Packaging system of heat-setting machine

Abstract

A system has at least one winder configured to wind a yarn to form a yarn package. At least one sampling knotting machine is configured to remove a portion of the yarn in the yarn package and knot a free end of the yarn around the yarn package to prevent unwinding of the yarn package. There is at least one support structure in the dunnage supply zone for receiving a plurality of yarn packages thereon. The robotic arm is configured to: move the yarn package from the at least one winder to the at least one sampling knotting machine; moving the yarn package from the at least one sampling knotting machine to at least one box body assembling area; and stacking the yarn package on the support structure in the at least one box assembly area.

Description

[0001] Cross - Reference to Related Applications

[0002] This application claims the benefit and priority of the filing dates of U.S. Provisional Patent Application No. 63 / 381,838, filed on November 1, 2022, and U.S. Provisional Patent Application No. 63 / 478,780, filed on January 6, 2023, the entire contents of each of which are hereby incorporated by reference herein. Technical Field

[0003] This disclosure relates to systems and methods for handling packages of yarn. Background Art

[0004] Traditionally, packages of yarn formed on the winders of a heat setting machine are handled by an operator. The operator cuts a sample of the yarn, ties a knot in the loose end of the package of yarn, and then stacks the packages of yarn on a tray. This requires a large number of operators and exposes the operators to typical occupational hazards. Accordingly, a way to reduce direct operator interaction is desired.

[0005] Further, traditionally, an operator cuts a sample of the yarn from the package of yarn for dyeing and tests the sample to ensure quality. The operator then ties a knot in the loose end of the package of yarn to secure the package of yarn. This operation exposes the operator to typical occupational hazards. Accordingly, a way to reduce direct operator interaction is desired. Summary of the Invention

[0006] Described herein in various aspects is a system having at least one winder configured to wind yarn to form packages of yarn. At least one sampling and knotting machine is configured to remove a portion of the yarn from the package of yarn and tie the free end of the yarn around the package of yarn to prevent the package of yarn from unwinding. At least one support structure is provided in a padding supply area for receiving a plurality of packages of yarn thereon. The system further includes at least one box assembly area and a robotic arm. The robotic arm is configured to: move the package of yarn from the at least one winder to the at least one sampling and knotting machine; move the package of yarn from the at least one sampling and knotting machine to the at least one box assembly area; and stack the package of yarn on the support structure in the at least one box assembly area.

[0007] In another aspect, a method includes winding yarn with a winder to form a package of yarn. A robotic arm moves the package of yarn from the winder to at least one sampling and knotting machine. The robotic arm moves the package of yarn from the at least one sampling and knotting machine to a box assembly area. The robotic arm stacks the package of yarn on a support structure in the at least one box assembly area.

[0008] This document also describes, in various aspects, a system for sampling and knotting a wound yarn having a free end. The system includes a spindle and a first actuator. The first actuator is configured to rotate the spindle in a first direction and an opposite second direction. A yarn sampling assembly is configured to receive a portion of the yarn that includes the free end. A yarn knotting assembly is configured to tie a knot in the wound yarn to prevent the yarn from unwinding from the wound package.

[0009] In another aspect, a method includes receiving a wound package containing a yarn on a spindle. The yarn has a free end. A first actuator coupled to the spindle rotates the wound package to deliver the free end to a sampling assembly. The sampling assembly removes a portion of the yarn that includes the free end to provide a yarn sample and forms a new free end of the yarn remaining on the spindle. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 is a top plan view of the system as disclosed herein.

[0011] Figure 2 is Figure 1 a perspective view of the system of

[0012] Figure 3 is Figure 1 a perspective view of a global system among a plurality of systems as shown

[0013] Figure 4 is a block diagram of an operating environment that includes a computing device for controlling the system as disclosed herein Figure 1 of

[0014] Figure 5 shows an exemplary housing as disclosed herein.

[0015] Figure 6 shows Figure 5 the exemplary housing being transported on a first conveyor to a second conveyor.

[0016] Figure 7 shows an exemplary first wrapper as disclosed herein.

[0017] Figure 8 shows an exemplary second wrapper as disclosed herein.

[0018] Figure 9 shows an exemplary yarn wound package as disclosed herein.

[0019] Figure 10 is a perspective view of an exemplary sampling and knotting machine as disclosed herein.

[0020] Figure 11 is Figure 10A perspective view of an exemplary sampling knotter showing a loaded exemplary yarn package.

[0021] Figure 12 is Figure 10 A perspective view of an exemplary sampling knotter showing an exemplary yarn sampling assembly.

[0022] Figure 13 is Figure 10 A perspective view of an exemplary sampling knotter showing an exemplary sensor location.

[0023] Figure 14 is Figure 10 A perspective view of an exemplary sampling knotter showing Figure 12 an exemplary component of the yarn sampling assembly in an open position.

[0024] Figure 15 is Figure 14 A perspective view of an exemplary component of the yarn sampling assembly in a closed position.

[0025] Figure 16 is Figure 10 A perspective view of an exemplary sampling knotter showing an exemplary yarn knotting assembly.

[0026] Figure 17 is Figure 16 A perspective view of an exemplary first surface, second surface, and knotting fixture of the yarn knotting assembly.

[0027] Figure 18 is Figure 10 A perspective view of an exemplary sampling knotter showing the rotation of an exemplary first actuator. Detailed Description

[0028] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. In fact, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Throughout the specification, like reference numerals refer to like elements. It should be understood that the invention is not limited to the particular methods and procedures described, as these may vary. It should be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of the invention.

[0029] Benefiting from the teachings presented in the foregoing description and the associated drawings, those skilled in the art to which this invention pertains will envision many modifications and other embodiments of the invention set forth herein. Accordingly, it is to be understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a general and descriptive sense only and not for purposes of limitation.

[0030] As used herein, unless the context clearly indicates otherwise, the singular forms "a", "an", and "the" may include plural referents. For example, the use of the term "winder" may represent the disclosure of an embodiment providing only a single winder, and in alternative aspects, may also represent the disclosure of an embodiment providing a plurality of such winders, unless the context indicates otherwise.

[0031] All technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains, unless otherwise clearly indicated.

[0032] In this document, ranges may be expressed as from "about" a particular value and / or to "about" another particular value. When expressing such ranges, on the other hand, it includes from a particular value and / or to another particular value. Similarly, when a value is expressed as an approximation by use of the antecedent "about", it is to be understood that the particular value forms another aspect. It will be further understood that the endpoints of each range are significant both relative to the other endpoint and independently of the other endpoint. Optionally, in some aspects, when a value is approximated by use of the antecedent "about", it is contemplated that values within up to 15%, up to 10%, up to 5% or up to 1% (higher or lower) of the specifically recited value may be included within the scope of these aspects. Similarly, in some optional aspects, when a value is approximated by use of the terms "approximately", "substantially" or "generally", it is contemplated that values within up to 15%, up to 10%, up to 5% or up to 1% (higher or lower) of the particular value may be included within the scope of these aspects. When used with respect to an identified property or circumstance, "substantially" or "generally" may refer to a degree of deviation small enough not to measurably depart from the identified property or circumstance, and the exact degree of deviation permitted may in some cases depend on the specific context.

[0033] As used herein, the term "optional" or "optionally" means that the subsequent described event or circumstance may or may not occur, and the description includes instances where the event or circumstance occurs and instances where it does not occur.

[0034] As used herein, the word "or" means any member of a particular list and, unless the context otherwise indicates, in the alternative aspect, may also include any combination of members of the list.

[0035] The following description provides specific details to provide a thorough understanding. However, those skilled in the art will understand that the device and the associated method of using the device can be implemented and used without adopting these specific details. In fact, the device and the associated method can be practiced by modifying the shown device and the associated method and can be used in combination with any other devices and technologies commonly used in the industry.

[0036] Introduction

[0037] References herein Figure 1 and 2 A system 10 for processing yarn is disclosed. Once a yarn package is formed on one or more winders 10, the system 10 can automatically process the yarn package. For example, the system 10 can use a robotic arm 60 to move the yarn package from the winder 20 to a sampling knotter 30. The sampling knotter 30 can be configured to remove a portion of the yarn in the yarn package and tie the free end of the yarn around the yarn package to prevent the yarn package from unwinding. Once the yarn package is sampled and the free end of the yarn is tied, the robotic arm can stack the yarn to form a bin 50. In some aspects, the bin can contain yarn packages stacked on one or more support components (collectively referred to herein as padding). An automated guided vehicle (AGV) can remove the bin and deliver the padding to form additional bins.

[0038] Exemplary embodiments

[0039] In some aspects, the system 10 can include at least one winder 20 configured to wind yarn to form a yarn package 22 known in the art. For example, at least one winder 20 can be a winder of a heat setting device 24 known in the art. Generally, the winder receives the yarn after the heat setting process, and the winder is configured to wind the yarn (e.g., around a substrate such as a tube or a cone) to form a yarn package 22. The winder can have a driven roller that contacts the yarn package. The driven roller can rotate the yarn package to wind the yarn around the substrate (e.g., when the yarn exits the heat setting device 24).

[0040] The system 10 can further include at least one sampling knotter 30. Each sampling knotter 30 can be configured to remove a portion of the yarn in the yarn package 22 and tie the free end of the yarn around the yarn package to prevent the yarn package from unwinding. The sampling knotter 30 can deliver the yarn to a corresponding sample drawer 32. A quality control specialist can retrieve the sample in the sample drawer 32 for inspection. Additional aspects of the exemplary sampling knotter 30 are described in detail herein.

[0041] System 10 may include a padding supply area 40 having one or more support structures 42 thereon for receiving a plurality of yarn packages. The one or more support structures 42 may include a tray 44 (yarn packages not shown to include details of the support structure) that may form the bottom of a box 48, and a partition 46 positioned between adjacent layers of yarn packages. Optionally, the partition 46 may also form the top layer (e.g., lid) of the box 48. Each of the support structures 42 may include features for supporting the positions of the packages positioned thereon. For example, the support structure 42 may define a cylindrical groove 43 configured to support the yarn package 22 and maintain the yarn package at a specific spacing. The tray 44 may further define a carriage 45 for receiving the forks of a forklift.

[0042] System 10 may include at least one box assembly area 50 for forming the box 48. In some optional aspects, each box 48 may include a tray 44 that defines the bottom of the box. One or more layers of yarn packages 22 may be stacked on the tray 44. For example, the box 48 may include one, two, three, four, or more than four layers of yarn packages 22. The partition 46 may be positioned between each layer of yarn packages 22. Optionally, the partition 46 may define the top of the box 48.

[0043] Reference Figure 5 In additional exemplary aspects, the tray 44 may be a thin sheet. For example, the tray 44 may be cardboard. In an exemplary aspect, the tray may be flat cardboard. In additional aspects, each partition 46 may be a thin sheet (e.g., cardboard). In some aspects, the tray 44 and the partition 46 may be similar or the same. For example, the same type of cardboard may be used for the tray 44 and the partition 46. Thus, in some aspects, the support structures may be interchangeable. In these aspects, elements (such as storage racks) for managing stacks of support structures containing different elements may be omitted. Optionally, the horizontal dimensions of the tray 44 and the partition 46 may be slightly smaller than the box 48 such that the yarn packages 22 on the outer edges extend outward from the tray 44 and the partition 46.

[0044] System 10 may include a robotic arm 60. The robotic arm 60 may be configured to move each yarn package 22 from one or more winders 20 to one or more sampling knotters 30. Then, the robotic arm 60 may move the yarn package 22 from at least one sampling knotter 30 to at least one box assembly area 50 and stack the yarn package 22 on the support structure 42 in at least one box assembly area 50.

[0045] In some aspects, each winder 20, each sampling and knotting machine 30, the padding supply area 40, at least one box assembly area 50, and the robotic arm 60 can be located within the locking area 70. For example, the system 10 can include a barrier 72 surrounding the locking area 70. The barrier 72 can include at least one retractable door 74 that selectively allows entry into the locking area 70. For example, the retractable door 74 can be positioned in front of each box assembly area 50 and the padding supply area 40. In this way, padding can be delivered and the box 48 can be removed. Each retractable door 74 can include an actuator 76 configured to rotate in a first direction to roll the door upward and in a second direction to lower the door.

[0046] In some aspects, each box assembly area 50 can include a conveyor 52. The conveyor 52 can be, for example, a belt conveyor or the like. The conveyor 52 can move the box 48 out of the corresponding retractable door 74 and onto the AGV 90. Similarly, the padding supply area 40 can include a conveyor 52 that receives the support structure 42 from the AGV 90 and moves the support structure into the system through the retractable door 74.

[0047] In an exemplary aspect, the support structure 42 in the padding supply area 40 can include at least one tray 44, at least one partition 46, or a combination thereof. For example, the support structure 42 can be provided to the padding supply area 40 according to the usage ratio of the support structure. For an exemplary system configured to form a box 48 having one tray 44, four layers of yarn packages 22, a partition 46 between each layer of yarn packages, and a partition 46 defining the top of the box, the box can use a total of one tray 44 and four partitions 46. Thus, padding can be delivered in the same ratio of four partitions 46 and one tray 44, and the padding can be arranged in the order of the completed boxes. For example, as Figure 2 shown, the support structure 42 can be arranged in a stack of alternating trays 44 and the corresponding number of partitions 46 used with each tray. A single padding delivery can include multiple trays (e.g., 2, 3, 4, 5, or more trays) and the corresponding ratio of partitions.

[0048] The robotic arm 60 can be further configured to handle the support structure 42. For example, the robotic arm 60 can be configured to move the support structure 42 in at least one support structure in the padding supply area 40 to at least one box assembly area 50. For example, the robotic arm 60 can place a tray in an empty box assembly area. The robotic arm 60 can place the partition 46 on top of a complete layer of the yarn packages 22.

[0049] The robotic arm 60 can include a dual-function end-of-arm tool (EOAT) 62. The EOAT can include a first clamp configured to grip a yarn package. In some exemplary aspects, the first clamp can include a plurality of protrusions that can be inserted into the tube of the yarn package 22 and radially displaced from each other to bias against the inner surface of the tube. For example, the first clamp can include two, three, four, or more radially displaced protrusions. The protrusions can contract inwardly to release the yarn package. The EOAT 62 can further include a second clamp for gripping and releasing the support structure 42. For example, the second clamp can include a vacuum clamp. For example, the EOAT can include a vacuum supply device (e.g., a pump) and one or more suction cups 64 (six are shown), which communicate with the vacuum supply device and are configured to apply negative pressure from the vacuum supply device to grip the support structure.

[0050] The system 10 can further include a storage rack 80 configured to store at least one support structure from the padding supply area. For example, as shown, a single stack of support structures is provided to supply two box assembly areas 50. Thus, it can be understood that the top support structure 42a of the stacked support structures 42 can be a tray or a separator. Depending on whether the partially assembled box 48 requires the current stack of the next support structure, the top support structure 42a of the stacked support structures 42 may or may not be needed. Thus, the robotic arm 60 can pick up from the top support structure 42a or the storage rack 80. The robotic arm 60 can further remove the top support structure 42a and position it on the storage rack, thereby exposing the lower support structure below the top support structure. Thus, the system 10 can be configured to track the order inventory of the support structures 42 in the padding supply area 40 and the support structures 42 on the storage rack 80. The storage rack 80 can be configured to accommodate at least one support structure 42, at least two support structures 42, or exactly two support structures 42.

[0051] The system 10 can further include one or more automated guided vehicles (AGVs) 90. The AGV 90 can be configured to deliver the support structure 42 to the padding supply area 40. The AGV 90 can further be configured to transport the box 48 from the box assembly area 40. Each AGV 90 can include a conveyor 92 configured to align with the corresponding conveyor 52 to transfer the support structure 42 and the box 48.

[0052] In some aspects, at least one winder 20 can include two winders. In some aspects, at least one sampling knotter 30 can include two sampling knotters. In some aspects, at least one case assembly area 50 can include two case assembly areas. System 10 can include logic configured to control the transfer of yarn packages from a first winder to a first sampling knotter, to a first case assembly area and to control the transfer of yarn packages from a second winder to a second sampling knotter, to a second case assembly area.

[0053] Reference Figure 3 , in some aspects, global system 100 can include a plurality of systems 10 as disclosed herein and a plurality of AGVs 90 for delivering padding to the plurality of systems 10 and receiving cases from the plurality of systems.

[0054] In additional or alternative aspects, and with reference Figures 5 - 6 , conveyor 120 (e.g., roller conveyor) can receive case 48 from conveyor 52 and transport cases from winder 20. For example, conveyor 52 can include track 53 that can be moved horizontally to laterally transport case 48. Then, track 53 can be moved vertically downward to place case 48 on conveyor 120.

[0055] In some optional aspects, case 48 can be packaged with packaging material (e.g., polymeric packaging). For example, with reference Figure 6 and 7 , conveyor 120 can transport case 48 from case assembly area 50 to a first wrapper 130 configured to wrap the case about a first axis (e.g., a horizontal axis). In an exemplary aspect, first wrapper 130 can surround case 48 such that case 48 can be received therein. First wrapper 130 can include actuator 132 that moves material roller 134 about the perimeter of the case about the first axis to wrap the packaging material around case 48. In an exemplary aspect, the first wrapper can include wheels that rotate about the package and material roller 134 can be mounted to the wheels. In some aspects, the first axis can be parallel or substantially parallel to the axis of movement of conveyor 53.

[0056] In additional aspects, a second wrapper 140 can be configured to wrap case 48 about a second axis (e.g., a vertical axis). For example, with reference Figure 8, the second wrapper 140 can be wrapped around the box 48 such that the wrapping extends circumferentially through the vertical axis of the box 48. In some aspects, the second wrapper 140 can include a rotatable platform 142 that rotates to rotate the box 48 relative to the second roll of packaging material. The second wrapper 140 can further include a stabilizing plate 144 that is vertically movable to be positioned on top of the box 48. The stabilizing plate 144 can hold the box 48 on the rotatable platform as the rotatable platform 142 rotates relative to a roll of packaging material in order to apply the packaging material to the periphery of the box.

[0057] Method of Use

[0058] The method can include winding yarn with a winder 20 to form a yarn package 22. The robotic arm 60 can move the yarn package 22 from the winder 20 to at least one sampling knotter 30. The robotic arm 60 can move the yarn package 22 from at least one sampling knotter 30 to a box assembly area 50. The robotic arm 60 can stack the yarn packages 22 on a support structure 42 in at least one box assembly area.

[0059] In some aspects, the robotic arm 60 can stack a first layer of yarn packages on a tray 44, place a separator 46 on the first layer of yarn packages 22, and stack a second layer of yarn packages on the separator 46. In additional aspects, the robotic arm 60 can stack a second layer of yarn packages and a second separator 46 on the second layer of yarn packages. In additional aspects, the robotic arm 60 can stack a third layer of yarn packages and a third separator 46 on the second layer of yarn packages. In additional aspects, the robotic arm 60 can stack a fourth layer of yarn packages and a fourth separator 46 on the second layer of yarn packages.

[0060] In some aspects, the robotic arm can move the support structure 42 from a storage rack 80 to at least one box assembly area 50. In some aspects, the robotic arm 60 can move the support structure 42 from a padding supply area 40 to the storage rack 80.

[0061] In some aspects, each step of the method disclosed herein is performed within a locked area.

[0062] Computing Device

[0063] System 10 may include at least one computing device for controlling system operations. For example, one or more computing devices may control multiple operations, including: the movement of robotic arm 60 and the actuation of end effector 62; the operation of conveyor 52 and door 74; the coordination with winder 20 and at least one sampling knotter 30; the scheduling of AGV 90; the operation of the AGV. In some optional aspects, a single computing device controls multiple such operations. In some aspects, system 10 may include multiple computing devices that coordinate operations. For example, a first computing device (e.g., a controller) may control the movement of robotic arm 60, and a second computing device may coordinate the operation of the robotic arm to indicate to the first computing device where to position the robotic arm next and further maintain the inventory of support structures in padding supply area 40 and on storage rack 80. Yet another computing device may schedule AGV 90. AGV 90 may further include a corresponding computing device that controls the operation of overall components (e.g., the wheels driving the AGV and the motor of conveyor 92). Yet another computing device may provide an interface for an operator at human-machine interface 110, thereby allowing the operator to control aspects of the system. Each of the computing devices may optionally be embodied according to computing device 1001 further disclosed herein.

[0064] Further, at least one computing device (e.g., the same computing device 1001 or another computing device described according to the computing device description disclosed herein) may be used to control the operation of sampling knotter 30. For example, one or more computing devices may control multiple operations, including: the rotation of first actuator 330; the control of vacuum device 356; and the movement of first clamp 358, end effector 363 of robotic arm 361, robotic arm 361, yarn cutter 354, and second actuator. In some optional aspects, a single computing device controls multiple such operations. In some aspects, sampling knotter 30 may include multiple computing devices that coordinate operations. For example, a first computing device (e.g., a controller) may control the movement of robotic arm 361, and a second computing device may coordinate the operation of the robotic arm to indicate to the first computing device where to position robotic arm 361 next. Yet another computing device may provide an interface for an operator at the human-machine interface, thereby allowing the operator to control aspects of the system. Each of the computing devices may optionally be embodied according to computing device 1001 further disclosed herein.

[0065] Figure 4 An exemplary operating system 1000 is shown, which includes an exemplary configuration of computing device 1001 for use with system 10 ( Figure 1 ) and sampling knotter 30 ( Figure 1 and 12 ).

[0066] The computing device 1001 may include one or more processors 1003, a system memory 1012, and a bus 1013 that couples the various components of the computing device 1001, including the one or more processors 1003, to the system memory 1012. In the case of multiple processors 1003, the computing device 1001 may utilize parallel computing.

[0067] The bus 1013 may include one or more of several possible types of bus structures, such as a memory bus, a memory controller, a peripheral bus, an accelerated graphics port, and a processor or local bus using any one of a variety of bus architectures.

[0068] The computing device 1001 may operate on and / or include various computer-readable media (e.g., non-transitory). The computer-readable media may be any available media accessible by the computing device 1001 and includes non-transitory, volatile, and / or non-volatile media, removable and non-removable media. The system memory 1012 has computer-readable media in the form of volatile memory, such as random access memory (RAM) and / or non-volatile memory, such as read-only memory (ROM). The system memory 1012 may store data such as positioning data 1007 and / or program modules such as an operating system 1005 and robot control software 1006, which may be accessible by and / or operated on by one or more processors 1003.

[0069] The computing device 1001 may also include other removable / non-removable, volatile / non-volatile computer storage media. A mass storage device 1004 may provide non-volatile storage of computer code, computer-readable instructions, data structures, program modules, and other data for the computing device 1001. The mass storage device 1004 may be a hard disk, a removable magnetic disk, a removable optical disk, a magnetic tape cartridge, or other magnetic storage device, a flash memory card, a CD-ROM, a digital versatile disk (DVD), or other optical storage device, random access memory (RAM), read-only memory (ROM), electrically erasable programmable read-only memory (EEPROM), etc.

[0070] Any number of program modules may be stored on the mass storage device 1004. The operating system 1005 and robot control software 1006 may be stored on the mass storage device 1004. One or more of the operating system 1005 and robot control software 1006 (or some combination thereof) may include program modules and robot control software 1006. The positioning data 1007 may also be stored on the mass storage device 1004. The positioning data 1007 may be stored in any one of one or more databases known in the art. The databases may be centralized or distributed at multiple locations within the network 1015.

[0071] A user may use an input device to input commands and information into the computing device 1001. Such input devices include, but are not limited to, joysticks, touch screen displays, keyboards, pointing devices (e.g., computer mice, remote controls), microphones, scanners, tactile input devices such as gloves and other body coverings, motion sensors, speech recognition, etc. These and other input devices may be connected to one or more processors 1003 using a human-machine interface 1002 coupled to the bus 1013, but may also be connected through other interfaces and bus structures, such as parallel ports, game ports, IEEE 1394 ports (also known as FireWire ports), serial ports, network adapter 1008, and / or Universal Serial Bus (USB).

[0072] The display device 1011 may also be connected to the bus 1013 using an interface such as a display adapter 1009. It is contemplated that the computing device 1001 may have more than one display adapter 1009, and the computing device 1001 may have more than one display device 1011. The display device 1011 may be a monitor, LCD (Liquid Crystal Display), light-emitting diode (LED) display, television, smart lens, smart glass, and / or projector. In addition to the display device 1011, other output peripheral devices may include components that may be connected to the computing device 1001 using an input / output interface 1010, such as speakers (not shown) and printers (not shown). Any step and / or result of the method may be output (or caused to be output) to an output device in any form. Such output may be any form of visual representation, including but not limited to text, graphics, animation, audio, tactile, etc. The display device 1011 and the computing device 1001 may be part of a certain device or separate devices.

[0073] The computing device 1001 can operate in a networked environment using logical connections to one or more remote computing devices 1014a, b, c. The remote computing devices 1014a, b, c can be personal computers, computing stations (e.g., workstations), portable computers (e.g., laptops, mobile phones, tablet devices), smart devices (e.g., smartphones, smartwatches, activity trackers, smart clothing, smart accessories), security and / or monitoring devices, servers, routers, network computers, peer devices, edge devices, or other common network nodes, etc. The remote computing devices 1014a, b, c can perform corresponding operations of the system. For example, one remote computing device 1014a can be a controller of an AGV. One remote computing device 1014b can control a winding machine. The logical connections between the computing device 1001 and the remote computing devices 1014a, b, c can be made using a network 1015 such as a local area network (LAN) and / or a general wide area network (WAN) or a cloud-based network. Such network connections can be made through a network adapter 1008. The network adapter 1008 can be implemented in both wired and wireless environments. Such networked environments are traditional and common in homes, offices, enterprise-wide computer networks, intranets, and the Internet. It is contemplated that the remote computing devices 1014a, b, c can optionally have some or all of the components disclosed as part of the computing device 1001. In various additional aspects, it is contemplated that some or all aspects of the data processing described herein can be performed on one or more servers or other remote computing devices via cloud computing. Accordingly, at least a portion of the system 1000 can be configured with an Internet connection.

[0074] Exemplary Sampling Knotter

[0075] Reference is made herein Figures 9 - 10 An exemplary sampling knotter 30 is disclosed that is configured to sample and knot a yarn 23 having a free end 25 of a yarn package 22. The free end 25 can be defined as the unfixed end of the wound yarn 23 of the yarn package. The sampling knotter 30 allows for the automatic sampling of the yarn 23 from the yarn package 22 and then knotting the free end 25 of the yarn 23 around the yarn package 22. For example, the sampling knotter 30 can rotate a spindle in a first direction and an opposite second direction, the spindle being configured to receive the yarn package 22. The yarn sampling assembly 350 of the system can be configured to receive and remove a portion of the free end 25 of the yarn 23 for sampling. After removing the portion, the yarn knotting assembly 360 can be configured to knot the yarn 23 around the yarn package 22, thereby inhibiting unwinding of the yarn 23 of the yarn package 22.

[0076] Reference is made to Figure 11, the sampling knotter 30 can receive the yarn package 22. In some aspects, the sampling knotter 30 can include a spindle (not shown) configured to receive the yarn package 22. In one aspect, an operator loads the yarn package 22 onto the spindle by inserting the spindle through the center of the yarn package 22. In one aspect, the spindle can consist of at least one clamp configured to expand within the loaded yarn package 22 to hold the yarn package 22 in place.

[0077] As Figure 12 shown, the sampling knotter 30 can include a first actuator 330 configured to rotate the yarn package 22 by rotating the spindle. The first actuator 330 can be configured to rotate the spindle in a first direction indicated by arrow 332 in Figure 12 and thus rotate the yarn package 22. Further, the first actuator 330 can be configured to rotate the spindle in a second direction opposite to the first direction indicated by arrow 34 in Figure 10 and thus rotate the yarn package 22. In one aspect, the first actuator 330 can rotate in the first direction to unwind the free end 25 of the yarn 23 from the yarn package 22.

[0078] The sampling knotter 30 can further include a yarn sampling assembly 350 configured to receive the free end 25 unwound from the loaded yarn package 22. For illustrative purposes, an exemplary free end 25 is represented by Figure 12 arrow 326 in. In one aspect, the sampling knotter 30 includes a guiding device 340 configured to guide the unwound free end 25 to the yarn sampling assembly 350. In one aspect, the guiding device 340 includes a base surface 342 and at least a pair of walls 344. The walls 344 can converge towards an opening 346 between the walls 344. The opening 346 can be close to the yarn sampling assembly 350. Thus, when the free end 25 is unwound, the free end 25 can slide along the base surface 342. The converging walls 344 guide the free end 25 towards the opening 346 to the yarn sampling assembly 350.

[0079] In one aspect, the sampling knotter 30 can include a sensor (not shown) configured to detect when the free end 25 of the yarn 23 is positioned at the yarn sampling assembly 350. For example, the sensor can be located at the opening 346 of the guiding device 340 to indicate when the free end 25 arrives at and / or extends through the opening 346. Alternatively, the sensor can face Figure 13Position one end of the yarn sampling assembly 350 indicated by arrow 352 therein. The sensor can be located at any position capable of detecting the length of the yarn sample. The first actuator 330 can continue to unwind the free end 25 of the yarn 23 from the yarn package 22 until the sensor senses the free end 25. When the sensor senses the free end 25 of the yarn 23, the first actuator 330 can stop rotating and thus stop unwinding the free end 25 of the yarn 23. In another aspect, when the free end 25 of the yarn 23 is positioned at the yarn sampling assembly 350, the sensor can emit a signal. The signal can be provided to a computing device, as further disclosed herein.

[0080] Reference Figure 14 , the yarn sampling assembly 350 can include a yarn cutter 354. The yarn cutter 354 can be configured to cut a portion of the free end 25 of the yarn 23 for sampling. The yarn sampling assembly 350 can further include a vacuum device 356 configured to suck the free end 25 of the yarn 23 through the yarn cutter 354. In one aspect, the vacuum device 356 can use air to guide the free end 25 through the yarn sampling assembly 350. The vacuum device 356 can be controlled by the sensor. For example, the sensor can sense the free end 25 of the yarn 23 and emit a signal to turn on the vacuum device until the sample is cut. The signal can be provided to a computing device, as further disclosed herein. In one aspect, the vacuum device 356 can be a Venturi vacuum. The yarn sampling assembly 350 can further include a first clamp 358 configured to hold a portion of the free end 25 of the yarn 23 when the yarn cutter 354 cuts the yarn 23. In one aspect, the yarn sampling assembly 350 can include a second clamp 359. Each clamp 358, 359 can include two opposing surfaces configured to be spaced apart when the clamps 358, 359 are open, as Figure 14 shown, thereby allowing a portion of the free end 25 of the yarn 23 to extend between the two opposing surfaces of each clamp 358, 359. As Figure 15 shown, the first clamp 358 and the second clamp 359 can be configured to close by moving the opposing surfaces of each clamp 358, 359 together so that the opposing surfaces meet. When the clamps 358, 359 are closed, the clamps 358, 359 can clamp and fix the free end 25 of the yarn 23 between the opposing surfaces.

[0081] Reference Figure 15, when the first clamp 358 or both the first clamp 358 and the second clamp 359 are closed and a portion of the free end 25 of the yarn 23 is fixed, the yarn cutter 354 can be advanced forward so that the yarn cutter 354 can cut a portion of the free end 25 of the yarn 23. After the portion of the free end 25 of the yarn 23 is cut, the cut portion can be collected in a collection box for sampling. In one aspect, the collection box can be close to the yarn sampling assembly 350 to allow the cut yarn portion to fall into the collection box. In one aspect, the yarn sampling assembly 350 can be configured to cut a yarn sample having a length of from about 3 inches to about 32 inches. In one example, the yarn sampling assembly 350 can cut a yarn sample having a length of about 16 inches.

[0082] Reference Figures 8 - 10 , the sampling and knotting machine 30 further includes a yarn knotting assembly 360. The yarn knotting assembly 360 can be configured to tie a new or remaining free end 25 of the yarn 23 around the yarn package 22 to prevent the yarn 23 from unwinding from the yarn package 22. The yarn knotting assembly 360 can include a multi-axis robotic arm 361. The multi-axis robotic arm 361 can include an end effector 363 configured to grip the remaining portion of the free end 25 of the yarn 23 wound on the yarn package 22. In one aspect, the end effector 363 can be the first clamp 358 of the yarn sampling assembly 350, where the remaining portion of the free end 25 of the yarn 23 is still gripped by the first clamp 358. After the yarn sample is cut, the first clamp 358 that grips the remaining free end 25 of the yarn 23 can be used to tie the remaining free end 25 of the yarn 23 around the yarn package 22.

[0083] The yarn knotting assembly 360 can further include a first surface 362 and a second surface 364. The first surface 362 and the second surface 364 can be spaced apart along a first axis 370. In one aspect, the first surface 362 and the second surface 364 can include a first rod 367 and a second rod 369. Further, the first rod 367 and the second rod 369 can extend along a second axis 372 that is substantially perpendicular to the first axis 370. The first surface 362 and the second surface 364 can be configured to engage the yarn 23 of the yarn package 22. For example, the end effector 363 controlled and moved by the multi-axis robotic arm 361 can surround the first surface 362 and the second surface 364 to loop the remaining free end 325 of the yarn 323 around the first surface 362 and the second surface 364. The path of the end effector 363 and thus the remaining free end 25 of the yarn 23 is indicated by the arrows 365 in Figure 16 and Figure 17 . The looped yarn 23 around the first surface 362 and the second surface 364 creates a through opening 376.

[0084] The yarn knotting assembly 360 may further include a knotting fixture 366. The knotting fixture 366 may be positioned between the first surface 362 and the second surface 364 along a first axis 370. The knotting fixture 366 may be configured to receive the remaining free end 25 of the yarn 23. For example, an end effector 363 controlled and moved by a multi-axis robotic arm 361 may surround the first surface 362 and the second surface 364, wind the yarn package 22, and feed the remaining free end 25 of the yarn 23 through the knotting fixture 366, as shown by the arrows 365 in Figure 16 and Figure 17 . The knotting fixture 366 may include opposing clamping surfaces 374 that may be configured to move towards and away from each other. When the opposing clamping surfaces 374 are moved apart or spaced from each other, the remaining free end 25 of the yarn 23 may pass between the opposing clamping surfaces 374. Then, the opposing clamping surfaces 374 may move towards each other to clamp or grip the remaining free end 25 of the yarn 23. In one aspect, the opposing clamping surfaces 374 may include a protruding edge 377 and a recessed edge 378 complementary to the protruding edge 377. Further, the protruding edge 377 and the recessed edge 378 may have corresponding and complementary wedge shapes. When the knotting fixture 366 is closed, the wedge shapes come together and the protruding edge 377 and the recessed edge 378 may overlap each other along the first axis 370. Further, the protruding edge 377 may include a protrusion, and the recessed edge 378 may include a groove configured to receive the protrusion when the knotting fixture 366 is closed. These exemplary configurations of the opposing clamping surfaces 374 ensure that the remaining free end 25 of the yarn 23 is fixed by the closed knotting fixture 366.

[0085] The yarn knotting assembly 360 may include a second actuator. The second actuator may be configured to move the yarn 23 engaged on the first surface 362 and the second surface 364 relative to the yarn 23 in the knotting fixture 366 along a second axis 372. In one aspect, the second actuator may include a pusher 381 configured to push the yarn 23 away from the first rod 367 and the second rod 369. Further, the pusher 381 may push the yarn 23 away from the first rod 367 and the second rod 369 by pushing a plate 379 configured to engage the yarn 23. When the yarn 23 is pushed away from the first surface 362 and the second surface 364, the yarn 23 looped around the first surface 362 and the second surface 364 is pushed through the knotting fixture 366 that secures the remaining free end 25 of the yarn 23, and the remaining free end 25 of the yarn 23 is pushed through the through-opening 376 created by the looped yarn 23, thereby creating a overhand knot in the yarn 23. In one aspect, after the yarn 23 is pushed away from the first surface 362 and the second surface 364, the first actuator 330 may move along Figure 18Rotate the spindle in the second direction indicated by arrow 34 therein, and thus rotate the yarn package 22, while the remaining free end 25 of the yarn 23 is still clamped by the knotting fixture 366. When the yarn package 22 rotates in the second direction, the overhand knot generated by the yarn knotting assembly 360 is tightened. After the knot is tightened, the knotting fixture 366 can be opened to release the remaining free end 25 of the yarn 23, and the yarn package 22 can be removed from the sampling knotting machine 30, and the free end 25 of the yarn 23 can be fixed.

[0086] Method of Using an Exemplary Sampling Knotter

[0087] The method can include receiving a yarn package 22 including a yarn 23 on a spindle. The yarn 23 can have a free end 25. A first actuator 30 coupled to the spindle can rotate the yarn package 22 to deliver the free end 25 to the yarn sampling assembly 350. The yarn sampling assembly 350 can remove a portion of the yarn 23 including the free end 25 to provide a yarn sample and form a new or remaining free end 25 of the remaining yarn 23 on the spindle.

[0088] In some aspects, the yarn sampling assembly 350 can remove a portion of the yarn 23 including the free end 25 to provide a yarn sample and form a new or remaining free end 25. Further, a portion of the yarn 23 can be removed by sucking the portion of the yarn 23 including the free end 25 through the yarn cutter 354 by a vacuum device 356; clamping the yarn 23 at a first position with a first clamp 358; clamping the free end 25 of the yarn 23 at a second position with an end effector 363 of a multi-axis robotic arm 361; and cutting the yarn 23 with the yarn cutter 354.

[0089] In some aspects, the multi-axis robotic arm 361 can move the yarn 23 to form loops around a first surface 362 and a second surface 364 separated along a first axis 370. The multi-axis robotic arm 361 can wind the yarn 23 around the yarn package 22. The multi-axis robotic arm 361 can position the yarn 23 in the knotting fixture 366, which is positioned between the first surface 362 and the second surface 364 along the first axis 370. The yarn 23 on the first surface 362 and the second surface 364 can move relative to the yarn 23 in the knotting fixture 366 along a second axis 372 that is substantially perpendicular to the first axis 370 to form a knot. The first actuator 30 can rotate the spindle to tighten the knot.

[0090] Exemplary Aspects

[0091] In view of the described products, systems, and methods and their variations, certain more specifically described aspects of the present invention are described below. However, these specifically elaborated aspects should not be construed as having any limiting effect on any different claims containing the different or more general teachings described herein, or that the "specific" aspects are limited in some way other than the inherent meaning of the language literally used therein.

[0092] Aspect 1A: A system comprising:

[0093] At least one winder configured to wind yarn to form a yarn package;

[0094] At least one sampling knotter configured to remove a portion of the yarn from the yarn package and tie the free end of the yarn around the yarn package to prevent unwinding of the yarn package;

[0095] A padding supply area having at least one support structure thereon for receiving a plurality of yarn packages;

[0096] At least one box assembly area; and

[0097] A robotic arm configured to:

[0098] Move the yarn package from the at least one winder to the at least one sampling knotter;

[0099] Move the yarn package from the at least one sampling knotter to the at least one box assembly area; and

[0100] Stack the yarn packages on the support structure in the at least one box assembly area.

[0101] Aspect 2A: The system according to Aspect 1A, wherein each of the at least one winder, the at least one sampling knotter, the padding supply area, the at least one box assembly area, and the robotic arm is within a locked area.

[0102] Aspect 3A: The system according to Aspect 2A, further comprising a barrier surrounding the locked area.

[0103] Aspect 4A: The system according to any of the preceding aspects, wherein the at least one support structure of the padding supply area comprises at least one tray, at least one partition, or a combination thereof.

[0104] Aspect 5A: The system according to any one of the preceding aspects, wherein the robotic arm is further configured to move a support structure in the at least one support structure in the padding supply area to the at least one box assembly area.

[0105] Aspect 6A: The system according to any one of the preceding aspects, wherein the at least one winder is a winder of a heat setting device.

[0106] Aspect 7A: The system according to any one of the preceding aspects, further comprising at least one automated guided vehicle (AGV), the at least one automated guided vehicle being configured to deliver the at least one support structure to the padding supply area.

[0107] Aspect 8A: The system according to aspect 7A, wherein the at least one AGV is further configured to transport boxes from the at least one box assembly area, wherein the boxes comprise at least one support structure and a plurality of yarn packages on the support structure.

[0108] Aspect 9A: The system according to any one of the preceding aspects, wherein the robotic arm is configured to form a box, the box comprising at least one tray, a plurality of packages stacked on the tray, at least one partition stacked on the plurality of packages stacked on the tray, and a plurality of packages stacked on the partition.

[0109] Aspect 10A: The system according to aspect 9A, wherein the box comprises four layers of yarn packages and three partitions, and each of the three partitions is positioned between the layers of yarn packages.

[0110] Aspect 11A: The system according to any one of the preceding aspects, further comprising a storage rack configured to store at least one support structure from the padding supply area.

[0111] Aspect 12A: The system according to any one of the preceding aspects, wherein the at least one winder comprises two winders.

[0112] Aspect 13A: The system according to any one of the preceding aspects, wherein the at least one sampling knotter comprises two sampling knotters.

[0113] Aspect 14A: The system according to any one of the preceding aspects, further comprising a first conveyor configured to transport boxes from the at least one box assembly area.

[0114] Aspect 15A: The system according to aspect 14, further comprising a second conveyor configured to receive the boxes from the first conveyor.

[0115] Aspect 16A: The system according to any one of the foregoing aspects further includes a vertical wrapper configured to move a roll of packaging material around the periphery of a box, the box including at least one support structure and a plurality of yarn packages on the support structure.

[0116] Aspect 17A: The system according to any one of the foregoing aspects further includes a horizontal wrapper configured to rotate the box to apply packaging material to the periphery of the box, the box including at least one support structure and a plurality of yarn packages on the support structure.

[0117] Aspect 18A: A method of using the system according to any one of the foregoing aspects, the method including:

[0118] Winding yarn with the winder to form a yarn package;

[0119] Moving the yarn package from the winder to the at least one sampling knotter with the robotic arm;

[0120] Moving the yarn package from the at least one sampling knotter to a first box assembly area in the at least one box assembly area with the robotic arm; and

[0121] Stacking the yarn packages on a support structure in the first box assembly area with the robotic arm.

[0122] Aspect 19A: The method according to aspect 18A, wherein stacking the yarn packages on the support structure in the at least one box assembly area with the robotic arm includes:

[0123] Stacking a first layer of yarn packages on a tray;

[0124] Placing a separator on the first layer of yarn packages; and

[0125] Stacking a second layer of yarn packages on the separator.

[0126] Aspect 20A: The method according to aspect 19A, wherein the tray and the separator each include cardboard.

[0127] Aspect 21A: A method including:

[0128] Winding yarn with a winder to form a yarn package;

[0129] Moving the yarn package from the winder to at least one sampling knotter with a robotic arm;

[0130] Moving the yarn package from the at least one sampling knotter to the box assembly area using the robotic arm; and

[0131] Stacking the yarn package on a support structure in the box assembly area using the robotic arm.

[0132] Aspect 22A: The method according to aspect 21A, wherein stacking the yarn package on the support structure in the box assembly area using the robotic arm comprises:

[0133] Stacking a first layer of yarn packages on a tray;

[0134] Placing a separator on the first layer of yarn packages; and

[0135] Stacking a second layer of yarn packages on the separator.

[0136] Aspect 23A: The method according to aspect 21A or aspect 22A, further comprising moving the support structure from a storage rack to the box assembly area using the robotic arm.

[0137] Aspect 24A: The method according to aspect 23A, further comprising moving the support structure from a padding supply area to the storage rack using the robotic arm.

[0138] Aspect 25A: The method according to aspect 21A, wherein the method is performed in a locked area.

[0139] Aspect 1B: A system for sampling and knotting yarn having a free end on a package, the system comprising:

[0140] A yarn spindle;

[0141] A first actuator configured to rotate the yarn spindle in a first direction and an opposite second direction;

[0142] A yarn sampling assembly configured to receive a portion of the yarn including the free end; and

[0143] A yarn knotting assembly configured to knot the yarn on the package to prevent the yarn from unwinding from the package.

[0144] Aspect 2B: The system according to aspect 1B, wherein the yarn sampling assembly comprises:

[0145] A yarn cutter;

[0146] A vacuum device configured to suck a portion of the yarn including the free end through the yarn cutter; and

[0147] A first clamp configured to hold the portion of the yarn including the free end when the yarn cutter cuts the yarn.

[0148] Aspect 3B: The system according to aspect 2B, wherein the yarn sampling assembly further comprises a sensor configured to detect the yarn positioned at the yarn sampling assembly.

[0149] Aspect 4B: The system according to any one of aspects 1B - 3B, further comprising a guiding device configured to guide the free end of the package to the yarn sampling assembly.

[0150] Aspect 5B: The system according to aspect 4B, wherein the guiding device comprises:

[0151] A base surface; and

[0152] A pair of walls on opposite sides of the base surface, wherein the walls converge towards an opening therebetween, and wherein the opening is positioned near the yarn sampling assembly.

[0153] Aspect 6B: The system according to any one of aspects 1B - 5B, wherein the yarn knotting assembly comprises:

[0154] A multi - axis robotic arm comprising an end - effector tool configured to pick up the yarn in the yarn package;

[0155] A first surface and a second surface spaced apart along a first axis and each configured to engage the yarn in the yarn package;

[0156] A knotting clamp positioned along the first axis between the first surface and the second surface and configured to receive the yarn in the yarn package, wherein the knotting clamp comprises opposing gripping surfaces configured to move towards and away from each other; and

[0157] A second actuator configured to move the yarn on the first surface and the second surface relative to the yarn in the knotting clamp along a second axis perpendicular to the first axis.

[0158] Aspect 7B: The system according to aspect 6B, wherein the first surface and the second surface spaced apart along the first axis comprise a first rod and a second rod extending along the second axis, and wherein the second actuator comprises a pusher configured to push the yarn away from the first rod and the second rod.

[0159] Aspect 8B: The system according to Aspect 6B or Aspect 7B, wherein the opposing gripping surfaces of the knotting fixture comprise a protruding edge and an opposing recessed edge complementary to the protruding edge.

[0160] Aspect 9B: The system according to Aspect 8B, wherein the protruding edge and the recessed edge have corresponding wedge shapes complementary to each other, and wherein in the closed configuration, the protruding edge and the recessed edge overlap each other along the first axis.

[0161] Aspect 10B: The system according to Aspect 9B, wherein the protruding edge and the recessed edge each have corresponding ends spaced apart along the second axis, wherein at least one of the ends of the protruding edge defines a protrusion, and wherein at least one of the ends of the recessed edge defines a groove configured to receive the protrusion of the corresponding end of the protruding edge in the closed configuration.

[0162] Aspect 11B: The system according to any one of Aspects 6B - 10B, wherein the yarn sampling assembly comprises:

[0163] A yarn cutter;

[0164] A vacuum device configured to suck a portion of the yarn including the free end thereof through the yarn cutter; and

[0165] A first fixture configured to hold the portion of the yarn including the free end thereof when the yarn cutter cuts the yarn,

[0166] wherein the system further comprises a controller, wherein the controller is configured to:

[0167] Rotate the yarn spindle in the first direction by the first actuator to release the yarn from the package,

[0168] Cause the vacuum device of the yarn sampling assembly to suck a portion of the yarn including the free end thereof through the yarn cutter,

[0169] Cause the first fixture of the yarn sampling assembly to grip the yarn in a first position,

[0170] Cause the end - effector of the robotic arm of the yarn knotting assembly to grip the yarn in a second position, and

[0171] Cause the yarn cutter of the yarn sampling assembly to cut the yarn.

[0172] Aspect 12B: The system according to Aspect 11B, wherein the controller is further configured to:

[0173] Move the robotic arm of the yarn knotting assembly to move the yarn to form loops around the first surface and the second surface, wind the yarn package, and then position the yarn in the knotting fixture;

[0174] Move the first surface and the second surface of the yarn on the second axis relative to the yarn in the knotting fixture by the second actuator of the yarn knotting assembly to form a knot; and

[0175] Rotate the yarn spindle by the first actuator to tighten the knot.

[0176] Aspect 13B: The system according to any one of Aspects 1B - 12B, wherein the yarn sampling assembly is configured to cut a yarn sample having a length of about 3 inches to about 32 inches.

[0177] Aspect 14B: A method comprising:

[0178] Receiving a package containing yarn on a yarn spindle, the yarn having a free end;

[0179] Rotating the package by a first actuator coupled to the yarn spindle to deliver the free end to the sampling assembly; and

[0180] Removing a portion of the yarn including the free end with the sampling assembly to provide a yarn sample and forming a new free end of the remaining yarn on the yarn spindle.

[0181] Aspect 15B: The method according to Aspect 14B, wherein removing a portion of the yarn including the free end with the sampling assembly to provide the yarn sample and forming the new free end comprises:

[0182] Suctioning a portion of the yarn including the free end through a yarn cutter with a vacuum device;

[0183] Clamping the yarn at a first position with a first clamp;

[0184] Clamping the free end of the yarn at a second position with an end - effector of a multi - axis robotic arm; and

[0185] Cutting the yarn with the yarn cutter.

[0186] Aspect 16B: The method according to Aspect 15B, further comprising:

[0187] Moving the yarn with the robotic arm to form loops around a first surface and a second surface, the first surface and the second surface being spaced apart along a first axis;

[0188] Wind the yarn around the yarn package using the robotic arm;

[0189] Position the yarn in a knotting fixture using the robotic arm, the knotting fixture being positioned between the first surface and the second surface along the first axis;

[0190] Move the yarn on the first surface and the second surface relative to the yarn in the knotting fixture along a second axis perpendicular to the first axis to form a knot; and

[0191] Rotate the yarn spindle with the first actuator to tighten the knot.

[0192] Aspect 1C: The system according to any one of Aspects 1A - 17A, wherein the sampling knotting machine comprises at least a part of or is defined by the system according to any one of Aspects 1B - 13B.

[0193] Aspect 1D: The system according to any one of Aspects 1A - 17A, wherein the sampling knotting machine comprises:

[0194] A yarn spindle;

[0195] A first actuator configured to rotate the yarn spindle in a first direction and an opposite second direction;

[0196] A yarn sampling assembly configured to receive a portion of the yarn including a free end; and

[0197] A yarn knotting assembly configured to tie a knot in the yarn on the yarn package to prevent the yarn from unwinding from the yarn package.

[0198] Although the foregoing invention has been described in detail by way of illustration and example for the purpose of clear understanding, certain changes and modifications may be made within the scope of the appended claims.

Claims

1. A system comprising: At least one winder configured to wind yarn to form a yarn package; At least one sampling knotter configured to remove a portion of the yarn from the yarn package and tie the free end of the yarn around the yarn package to prevent unwinding of the yarn package; A padding supply area having at least one support structure thereon for receiving a plurality of yarn packages; At least one box assembly area; And A robotic arm configured to: Move the yarn package from the at least one winder to the at least one sampling knotter; Move the yarn package from the at least one sampling knotter to the at least one box assembly area; and And Stack the yarn packages on the support structure in the at least one box assembly area.

2. The system according to claim 1, wherein each of the at least one winder, the at least one sampling knotter, the padding supply area, the at least one box assembly area, and the robotic arm is within a locked area.

3. The system according to claim 2, further comprising a barrier surrounding the locked area.

4. The system according to claim 1, wherein the at least one support structure in the padding supply area comprises at least one tray, at least one partition, or a combination thereof.

5. The system according to claim 1, wherein the robotic arm is further configured to move the support structure in the at least one support structure in the padding supply area to the at least one box assembly area.

6. The system according to claim 1, wherein the at least one winder is a winder of a heat setting device.

7. The system according to claim 1, further comprising at least one automated guided vehicle (AGV) configured to deliver the at least one support structure to the padding supply area.

8. The system according to claim 7, wherein the at least one AGV is further configured to transport boxes from the at least one box assembly area, wherein the boxes comprise at least one support structure and a plurality of yarn packages on the support structure.

9. The system according to claim 1, wherein the robotic arm is configured to form a box comprising at least one tray, a plurality of packages stacked on the tray, at least one partition stacked on the plurality of packages stacked on the tray, and a plurality of packages stacked on the partition.

10. The system according to claim 9, wherein the box comprises four layers of yarn packages and three partitions, wherein each of the three partitions is positioned between the layers of yarn packages.

11. The system according to claim 1, further comprising a storage rack configured to store at least one support structure from the padding supply area.

12. The system according to claim 1, wherein the at least one winder comprises two winders.

13. The system according to claim 1, wherein the at least one sampling and knotting machine comprises two sampling and knotting machines.

14. The system according to claim 1, further comprising a first conveyor configured to transport the boxes from the at least one box assembly area.

15. The system according to claim 14, further comprising a second conveyor configured to receive the boxes from the first conveyor.

16. The system according to claim 1, further comprising a vertical wrapper configured to move a roll of packaging material around the periphery of a box, the box comprising at least one support structure and a plurality of yarn packages on the support structure.

17. The system according to claim 1, further comprising a horizontal wrapper configured to rotate the box to apply packaging material to the periphery of the box, the box comprising at least one support structure and a plurality of yarn packages on the support structure.

18. A method of using the system according to any one of the preceding claims, the method comprising: winding yarn with the winder to form yarn packages; moving the yarn packages from the winder to the at least one sampling and knotting machine with the robotic arm; moving the yarn packages from the at least one sampling and knotting machine to a first box assembly area in the at least one box assembly area with the robotic arm; and stacking the yarn packages on a support structure in the first box assembly area with the robotic arm.

19. The method according to claim 18, wherein stacking the yarn packages on the support structure in the at least one box assembly area with the robotic arm comprises: stacking a first layer of yarn packages on a tray; placing a separator on the first layer of yarn packages; and stacking a second layer of yarn packages on the separator.

20. The method according to claim 19, wherein the tray and the separator each comprise cardboard.

21. A method comprising: winding yarn with a winder to form yarn packages; moving the yarn packages from the winder to at least one sampling and knotting machine with a robotic arm; moving the yarn packages from the at least one sampling and knotting machine to a box assembly area with the robotic arm; and stacking the yarn packages on a support structure in the box assembly area with the robotic arm.

22. The method according to claim 21, wherein stacking the yarn packages on the support structure in the box assembly area with the robotic arm comprises: stacking a first layer of yarn packages on a tray; placing a separator on the first layer of yarn packages; and stacking a second layer of yarn packages on the separator.

23. The method according to claim 21, further comprising moving the support structure from a storage rack to the box assembly area with the robotic arm.

24. The method according to claim 23, further comprising moving the support structure from a padding supply area to the storage rack with the robotic arm.

25. The method according to claim 21, wherein the method is performed in a locked area.

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