Spinning frame with a yarn management system based on a texturing process
Through AGV transport vehicles and automated systems, fully automated management from POY raw yarn to DTY spindles has been achieved, solving the problem of low management efficiency in existing technologies, improving production efficiency and reducing costs.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- ZHEJIANG HENGYI PETROCHEMICAL CO LTD
- Filing Date
- 2023-12-22
- Publication Date
- 2026-05-29
AI Technical Summary
In the existing technology, the management efficiency of processing POY raw yarn into DTY yarn spindles is low, which makes it difficult to meet the needs of large-scale production, and manual operation increases production costs and quality risks.
By employing AGV transport vehicles, texturing machines, transport systems, and packaging systems, a fully automated process from POY raw yarn to DTY spindles is achieved, including transportation, storage, quality inspection, and packaging. Through the collaborative work of robotic arms and computer equipment, manual intervention is reduced.
It has improved production efficiency, reduced labor costs, ensured production accuracy and quality control, and achieved automated production from raw silk to finished products.
Smart Images
Figure CN117842568B_ABST
Abstract
Description
Technical Field
[0001] This disclosure relates to the field of computer technology, and in particular to a spindle management system based on the texturing process. Background Technology
[0002] In related technologies, after POY (Pre-Oriented Yarn) raw yarn is processed into DTY (Draw Textured Yarn) spindles, the subsequent processes place increasing demands on the management of the spindles. How to efficiently manage these spindles is a pressing issue that needs to be addressed. Summary of the Invention
[0003] This disclosure provides a spindle management system based on the texturing process to improve the management efficiency of spindles.
[0004] According to one aspect of this disclosure, a spindle management system for a texturing process is provided, comprising:
[0005] AGV (Automated Guided Vehicle) transport vehicles are used to transport POY filament spindles from the raw material warehouse to the target filament rack position on the texturing machine in response to order-triggered production instructions;
[0006] Texturing machine is used to process the POY raw yarn spindle using a texturing process to obtain DTY yarn spindle, and to store the DTY yarn spindle in the yarn spindle temporary storage area and trigger the drop-on signal;
[0007] A transport system for storing the DTY yarn spindles in an automated storage and retrieval system in response to the doffing signal;
[0008] A packaging system for retrieving the DTY spindles from the automated warehouse and packaging them in response to a packaging instruction.
[0009] This disclosure proposes a transportation system and a packaging system to achieve a fully automated process from the generation of POY raw yarn to DTY yarn spindles, and then to the shipment of packaged DTY yarn spindles, thereby improving production efficiency.
[0010] It should be understood that the description in this section is not intended to identify key or essential features of the embodiments of this disclosure, nor is it intended to limit the scope of this disclosure. Other features of this disclosure will become readily apparent from the following description. Attached Figure Description
[0011] The accompanying drawings are provided to better understand this solution and do not constitute a limitation of this disclosure. Wherein:
[0012] Figure 1This is a schematic diagram of the spindle management system structure in the texturing process provided in one embodiment of the present disclosure;
[0013] Figure 2 This is a schematic diagram of the process of transporting DTY wire spindles to the automated warehouse using an AGV dropper according to an embodiment of this disclosure;
[0014] Figure 3a This is a schematic diagram showing the distribution of the bird's-eye view perspective of an automated warehouse according to an embodiment of this disclosure;
[0015] Figure 3b This is a schematic diagram of the process of transferring DTY spindles to the target storage area according to an embodiment of the present disclosure;
[0016] Figure 4 This is a schematic diagram of the DTY spindle quality inspection process according to an embodiment of this disclosure;
[0017] Figure 5 This is a schematic diagram of the process of transporting DTY yarn to the packaging line according to an embodiment of the present disclosure;
[0018] Figure 6a This is a schematic diagram of the silk spindle packaging process for large order requirements according to an embodiment of this disclosure;
[0019] Figure 6b This is a schematic diagram of a silk spindle stacking structure according to an embodiment of the present disclosure;
[0020] Figure 7 This is a schematic diagram of the silk spindle packaging process for ordinary order requirements according to an embodiment of this disclosure;
[0021] Figure 8 This is a schematic diagram of the DTY spindle finished product outbound process according to an embodiment of this disclosure;
[0022] Figure 9 This is a schematic diagram of the AGV drop-off vehicle structure provided in one embodiment of the present disclosure;
[0023] Figure 10 This is a schematic diagram of the airbag inflation state structure according to an embodiment of the present disclosure; Detailed Implementation
[0024] The exemplary embodiments of this disclosure are described below with reference to the accompanying drawings, including various details of the embodiments to aid understanding, and should be considered merely exemplary. Therefore, those skilled in the art will recognize that various changes and modifications can be made to the embodiments described herein without departing from the scope of this disclosure. Similarly, for clarity and brevity, descriptions of well-known functions and structures are omitted in the following description.
[0025] Furthermore, it should be noted that the terms "first," "second," etc., used in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of this application described herein can be implemented in orders other than those illustrated or described herein. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this application. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this application as detailed in the appended claims.
[0026] In some spindle production processes, manual operation is the primary method. While this method ensures production stability and quality, it also presents several obvious problems. First, manual operation is relatively inefficient, making it difficult to meet the demands of large-scale production. Second, with the annual increase in labor costs, the production costs of manual operation also rise accordingly.
[0027] In the entire process of producing DTY yarn from POY raw yarn to packaging and shipping the DTY yarn, it is necessary to reduce the quality risks caused by human operation, lower production costs, and significantly improve production efficiency.
[0028] In view of this, the present invention provides a yarn spindle management system based on the texturing process, such as... Figure 1 As shown, it includes:
[0029] AGV transport vehicles are used to transport POY filament spindles from the raw material warehouse to the target filament rack position on the texturing machine in response to order-triggered production instructions;
[0030] Texturing machine is used to process the POY raw yarn spindle using a texturing process to obtain DTY yarn spindle, and to store the DTY yarn spindle in the yarn spindle temporary storage area and trigger the drop-on signal;
[0031] A transport system for storing the DTY yarn spindles in an automated storage and retrieval system in response to the doffing signal;
[0032] A packaging system for retrieving the DTY spindles from the automated warehouse and packaging them in response to a packaging instruction.
[0033] For example, based on order demand, the server sends a signal to call an AGV transport vehicle to transfer POY raw yarn to the platform. Upon arrival at the platform, a robotic arm transfers the POY spindles to the yarn rack in the DTY workshop. Once the yarn rack is full, the AGV transport vehicle enters the texturing workshop via a transfer corridor and is transported to the texturing machine. The same texturing machine can simultaneously texture hundreds of POY raw yarn spindles.
[0034] A common texturing machine, the 384 machine, performs texturing operations on 384 spindles of POY raw yarn to produce 384 spindles of DTY yarn. Each POY raw yarn and DTY yarn spindle is in one-to-one correspondence.
[0035] The texturing machine 576 single-strand yarn machine performs texturing operations on 576 spindles of POY raw yarn to produce 576 spindles of DTY.
[0036] The texturing machine 576 double-strand yarn machine performs texturing operations on 576 spindles of POY raw yarn to generate 288 spindles of DTY yarn, with each pair of POY raw yarn spindles corresponding to one DTY yarn spindle.
[0037] The texturing machine has a designated pipe connecting the yarn holder on the target yarn holder to the texturing machine. The texturing machine draws the yarn from the yarn holder through this pipe. After being processed by the texturing machine, the yarn is wound onto a paper tube to form a DTY yarn spool. The generated DTY yarn spool is temporarily stored in the yarn spool storage area on the texturing machine. When there is a DTY yarn spool in the storage area, the texturing machine will send a bobbin drop signal. For example, the bobbin drop signal can be triggered when a sensor detects a new DTY yarn spool.
[0038] During the texturing machine's operation, the texturing machine will also send a paper tube replenishment signal. After receiving the paper tube replenishment signal, the AGV transport vehicle will move to the paper tube replenishment machine to replenish the paper tubes for the texturing machine.
[0039] In this embodiment, the AGV transport vehicle automatically delivers raw materials according to order instructions, the texturing machine automatically performs the texturing process, and the transportation and packaging systems respond to instructions to automatically complete the storage and packaging of DTY yarn spindles. Throughout the process, manual intervention is reduced, and production efficiency is improved. The entire process forms a closed loop, realizing automated production from raw yarn to finished product, thus enhancing production efficiency.
[0040] To better understand the yarn spindle management system in the texturing process, the transportation system and packaging system will be explained separately below.
[0041] I. Transportation System
[0042] The transportation system includes:
[0043] An AGV (Automated Guided Vehicle) is used to transfer DTY (Digital Turbine) spindles from the spindle temporary storage area to the target operation area.
[0044] The first robotic arm, located in the target operation area, is used to sort the DTY yarn spindles on the AGV unloading cart onto the DTY yarn cart in response to a first call signal when the AGV unloading cart arrives at the target operation area.
[0045] The DTY silk-cart is located on the first slide rail;
[0046] The first slide rail, in response to a second call signal indicating that the DTY yarn cart is full, delivers the DTY yarn cart to a first designated position and then triggers a third call signal;
[0047] A first track car, in response to the third call signal, transfers the DTY yarn car onto a hoist, and then, based on the hoist, transfers the DTY yarn car to an automated warehouse for storage.
[0048] like Figure 2 As shown, after the AGV unloading vehicle transfers the DTY yarn spindles to the target operation area, it sends a first call signal. The robotic arm then places the DTY yarn spindles into different DTY yarn carts according to their different categories. Once the DTY yarn carts are full, a second call signal is sent, and the first slide rail transports the DTY yarn carts to the first railcar. A third call signal is then sent, and the first railcar transfers the DTY yarn carts to the elevator. The elevator then transfers the DTY yarn carts to the automated warehouse for temporary storage.
[0049] In this embodiment, after the AGV unloading vehicle arrives at the target operating area, the first robotic arm loads different wire cars and transports them to the automated warehouse. This process design enables automated operation, saves labor costs, and improves production efficiency.
[0050] In this embodiment of the disclosure, in order to make full use of the storage space, multiple storage layers can be set in the automated library, and each storage layer contains multiple storage areas with partition identifiers;
[0051] Figure 3a This diagram illustrates the layout of an automated storage and retrieval system (AS / RS) from an aerial view. The AS / RS is divided into three storage areas: a first storage area, a second storage area, and a third storage area. Each storage area has multiple storage layers visible. Different storage areas can be used to store different intermediate production products. The first storage area stores DTY yarn carts sorted by the first robotic arm. The second storage area stores DTY yarn spindles that have undergone inspection. The third storage area stores packaged DTY yarn spindles.
[0052] Therefore, DTYs need to be transported to the corresponding storage level by a hoist to enter the automated warehouse. The entire process from hoisting to entry into the warehouse can be automated as follows:
[0053] The elevator is used to transfer the DTY yarn car onto the second slide rail of the automated warehouse;
[0054] The second slide rail is used to trigger a fourth call signal after the DTY yarn car is transferred to the second designated position;
[0055] The second track car is used to transfer the DTY silk car to the target storage area of the target storage layer indicated by the fourth call signal in response to the fourth call signal.
[0056] like Figure 3b As shown, the hoist transfers the DTY wire car to the second slide rail of the automated warehouse. After the second slide rail transfers the DTY wire car to the second designated position, the slide rail will sense the DTY wire car and issue a fourth call signal. The second railcar will then transfer the DTY wire car to the pre-assigned position (i.e., the target storage area of the target storage layer indicated by the fourth call signal).
[0057] In this embodiment, the automated warehouse includes storage areas with different labels. DTY yarn carts can be placed in different areas, making the entry and exit of DTY yarn spindles more standardized, facilitating streamlined operations, and improving production efficiency.
[0058] During the production process, to improve quality control, it is necessary to perform certain inspections on the yarn spindles. These inspections can detect various surface defects, such as trapped yarn, stranded yarn, unstripped yarn, and tail yarn. This allows for early detection and repair of these defects, preventing low-quality products from entering the market and thus improving overall product quality. Therefore, for uninspected DTY yarn spindles, the following automated transfer process is required to complete the inspection:
[0059] The third track vehicle, in response to the outbound command, transfers the DTY yarn cart from the automated warehouse to the stripping station, so that the DTY yarn cart can complete the stripping and knotting operations at the stripping station.
[0060] The first transport vehicle, in response to the instruction that the DTY yarn spindle has completed the stripping and knotting operations, transfers the DTY yarn spindle to the quality inspection station, so that the knitting and dyeing identification and grading operations of the DTY yarn spindle can be completed at the quality inspection station.
[0061] The second transport vehicle, in response to the signal indicating that the DTY yarn spindles for weaving socks and the dyeing and grading results are complete, loads the DTY yarn spindles onto the DTY yarn cart to transport the DTY yarn cart back to the automated warehouse, and records the position information of the DTY yarn spindles in the automated warehouse.
[0062] like Figure 4 As shown, after receiving the outbound instruction, the third railcar transports the DTY yarn spindles to be inspected from the automated warehouse to the stripping station for stripping and knotting. After stripping and knotting are completed, an instruction to complete the stripping and knotting operations is issued, and the first transport car transports the DTY yarn spindles to the quality inspection station for sock knitting and dyeing grading. After completing the sock knitting and dyeing grading, a signal indicating completion of the grading results is issued, and the second transport car transports the DTY yarn cart back to the automated warehouse, recording the location information. In specific implementation, after completing the dyeing grading, a signal indicating completion of the dyeing grading is issued, and the second transport car transports the DTY yarn cart back to the automated warehouse, recording the dyeing grading information of the yarn spindles at each position on each yarn cart.
[0063] In this embodiment, a third railcar transports DTY yarn spindles from the automated warehouse to the stripping station for stripping and knotting. A first transport vehicle then transports them to the quality inspection station for sock knitting and dyeing assessment and grading. Finally, a second transport vehicle transports the DTY yarn spindles with normal assessment results back to the automated warehouse. This automated process improves production efficiency by completing the inspection of the DTY yarn spindles.
[0064] Therefore, the entire process, from DTY spindle warehousing to quality inspection, can be completed on a fully automated production line. Each operation is driven by a corresponding system, and the result of each operation can be automatically recorded in the database, making the entire process traceable and trackable.
[0065] Once qualified DTY spindles are stored in the warehouse, orders can be fulfilled. Therefore, a packaging system can also be provided in this embodiment.
[0066] II. Packaging System
[0067] After the silk spindles pass quality inspection, professional packaging is required to protect them from external environmental influences such as dust, moisture, and other contaminants. This packaging system includes:
[0068] The third transport vehicle is used to retrieve the DTY yarn car from the automated warehouse and transfer it to the packaging area in response to a packaging instruction, based on the storage area code in the packaging instruction.
[0069] The second robotic arm, in response to the instruction that the third transport vehicle has arrived at the packaging area, transfers DTY yarn spindles from the DTY yarn cart to the target packaging line;
[0070] The target packaging line is used for packing, sealing, and palletizing the DTY filaments.
[0071] like Figure 5 As shown, after receiving the packaging instruction, the third transport vehicle takes the DTY yarn cart out of the automated warehouse and transfers it to the packaging area. The second robotic arm then transfers the DTY yarn spindles on the DTY yarn cart to the packaging line for packaging.
[0072] This disclosure provides a packaging system. Further packaging of the silk spindles facilitates storage and prepares them for subsequent transportation.
[0073] When packaging yarn spindles, different packaging methods are selected based on product characteristics and customer needs. Therefore, the yarn spindle management system in the texturing process provides two target packaging lines: a first packaging line and a second packaging line. The first packaging line is used for large packaging to facilitate container shipping, while the second packaging line is used for regular transportation to achieve smaller packaging. For ease of understanding, these two target packaging lines are explained below:
[0074] 1) The target packaging line is the first packaging line:
[0075] The first packaging auxiliary material transfer device is used to transfer various packaging auxiliary materials required by the first packaging line to the auxiliary material storage area next to the first packaging line and place them in categories; the packaging auxiliary materials include, for example, rigid pallets, foam partitions as protective boards, cardboard top covers, cartons, etc.; for example, the rigid pallets are large plastic pallets or wooden pallets.
[0076] The first packaging line is used to stack the DTY silk spindles in the stacking area by placing a pallet at the bottom, alternating layers of silk spindles and protective plates in the middle, and placing a top cover cardboard at the top to obtain a stack to be packaged. After automatically packaging the stack to be packaged, a fifth call signal is triggered.
[0077] The fourth transport vehicle, responding to the fifth call signal, transfers the sealed stacks to the automated warehouse for storage.
[0078] like Figure 6a As shown, before packaging DTY spindles, the first packaging auxiliary material transfer device will transfer the two types of packaging auxiliary materials required by the first packaging line to the auxiliary material storage area next to the first packaging line and place them in categories.
[0079] The first packaging line has corresponding robotic arms that stack DTY silk spindles in an alternating pattern: a bottom layer of pallets, a middle layer of silk spindles, a middle layer of protective plates, and a top layer of cardboard covers. Once stacked, as... Figure 6b As shown, the stacked filaments are transported to the film-wrapping area for overall film wrapping, thus completing the encapsulation of the stack. After the stacking and encapsulation are completed, a fifth call signal is sent, and the fourth transport vehicle transports the encapsulated stack to the automated warehouse.
[0080] In this embodiment of the disclosure, for DTY spindles that need to be transported in containers, the spindles are packaged by a robotic arm on the first packaging line in a fixed stacking manner, thereby improving production efficiency.
[0081] 2) The target packaging line is the second packaging line:
[0082] The second packaging auxiliary material transfer device is used to transfer the packaging boxes to the sealing area of the second packaging line;
[0083] The second packaging line is used to seal the DTY spindles in the sealing area according to their spindle type.
[0084] like Figure 7 As shown, the second packaging auxiliary material transfer device is used to transfer the packaging box to the sealing area of the second packaging line.
[0085] Within the sealing area, one slide rail serves as the spindle transport line, and the other as the carton transport line. Between the two transport lines is a corresponding robotic arm that loads the spindles into the carton.
[0086] In this embodiment of the disclosure, different packaging methods are applied to DTY spindles according to their different categories, which can better achieve the management of different categories and thus improve production efficiency.
[0087] When the target packaging line is the second packaging line, different packaging methods are required because DTY yarn spindles may be in full rolls or not. The following explains these two scenarios separately:
[0088] Case (1): When the DTY spindle is a full roll of spindle, the DTY spindle is grouped into groups of n spindles and multiple spindles in the same group are arranged in the target manner; n is a positive integer.
[0089] When the same set of spindles arrives at the sealing area, the packing and sealing operation is automatically completed in the sealing area.
[0090] The third robotic arm is used to automatically stack m boxes; m is a positive integer.
[0091] The system also includes a fifth transport vehicle for transporting a stack of packaging boxes to the automated warehouse for storage.
[0092] like Figure 7 As shown, when the DTY yarn spindles are in full rolls, six yarn spindles can be grouped together and placed in a carton in a double row. The packed DTY yarn spindles are then transported to the carton sealing machine via a conveyor belt for automatic sealing. The sealed yarn spindles are then transported to the tape-binding machine for automatic tape binding. Finally, the cartons of yarn spindles with tape binding are stacked in the palletizing area by the third robotic arm. Finally, the fifth transport vehicle transports the stacked packaging boxes to the automated warehouse.
[0093] In this embodiment, a third robotic arm packs fully wound DTY yarn spindles into boxes in groups of n, automatically seals the boxes and attaches the tape, then stacks them using the robotic arm. Finally, the stacked boxes are transported to an automated warehouse. This automated process facilitates subsequent management and scheduling, saves manpower and time costs, and thus improves production efficiency.
[0094] In case (2), when the DTY spindle is not a full roll spindle, the DTY spindle is grouped according to the method of one spindle per target weight range, and multiple spindles in the same group are arranged according to the target method.
[0095] When the same set of spindles arrives at the sealing area, the packing and sealing operation is automatically completed in the sealing area.
[0096] The third robotic arm is used to automatically stack m boxes; m is a positive integer.
[0097] The fifth transport vehicle is used to transport the automatically palletized packaging boxes to the automated warehouse for storage.
[0098] When DTY yarn spindles are not fully rolled, a packing weight standard needs to be set. This standard is usually determined based on transportation and storage requirements. Before packing, each roll of yarn spindle needs to be weighed. This can be done using specialized weighing equipment. The weighed yarn spindles are then sorted according to weight. For example, yarn spindles with similar weights can be grouped together. Then, according to the packing weight standard, the appropriate amount of yarn spindles is placed into the box. For example, if the packing standard is 50 kg, then yarn spindles with a total weight close to 50 kg need to be placed in the box. The packed DTY yarn spindles are then transported to the sealing machine via conveyor belt for automatic sealing. The sealed yarn spindles are then transported to the binding machine for automatic binding. Finally, the bound yarn spindle cartons are stacked in the palletizing area by a third robotic arm, and finally, a fifth transport vehicle transports the stacked cartons to the automated warehouse.
[0099] In this embodiment of the disclosure, by packing the wire spindles by weight, the weight of the spindles in each box can be made similar. Weight-based packing allows for rapid categorization of wire spindles during the production process, improving production efficiency. It also reduces the complexity of subsequent processing and simplifies operations.
[0100] III. Loading System
[0101] The yarn spindle management system in the texturing process also includes a loading system, which includes:
[0102] The fourth railcar is used to retrieve the packaged DTY spindles from the automated warehouse in response to a delivery instruction;
[0103] The sixth transport vehicle is used to load the spindles onto the transport vehicle in response to the instruction from the fourth railcar to reach the loading position.
[0104] like Figure 8 As shown, after receiving the delivery instruction, the fourth railcar uses the WMS (Warehouse Management System) to control the steel structure platform inside the automated warehouse to transport the packaged DTY spindles to the fourth railcar. The fourth railcar then transports the spindles to the loading platform and issues a loading instruction, which is then used by the sixth transport car to load the spindles onto the transport car.
[0105] In this embodiment of the disclosure, based on the delivery instruction, the coordinated work of the fourth railcar and the sixth transport car can efficiently complete the retrieval and loading of goods, reducing the demand for human resources and improving outbound efficiency.
[0106] In this embodiment of the disclosure, to facilitate the gripping of DTY yarn spindles on the texturing machine, an AGV (Automated Guided Vehicle) dropper is also provided in the yarn spindle management system of the texturing process, comprising:
[0107] The base of the AGV (Automated Guided Vehicle) dropper;
[0108] At least one support layer is mounted on the base;
[0109] Each layer of the support has at least one gripper with an airbag, which is used to grip the target yarn spindle produced by the texturing machine to transfer the target yarn spindle from the texturing machine to the AGV dropper.
[0110] The airbag is equipped with a weight sensor, which is used to determine the type of DTY yarn spindle when the grippers pick it up. That is, it enables the weight grading of the DTY yarn spindle to identify whether it is a full roll.
[0111] This disclosure provides an AGV (Automated Guided Vehicle) unloading cart. The unloading cart uses grippers to pick up target yarn spindles and loads them onto the AGV. Weight sensors on the airbags are used to classify the DTY (Digital Tissue) yarn spindles, thereby automating the process, reducing the need for manual operation, and improving production efficiency.
[0112] The AGV (Automated Guided Vehicle) dropper 102 has at least one layer of support 1021. For example... Figure 9 As shown, the AGV unloading vehicle 102 generally consists of an AGV base 1020 and a wire spindle support 1021 for storing wire spindles. Figure 9 In the figure, the solid line cube represents the spindle support 1021 for storing the target spindle. The figure shows two layers of spindle support 1021. During implementation, the number of layers of spindle support 1021 can be increased or decreased according to actual needs.
[0113] Each layer of the spindle support 1021 is equipped with a gripper 1022 that can move left, right, up, and down.
[0114] like Figure 9 As shown, the end of the gripper 1022 that is away from the spindle support 1021 is the clamping end 10221.
[0115] The gripping end 10221 of the gripper 1022 is covered with an inflatable and deflated airbag. Figure 9 (Not shown in the image). In this embodiment of the present disclosure, in order to support the airbag, the clamping end 10221 is made of a rigid material, such as metal or ceramic.
[0116] The AGV dropper 102 is used to control the clamping end 10221 to enter the inner wall of the paper tube of the target yarn spindle when the gas content of the air bladder is lower than a preset threshold. While clamping the target yarn spindle, the air bladder is inflated so that the air bladder fills the inner wall of the paper tube of the target yarn spindle. After inflation, the target yarn spindle is loaded onto the AGV dropper 102 based on the force between the air bladder and the inner wall of the paper tube.
[0117] That is, by controlling the gas content to a first preset threshold, the air bladder is either empty or contains very little gas. In this case, the air bladder is small in volume, and the clamping end 10221 is also small in volume, which facilitates the feeding of the clamping end 10221 into the inner wall of the paper tube. Since the size of the clamping end 10221 is much smaller than that of the inner wall of the paper tube, precise position control is not required to feed the clamping end 10221 into the space between the inner walls of the hollow paper tube.
[0118] Therefore, in this embodiment of the present disclosure, the AGV dropper 102 is designed with an inflatable and deflated airbag. The deflated airbag (i.e., not fully filled with gas, or with a small amount of residual gas) is inserted into the inner wall of the paper tube. Since the airbag is small at this point, it only needs to be able to extend into the inner wall of the paper tube, thus the positional accuracy requirement of the clamping end 10221 relative to the inner wall of the paper tube can be appropriately reduced. Then, by inflating, the clamping end 10221 generates an interaction force with the inner wall of the paper tube through the airbag. Under the action of this force, the target yarn spindle can be transferred onto the AGV dropper 102. It is evident that the inflatable and deflated airbag simplifies the clamping operation of the yarn spindle, thereby improving the gripping efficiency.
[0119] like Figure 9 As shown, the gripper 1022 has a metal arm 10223, one end of which is connected to the gripping end 10221. The side of the metal arm 10223 facing away from the gripping end 10221 is mounted on the slider 10222. The slider 10222 is mounted on the AGV hopper 102, and the slider 10222 can slide in a direction perpendicular to the ground under the drive of the slider 10222 motor, so that the gripping end 10221 can move in a direction perpendicular to the ground.
[0120] like Figure 9 As shown, the slider 10222 can be fixed on the spindle bracket 1021 of the AGV dropper 102. Figure 9 The slider 10222 is shown to be fixed to the frame of the spindle support 1021. The slider 10222 can be driven by the motor ( Figure 2 Driven by a motor (not shown), it moves up and down along the edge of the spindle support 1021. The metal arm 10223 of the gripper 1022 can be hinged to the slider 10222, and the position of the gripping end 10221 can be finely adjusted up, down, left, and right based on the motor drive.
[0121] In one embodiment of this disclosure, the airbag includes multiple independent sub-airbags, each of which supports independent inflation and deflation, and the total length of the airbag is greater than the length of the inner wall of the paper tube.
[0122] Figure 10 A schematic diagram of an airbag structure is shown. The airbag comprises three independent sub-airbags, each of which can be individually inflated and deflated via a corresponding control valve. Figure 10 As shown, each sub-airbag has a corresponding inlet / outlet air pipe at the clamping end 10221, and an independent solenoid valve 10225 is provided at or outside the inlet / outlet air pipe. For each sub-airbag, inflation or deflation can be controlled by the corresponding solenoid valve 10225. Each sub-airbag's solenoid valve 10225 corresponds to its own air pump 10224. The air pump 10224 is located outside the gripper 1022 and can be mounted on the base of the AGV discharge trolley 102.
[0123] In this embodiment, the total length of the airbag is greater than the length of the inner wall of the paper tube. For example, if the length of the inner wall of the paper tube is 15cm, then the middle part of the airbag needs to be greater than this length.
[0124] After inflation, the sub-airbags located on both sides of the inner wall of the paper tube take on a specific shape, so that the inner wall of the paper tube is engaged between the sub-airbags on both sides of the inner wall. For example, after inflation, this specific shape requires that the radius of the sub-airbags on both sides of the inner wall of the paper tube is greater than the radius of the inner wall of the paper tube.
[0125] Figure 10 A schematic diagram of a dumbbell-shaped structure of an airbag is shown. Figure 10 The middle sub-airbag has filled the inner wall of the paper tube, and the two side sub-airbags clamp the ends of the paper tube. In this way, when the target yarn spindle is moved from the yarn spindle temporary storage area to the AGV dropper 102, the target yarn spindle can be fixed by the clamping method, which further ensures that the airbag has a certain gripping force on the target yarn spindle, and further improves the safety and accuracy of the target yarn spindle transfer.
[0126] Correspondingly, in order to successfully place the target wire spindle onto the wire rack of the AGV dropper 102, this disclosure provides a corresponding solution.
[0127] Specifically, when the target yarn spindle is loaded onto the AGV dropper 102, the AGV dropper 102 is used to sequentially deflate multiple sub-airbags. Among them, the sub-airbags on the inner wall of the paper tube closer to the yarn frame of the AGV dropper 102 are deflated first, and the sub-airbags on the inner wall of the paper tube away from the yarn frame of the AGV dropper 102 are deflated last, so that the target yarn spindle slides onto the yarn frame of the AGV dropper 102 in sequence.
[0128] After the gripper 1022 loads the target wire spindle onto the AGV dropper 102, the process continues... Figure 10 For example, the sub-airbag on the right side of the airbag will preferentially deflate via solenoid valve 10225. The deflation process of each sub-airbag can be carried out slowly to gradually reduce the force between the airbag and the target spindle, and to release the cavity in the inner wall of the paper tube filled by the sub-airbag, so as to hang the target spindle on the yarn frame. In implementation, such as Figure 10 As shown, the gas in the right sub-airbag is released slowly first, followed by the middle sub-airbag, and finally the left sub-airbag, so that the target spindle slides onto the wire rack of the AGV dropper 102.
[0129] In this embodiment, an airbag with two sub-airbags of a specified shape is provided. The specified shape of the two sub-airbags is used to clamp the paper tube of the target yarn spindle, thereby protecting the paper tube from damage. Then, by sequentially deflating one side of the airbag, the target yarn spindle slides onto the AGV dropper 102, thereby improving transfer efficiency.
[0130] In some embodiments, the clamping end 10221 can be implemented as a telescopic rod. During inflation, the clamping end 10221 is controlled to automatically extend to provide better support for the airbag. During deflation, the clamping end 10221 can retract to release the cavity inside the paper tube.
[0131] The airbag is made of a rubber material with a friction coefficient greater than a preset threshold, and the surface of the rubber material has particles of different sizes.
[0132] In this embodiment of the disclosure, the management of all hardware devices in the system can be achieved through a computer device. This computer device can receive signals, record equipment parameters for the process flow, record the material input status of each process step, and record the execution results.
[0133] In summary, the yarn spindle management system in the texturing process provided in this disclosure embodiment,
[0134] In the texturing process, the entire process from POY raw yarn to DTY yarn spindle production, as well as warehousing, quality inspection, packaging, and delivery, has been fully automated.
[0135] The main design effects are summarized as follows:
[0136] High efficiency: The yarn spindle management system, through the cooperation of AGV transport vehicles, railcars, and the server, achieves a fully automated process from POY raw yarn leaving the warehouse to processing it into DTY yarn spindles, then to the quality inspection of the DTY yarn spindles, and finally loading the qualified DTY yarn spindles back onto the DTY yarn carts and returning them to the automated warehouse. This improves production efficiency.
[0137] Precision: In the spindle management system, each step relies on corresponding instructions and signals to trigger, ensuring the accuracy of production.
[0138] Reduced labor costs: The automated operation achieved through the spindle management system reduces the need for manual intervention, lowers labor costs, and improves production efficiency.
[0139] It should be understood that the various forms of processes shown above can be used to rearrange, add, or delete steps. For example, the steps described in this disclosure can be executed in parallel, sequentially, or in different orders, as long as the desired result of the technical solution disclosed in this disclosure can be achieved, and this is not limited herein.
[0140] The specific embodiments described above do not constitute a limitation on the scope of protection of this disclosure. Those skilled in the art should understand that various modifications, combinations, sub-combinations, and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the principles of this disclosure should be included within the scope of protection of this disclosure.
Claims
1. A yarn spindle management system based on the texturing process, characterized in that, include: AGV transport vehicles are used to transport POY filament spindles from the raw material warehouse to the target filament rack position on the texturing machine in response to order-triggered production instructions; Texturing machine is used to process the POY raw yarn spindle using a texturing process to obtain DTY yarn spindle, and to store the DTY yarn spindle in the yarn spindle temporary storage area and trigger the drop-on signal; A transport system for storing the DTY yarn spindles in an automated storage and retrieval system in response to the doffing signal; A packaging system for retrieving the DTY spindles from the automated warehouse and packaging them in response to a packaging instruction; The transportation system includes: An AGV (Automated Guided Vehicle) is used to transfer DTY (Digital Turbine) spindles from the spindle temporary storage area to the target operation area. The first robotic arm, located in the target operation area, is used to sort the DTY yarn spindles on the AGV unloading cart onto the DTY yarn cart in response to a first call signal when the AGV unloading cart arrives at the target operation area. The DTY silk-cart is located on the first slide rail; The first slide rail, in response to a second call signal indicating that the DTY yarn cart is full, delivers the DTY yarn cart to a first designated position and then triggers a third call signal; A first track car, in response to the third call signal, transfers the DTY yarn car onto a hoist, so that the DTY yarn car can be transferred to an automated warehouse for storage via the hoist. The automated library includes multiple storage layers, and each storage layer contains multiple storage areas with partition identifiers; The elevator is used to transfer the DTY yarn car onto the second slide rail of the automated warehouse; The second slide rail is used to trigger a fourth call signal after the DTY yarn car is transferred to the second designated position; The second track car is used to transfer the DTY silk car to the target storage area of the target storage layer indicated by the fourth call signal in response to the fourth call signal; Also includes: The third track vehicle, in response to the outbound command, transfers the DTY yarn cart from the automated warehouse to the stripping station, so that the DTY yarn cart can complete the stripping and knotting operations at the stripping station. The first transport vehicle, in response to the instruction that the DTY yarn spindle has completed the stripping and knotting operations, transfers the DTY yarn spindle to the quality inspection station, so that the knitting and dyeing identification and grading operations of the DTY yarn spindle can be completed at the quality inspection station. The second transport vehicle, in response to the signal that the DTY yarn spindles are used for weaving socks and the dyeing and grading results are completed, loads the DTY yarn spindles onto the DTY yarn cart to transport the DTY yarn cart back to the automated warehouse, and records the position information of the DTY yarn spindles in the automated warehouse. The first transport vehicle transports the DTY yarn spindles to the quality inspection station for weaving and dyeing identification and grading. Finally, the DTY yarn spindles with normal identification results are transported back to the automated warehouse by the second transport vehicle.
2. The system according to claim 1, characterized in that, The packaging system includes: The third transport vehicle is used to retrieve the DTY yarn car from the automated warehouse and transfer it to the packaging area in response to a packaging instruction, based on the storage area code in the packaging instruction. The second robotic arm, in response to the instruction that the third transport vehicle has arrived at the packaging area, transfers DTY yarn spindles from the DTY yarn cart to the target packaging line; The target packaging line is used for packing, sealing, and palletizing the DTY filaments.
3. The system according to claim 2, characterized in that, If the target packaging line is the first packaging line, it further includes: The first packaging auxiliary material transfer device is used to transfer various packaging auxiliary materials required by the first packaging line to the auxiliary material storage area next to the first packaging line and place them in categories. The first packaging line is used to stack the DTY silk spindles in the stacking area by placing a pallet at the bottom, alternating layers of silk spindles and protective plates in the middle, and placing a top cover cardboard at the top to obtain a stack to be packaged. After automatically packaging the stack to be packaged, a fifth call signal is triggered. The fourth transport vehicle, responding to the fifth call signal, transfers the sealed stacks to the automated warehouse for storage.
4. The system according to claim 2, characterized in that, In the case where the target packaging line is a second packaging line, it also includes: The second packaging auxiliary material transfer device is used to transfer the packaging boxes to the sealing area of the second packaging line; The second packaging line is used to seal the DTY spindles in the sealing area according to their spindle type.
5. The system according to claim 4, characterized in that, The second packaging line is specifically used to, when the DTY yarn spindle is a full roll of yarn spindle, group the DTY yarn spindles into groups of n yarn spindles, and arrange multiple yarn spindles in the same group in a target manner; n is a positive integer; When the same set of spindles arrives at the sealing area, the packing and sealing operation is automatically completed in the sealing area. The third robotic arm is used to automatically stack m boxes; m is a positive integer. The system also includes a fifth transport vehicle for transporting a stack of packaging boxes to the automated warehouse for storage.
6. The system according to claim 4, characterized in that, The second packaging line is specifically used to, when the DTY yarn spindle is not a full roll of yarn spindle, group the DTY yarn spindles according to the method of grouping yarn spindles for each target weight range, and arrange multiple yarn spindles in the same group according to the target method. When the same set of spindles arrives at the sealing area, the packing and sealing operation is automatically completed in the sealing area. The third robotic arm is used to automatically stack m boxes; m is a positive integer. The fifth transport vehicle is used to transport the automatically palletized packaging boxes to the automated warehouse for storage.
7. The system according to claim 1, characterized in that, It also includes a loading system, which includes: The fourth railcar is used to retrieve the packaged DTY spindles from the automated warehouse in response to a delivery instruction; The sixth transport vehicle is used to load the packaged DTY spindles onto the transport vehicle in response to the instruction that the fourth railcar has arrived at the loading position.
8. The system according to claim 1, wherein the AGV unloading vehicle comprises: The base of the AGV (Automated Guided Vehicle) dropper; At least one support layer is mounted on the base; Each layer of the support has at least one gripper with an airbag, which is used to grip the DTY yarn spindle produced by the texturing machine to transfer the DTY yarn spindle from the texturing machine to the AGV dropper. The airbag is equipped with a weight sensor, which is used to determine the type of DTY spindle when the gripper picks up the DTY spindle.