after a predetermined time period has elapsed since the suction operation was started, the unit controller 15 determines that an end finding error has occurred once. Even if such an end finding error occurs, the unit controller 15 forces the upper-yarn catching and guiding member 36 to perform the suction operation again. The unit controller 15 determines that an automatic end finding error has occurred when, for example, an end finding error occurs even after three consecutive attempts. That is, the unit controller 15 determines based on the result of detection by the upper yarn sensor 44, that it is impossible to normally catch the yarn Y (upper yarn Y2) on the winding section 13. In this case, the upper yarn sensor 44 is equivalent to a catching detecting member of the present invention.
Next, the multiple end finding will be explained. The multiple end finding is a problem that resembles a situation where a plurality of upper yarns Y2 are sucked by the upper-yarn catching and guiding member 36 during the yarn joining operation. When sucking and catching of the upper yarn Y2 is being performed, if, for example, a part of the yarn Y that is wound around the package P becomes loose and the yarn end Ya is firmly stuck to the package P, as shown in FIG. 6A, a portion other than the yarn end Ya of the upper yarn Y2 becomes likely to be sucked. In such a state, if the upper yarn Y2 is detected by the upper yarn sensor 44, then the unit controller 15, as shown in FIG. 6B, rotates the arm 36b by controlling the motor 38, and by mistake guides two upper yarns Y2 to the yarn joining device 34. At this stage, the yarn clearer 33 arranged above the yarn joining device 34 detects the thickness of the upper yarn Y2 to be equivalent to a thickness of two yarns (a detection value clearly greater than the detection value of the thickness of a single yarn). As a result, the occurrence of the multiple end finding is detected, and a signal that indicates an abnormality is transmitted from the yarn clearer 33 to the unit controller 15. That is, the unit controller 15 determines, based on the result of detection by the yarn clearer 33, that it is impossible to normally catch the yarn Y (upper yarn Y2) on the winding section 13. In this case, the yarn clearer 33 is equivalent to a catching detecting member of the present invention.
When the automatic end finding error or the multiple end finding occur, the operator needs to find and guide the yarn end Ya that is stuck to the surface of the package P to the upper-yarn catching and guiding member 36 so as to solve these problems. After the completion of these operations, the operator must operate the operation button 53, so that the yarn joining operation can be normally performed. However, if, for example, a non-expert operator operates the operation button 53 without performing the necessary work, then the yarn joining operation restarts without the upper yarn Y2 undergoing the appropriate processing. As a result, the yarn joining may fail and stop again, making it almost impossible to restart the yarn winding operation for a long time or even permanently, thereby lowering the utilization rate. Therefore, in the present embodiment, the unit controller 15 performs the following control in order to help the operator perform the necessary work.
Control Performed by Unit Controller
The control performed by the unit controller 15 will be explained with reference to the flowchart of FIG. 7. As an outline, the unit controller 15 determines whether the package P has been rotated in the period between the stopping of the yarn joining operation and operation of the operation button 53 by the operator. The unit controller 15 causes the yarn processing section 12 to perform the yarn joining operation again only if the unit controller 15 determines that the package P was rotated.
First, during the yarn joining operation, upon determining that a problem such as the automatic end finding error or the multiple end finding related to the upper yarn Y2 has occurred (S101), the unit controller 15 stops the yarn joining operation (stop control) and causes the display section 14 to display information that indicates that the problem has occurred (S102).
Next, the unit controller 15 turns off a flag that is used to determine whether the package P has been rotated after the yarn joining operation was stopped (S103). The unit controller 15 causes the storage section 15a to store therein information regarding the flag.
Next, the unit controller 15 determines whether the operation button 53 has been operated by the operator (S104). If it is determined that the operation button 53 has not yet been operated (S104: No), the unit controller 15 determines, based on the result of detection (rotation angle) by the rotation number sensor 45, whether the package P has been rotated by the operator (S105). This determination is required because, in order to find the yarn end Ya that is stuck to the surface of the package P, it is basically necessary for the operator to visually and / or manually check the entire package P while rotating the package P.
Upon determining that the package P has been rotated (S105: Yes), the unit controller 15 sets the flag to on (S106) and the process procedure returns to S104. On the other hand, if the unit controller 15 determines that the package P has not been rotated, the process procedure returns to S104 without performing the processes related to the flag.
When the operator operates the operation button 53 to perform the restart operation in order to restart the winding operation (S104: Yes), the unit controller 15 determines whether the flag is on (S107). If the flag is on (S107: Yes), that is, when the package P has been rotated at least once in the period between the execution of the stop control by the unit controller 15 and the restart operation performed by the operator by operating the operation button 53, the unit controller 15 causes the yarn joining mechanism 32 and the like to perform the yarn joining operation again (S108). On the other hand, if the flag is off (S107: No), the unit controller 15 stores the information, performs alarm display control (S109), and the process procedure returns to S104 as follows. In other words, the unit controller 15 causes the storage section 15a (storage section of the present invention) to store the information that indicates that the package P has not been rotated, and causes the display section 14 to display (display alarm) the information that indicates that the package P has not been rotated. In this situation, the yarn joining operation is not performed again. That is, in the present embodiment, the yarn joining operation is performed again only if the flag is on when the operator operates the operation button 53.
Furthermore, as a method of displaying the alarm, the unit controller 15, for example, causes the lamps 51 to light or blink and causes the text display section 52 to display information that indicates that the appropriate work has not been performed.
Moreover, the unit controller 15 can send to the main control device 4 the information stored in the storage section 15a regarding the rotation of the package P. The main control device 4 can store in the storage section 4a in advance, for example, a log file that can be viewed by the operator. The main control device 4 can also save a log file by adding the information regarding the rotation of the package P to the log file.
As explained above, by determining, based on the result of detection by the rotation number sensor 45, whether the package P has been rotated, it can be determined whether the operator has appropriately processed the yarn Y. Accordingly, this determination result can be used to cause the operator to perform the necessary work.
Moreover, because the yarn joining operation is not performed again even if the operation button 53 is operated, wastage of time can be avoided in this case compared to the situation where the yarn joining operation fails and stops again due to a failure in joining the yarns. Moreover, contrary to the operator's intention to restart the operation of the winding unit 2, the winding unit 2 is maintained in the stopped state so as to suggest the operator that it is necessary to perform the appropriate work.
If the unit controller 15 determines that the package P was not been rotated in the period between the execution of the stop control by the unit controller 15 and the restart operation performed by the operator by operating the operation button 53, the information that indicates that the package P was not rotated is displayed on the display section 14. With such a configuration, it becomes easy to make the operator aware that the necessary work has not been performed.
Moreover, on determining that the package P was not rotated in the period between the execution of the stop control by the unit controller 15 and the restart operation performed by the operator by operating the operation button 53, the unit controller 15 stores in the storage section 15a the information that indicates that the package P was not rotated. Accordingly, the operator, by grasping the information that indicates that the package P was not rotated, can confirm the fact that the necessary work was not been performed. This can help the operator to realize that it was necessary to perform the appropriate work.
Next, a variant to the previous embodiment will be explained. However, the components that are identical to the previous embodiment are indicated by the same reference symbols and explanation thereof is omitted.
(1) In the yarn winding machine according to the embodiment explained above, if the flag is off when the operator operates the operation button 53, the unit controller 15 is configured to cause the display section 14 to display the information that indicates that the package P was not been rotated; however, the configuration is not limited to this. The unit controller 15 need not necessarily cause the display section 14 to display an alarm.
(2) In the yarn winding machine according to the embodiments so far, if the flag is off when the operator operates the operation button 53, the unit controller 15 is configured to store in the storage section 15a the information that indicates that the package P was not been rotated; however, the configuration is not limited to this. The unit controller 15 can store the information regarding the rotation of the package P in the storage section 15a even if the flag is on when the operator operates the operation button 53. Alternatively, the unit controller 15 need not necessarily store the information in the storage section 15a.
(3) In the yarn winding machines according to the embodiments explained so far, the unit controller 15 is configured to cause the yarn processing section 12 to perform the yarn joining operation again only if the flag is on when the operator operates the operation button 53; however, the configuration is not limited to this. The unit controller 15 can, for example, after storing in the storage section 15a the information that indicates that the package P has not been rotated or causing the display section 14 to display a predetermined alarm, cause the yarn processing section 12 to perform the yarn joining operation again.
(4) In the embodiments explained so far, the unit controller 15 is configured to determine, based on the result of detection by the rotation number sensor 45, whether the package P has been rotated; however, the configuration is not limited to this. The unit controller 15 can, for example, determine this based on the result of detection by the rotation number sensor 46 that detects the rotation of the traverse drum 42. When this configuration is employed, the rotation number sensor 46 is equivalent to the rotation detection section of the present invention. Alternatively, for example, a not-shown rotary encoder that can detect the rotation angle of the package P can be provided separately from the rotation number sensors 45 and 46. When this configuration is employed, the rotary encoder is equivalent to the rotation detection section of the present invention.
(5) In the embodiments so far, the yarn Y is traversed along the traverse groove 42a formed in the traverse drum 42; however, the traversing of the yarn is not limited to such a mechanism. That is, instead of the traverse drum 42, a contact drum that rotates while being in contact with the package P can be provided. When this configuration is employed, the package P can be rotationally driven by a not-shown motor. Furthermore, it is required that a traverse device for traversing the yarn Y is provided separately from the contact drum.
(6) In the embodiments explained so far, the upper-yarn catching and guiding member 36 is configured to suck and catch the yarn Y (upper yarn Y2) on the winding section 13; however, the means for catching the upper yarn Y2 is not limited to the given method. For example, the upper-yarn catching and guiding member 36 can be configured to be able to catch the upper yarn Y2 by gripping the upper yarn Y2.
(7) In the embodiments explained so far, the unit controller 15 is configured to notify the operator by causing the display section 14 to display an alarm; however, the configuration is not limited to this. The winding unit 2 can include, for example, a not-shown speaker that generates an alarm sound. The unit controller 15 can control the speaker to generate an alarm sound to notify the operator.
(8) In the embodiments explained so far, the timing at which the unit controller 15 turns off the flag was explained to be after the stopping of the yarn joining operation and the alarm display; however, the timing is not limited to this. The unit controller 15 can turn off the flag when, for example, causing the winding section 13 to start the winding operation and when restarting the winding operation after the yarn joining operation.
(9) In the embodiments explained so far, the unit controller 15 is explained to be equivalent to the control section of the present invention; however, the yarn winding machine is not limited to such a configuration. For example, the main control device 4 can control the plurality of winding units 2. When this configuration is employed, the main control device 4 is equivalent to the control section of the present invention.
(10) In the embodiments explained so far, the automatic winder 1 included a plurality of winding units 2; however, the configuration is not limited to this. The automatic winder 1 can include only one winding unit 2.
(11) The present invention is not limited to the automatic winder 1 and can be applied to various yarn winding machines such as a spinning machine that is disclosed in the Japanese Patent Application Laid-Open No. 2019-31380.
According to one aspect of the present invention, a yarn winding machine includes a yarn supplying section capable of supplying a yarn; a winding section that performs winding operation to form a package by winding onto a winding tube the yarn that has been supplied from the yarn supplying section; a yarn joining section that joins yarn ends when the yarn is disconnected between the yarn supplying section and the winding section in a yarn running direction; an operation section that can be operated by an operator; and a control section. The winding section includes a cradle that rotatably supports the package; a rotary roller that rotates while being in contact with the package that is supported by the cradle; and a rotation detection section that detects rotations of the package and / or rotations of the rotary roller. The yarn joining section includes a yarn joining device that joins the yarn ends; a catching member that catches the yarn running in the yarn running direction on the winding section and guides the yarn to the yarn joining device; and catching detecting members that detect the yarn caught by the catching member. The control section executes a stop control to stop the yarn joining operation upon determining, based on the result of detection by the catching detecting members, that it is impossible for the catching member to normally capture the yarn on the winding section side during the yarn joining operation, and determines, based on the result of detection by the rotation detection section, whether the package was rotated in a period between the execution of the stop control by the control section and a restart operation performed by operation of the operation section, when the restart operation is performed by the operation section after the stop control.
When the yarn joining operation stops due to a problem related to the yarn on the winding section side, generally, it is necessary for the operator to perform acts such as finding a yarn end while rotating the package, pulling the yarn, and the like. That is to say, for a normal resumption of the yarn joining operation, basically, it is necessary to rotate the package. In other words, if the package is not rotated in the period between the execution of the stop control and the restart operation performed by the operation section, it can be estimated that the necessary work is not performed by the operator. Form this fact, in the present invention, it can be determined whether the operator suitably processed the yarn by determining whether the package was rotated based on the detection result obtained in the rotation detection section. Accordingly, this determination result can be used to cause the operator to perform the necessary work.
In the above yarn winding machine, the control section causes the yarn joining section to perform the yarn joining operation only when determining that the package was rotated from an angle to which the package had rotated in the period between the execution of the stop control by the control section and the restart operation performed by operation of the operation section.
According to the above aspect, because the yarn joining operation is not performed again even if the operation section is operated, wastage of time can be avoided in this case compared to the situation where the yarn joining operation fails and stops again due to a failure in joining the yarns. Moreover, contrary to the operator's intention to restart the operation of the yarn winding machine, the yarn winding machine is maintained in the stopped state so as to suggest the operator that it is necessary to perform the appropriate work.
The above yarn winding machine includes a notifying section that notifies information, and, when the control section determines that the package was not rotated in the period between the execution of the stop control by the control section and the restart operation performed by operation of the operation section, the control section causes the notifying section to notify information that indicates that the package was not rotated.
According to the above aspect, it becomes easy to make the operator aware that the necessary work has not been performed. Moreover, at the same time as or immediately after the execution of the stop control, the control section can cause the notifying section to notify information that indicates that work by an operator is required.
The above yarn winding machine includes a storage section capable of storing information, and, the control section, upon determining that the package was not rotated in the period between the execution of the stop control by the control section and the restart operation performed by operation of the operation section, causes the storage section to store the information that indicates that the package was not rotated.
According to the above aspect, the operator, by grasping the information that indicates that the package was not rotated, can confirm the fact that the necessary work was not been performed. This can help the operator to realize that it was necessary to perform the appropriate work.
In the above explanation, the meaning of "a plurality of" also includes "a predetermined number of".
Although the invention has been explained with respect to specific embodiments for a complete and clear disclosure, the appended claims are not to be thus limited but are to be construed as embodying all modifications and alternative constructions that may occur to one skilled in the art that fairly fall within the scope of the claims.