In-line twisting process and multidevice twisting machine for carrying out same

Abstract

The invention relates to an in-line twisting process and a multidevice twisting machine for carrying out same, based on imparting transient twist to each yarn (1) before it is woven, by means of twisting devices (4) situated between the creel or bobbin feeding the yarn (1) and the loom (200), knitting machine or weaving machine, such that the yarn (1) passes through the shaft of the needle (8) with sufficient twisting to gather the filaments. The yarn (1) is twisted in an S direction, Z direction or a combination of both directions and is controlled using a controller. The machine (100) comprises a frame (3) on which between 1 and 3000 twisting devices (4) are mounted, and a pneumatic, mechanical, hydraulic or electromechanical actuating system (5), configured to control the number of twists imparted by each twisting device (4).

Description

[0001] DESCRIPTION

[0002] IN-LINE TORSION PROCESS AND MULTI-DEVICE TORSION MACHINE TO CARRY IT OUT

[0003] OBJECT OF THE INVENTION

[0004] The invention, as stated in the present descriptive memorandum, relates to an online torsion process and a multi-device torsion machine for carrying it out, which provide advantages and features, which are described in detail below.

[0005] The object of the present invention lies, on the one hand, in an in-line twisting process for treating yarns before they are woven on looms or needle knitting machines, consisting of applying sufficient twist to group the filaments, achieving a compact and uniform shape, which increases the efficiency of the loom by preventing yarn breakage, a second aspect of the invention being a multi-device twisting machine for applying said in-line twisting process to treat the yarns before they are woven on looms or needle knitting machines, being specially designed to be coupled between the yarn bobbin creel or winder on warp, weft or other types of looms.

[0006] This machine is specially designed to house one or more twisting devices, where each device causes the thread or threads passing through it to be temporarily twisted a certain number of turns / meter on their journey to the needle or heddle of what can be a weft, warp or other type of loom, such as a tufting machine or carpet making machine.

[0007] By giving the yarn a twist, the regularity of the yarn is increased, avoiding many subsequent problems in the weaving process (loom, knitting machine, etc.), which cause breakage of yarns in the heddles or needles, in addition to the lack of quality in the final product, with said twist of the yarn increasing the efficiency and effectiveness of the loom.

[0008] FIELD OF APPLICATION OF THE INVENTION The field of application of the present invention is framed within the textile sector, focusing particularly on the field of the industry dedicated to the manufacture of yarns and twisting devices, encompassing at the same time the field of looms and knitting machines for the production of fabrics.

[0009] BACKGROUND OF THE INVENTION

[0010] Currently, the warp threads that feed looms and needle knitting machines present several limitations when it comes to passing each individual thread or group of threads through the eye of its respective needle or heddle. These threads or groups of threads may be twisted or untwisted depending on the desired effect of the final fabric. When passing through the respective needle, there is a high probability of breakage of the thread and / or the corresponding needle or heddle if the thread becomes entangled with the needle or heddle due to a defect in the thread, such as a loop, a curl, or overfeeding because the thread is not sufficiently compact or round.

[0011] This phenomenon causes the production efficiency of these machines to be very low due to the loom stops made by the operator and caused by this phenomenon, it is common to apply prior corrective measures to eliminate these problems as much as possible, focused on checking that the raw material that feeds these machines is manufactured with a prior twisting operation and in good regularity conditions, without knots, loops, etc.

[0012] The multi-device twisting machine of the present invention restructures the current fabric production process, since the twisting operation is added online, which has not yet been done at present.

[0013] This device is especially important for those machines and sectors that have to twist the yarn only so that it is compact and round during its passage through the needle or heddle, but where twisting is not necessary in the final application of the product to be obtained.

[0014] This could be the case with warp knitting machines, also called tufting machines or tufting machines, used for manufacturing carpets and artificial turf. In this sector, the yarn twisting section is simply to increase the loom's efficiency, but the final product does not require twisting, especially artificial turf.

[0015] It should be noted that the twisting sections of carpet and / or artificial turf factories are just as large as those of looms, involving personnel, machinery, electricity consumption and physical effort.

[0016] In the carpet industry, for example, BCF-type PP yarns (or textured continuous filament yarns made of polypropylene) are primarily used. Depending on the final product and its quality, these yarns are twisted using a double-twist (TFO) or 2x1 machine. Even in lower-quality products, other methods are used to group or compact the yarn, such as "tangle" systems. These systems use air or other means to fix the fiber bundle at regular intervals along the yarn. This groups the filaments and improves loom efficiency by reducing downtime and yarn breakage.

[0017] The objective of the present invention is to replace all these TFO and / or tangle processes, among others, with an in-line twisting process using a multi-device twisting machine

[0018] EXPLANATION OF THE INVENTION

[0019] The online torsion process and the multi-device torsion machine proposed by the invention represent an optimal solution to achieve the aforementioned objectives, with the characterizing details that make it possible and that distinguish them being conveniently included in the final claims accompanying this description.

[0020] Specifically, what the invention proposes, as previously mentioned, is an in-line twisting process for treating yarns before they are woven on looms or needle knitting machines. This process consists of applying sufficient twist to group the filaments before weaving, achieving a compact and uniform shape, which increases the efficiency of the loom or knitting machine by preventing yarn breakage. A second aspect of the invention is a multi-device twisting machine for applying this in-line twisting process to treat yarns before they are woven on looms or needle knitting machines. This machine is specially designed to be attached between the yarn bobbin creel or winder on warp, weft, or other types of looms.

[0021] For this purpose, and more specifically, the multi-device twisting machine basically consists of an orientable frame, which has fixing elements so that said frame is fixed to the loom or knitting machine, once it has been conveniently oriented, and in which a plurality of twisting devices are mounted, which are preferably of the type called "false" twist, that is, they do not apply a permanent twist to the threads, these devices being any of those already known in the market, and being incorporated in variable number based on the number of needles that the loom or knitting machine has.

[0022] Thus, in single-needle knitting machines, the machine will only have a single twisting device, and when incorporated into needle looms it can have up to 3000 twisting devices, being able to adjust to the number of positions that the loom has.

[0023] The machine will be arranged on the loom or knitting machine in such a way that the twisting devices can be placed at the appropriate distance and orientation with respect to the needles or heddles of the loom or knitting machine, so that the threads from the bobbins of the feeder creel or warper pass, prior to their arrival at the needle, through the devices and the twisting effect produced by said devices reaches the needles of the loom or knitting machine.

[0024] Furthermore, in the multi-device machine of the invention, each twisting device is equipped with a drive system, which can be pneumatic using solenoid valves, electromechanical using an electric motor and mechanical transmission, or other, depending on the type of twisting device incorporated in each case from those known on the market. In any case, these devices generate a twist on each of the threads that pass through the respective twisting device. A twisting device is a apparatus that essentially has a point where the thread enters the device and a point where the thread exits the device, as well as an intermediate zone between these two points in which the thread rotates about its own longitudinal axis in one direction or the other, depending on how it is actuated.The multi-device machine of the invention allows the installation of twisting devices of any type known in the art. In this machine, the number of turns per meter generated on the yarn, the direction of rotation of said yarn, and the duration of the generated rotational movement are the parameters whose values ​​are set before the warp-making operation begins. The combination of these parameter values ​​is controlled and directed by a central unit through a work program, and this combination of values ​​is specific to the gauge and type of yarn or yarns being processed.

[0025] The distance from a specific point within the area where the yarn rotation occurs—that is, where the twist is generated before the yarn enters the loom needle—to the respective needle of the loom or knitting machine can also be adjusted. The yarn direction can be oriented according to each different product being processed, so that the yarns have the necessary number of twists just before entering the needle to eliminate defects or loops and to ensure smooth passage through the needles. However, once this distance is set, the orientation generally doesn't need to be changed because it is already correct for the vast majority of yarns.

[0026] When a yarn is twisted using this device, a double twist effect occurs. This means that when the yarn is rotated clockwise, it develops an "S" twist before the device and a "Z" twist after passing through the device. If the twist is always applied in the same direction, it causes a buildup of twist on both sides of the device, before and after. This creates problems, especially in the portion of the yarn before the device, as there is no element to fix the twist, such as the loop cutter in tufting machines for artificial turf or carpet manufacturing, where the twist acquired by the twisting device is undone.

[0027] However, in warp tufting machines, it's beneficial to have the yarn twisted from the creel to the needle, which can be several meters long (from 2 to 20 meters depending on the machine), so maintaining this accumulation is important. These machines have very small individual tubes where the yarn is inserted to guide it.

[0028] Another aspect of the invention aims to solve the problem of twist buildup between the twisting device and the creel or heddle, by performing alternating changes in twist direction, varying over time, from constant speed to accelerated or decelerated speed, and even combining pause periods. In other words, the invention allows the twist imparted to the yarns to be in the "S" or "Z" direction, alternating or not, accelerated or not, and with or without pause intervals. Furthermore, the number of twists can be varied at any given time and programmed according to the needs to reduce twist buildup and achieve a round yarn as it passes through the needle or heddle.

[0029] This device can also be combined with a rotary creel system such that the bobbins on the creel rotate at a specific speed, imparting twist to the yarn in an "S" or "Z" direction. The bobbins can rotate, or a double-twist system can be used where the yarn passes through the inside of a bobbin shaft on a hollow shaft. At its starting point, this shaft has a vane that rotates at a specific speed, imparting twist to the yarn. The combination of these two systems, or either one individually, is also the subject of this invention.

[0030] Regarding the mechanisms for performing twisting with the twisting devices, it should be said that they can be any of those that exist on the market, such as clamp type, Y type, star type, etc., with any shape that forces the thread to be twisted.

[0031] For their part, the drive mechanisms can be any type: mechanical, pneumatic, electromechanical, electropneumatic, hydraulic, using belts (flat or toothed or other types).

[0032] It is also possible to attach a set of individual or collective cylinders to control and limit accumulated twist. These cylinders can restrict the extent to which the twist can escalate. For example, if we place a set of pressure cylinders pulling the creel yarn (coordinated with the speed of the loom's feed rollers) and this set of rollers is positioned in front of the loom, the twist will not accumulate in the creel because the cylinders prevent it from escalating further back. The cylinder assembly can be positioned anywhere between the creel bobbin and the loom.

[0033] In the machine of the invention, there may be several combined twisting devices, two or more on the same loom. This effect causes the twist between the two twisting devices to be zero, and there may also be several sets of cylinders on a loom, combined or not with the twisting devices.

[0034] In short, the invention relates to an in-line twisting process and a multi-device twisting machine for carrying out said process, which is designed to be coupled to warp or weft looms in order to improve the quality and efficiency of fabric production. The process is based on introducing temporary twist to the yarns as they pass through the twisting devices, thus preventing problems such as yarn breakage or defects in the final product. The main purpose of the machine is to impart temporary twist to the yarns between the creel and the loom, as they advance towards the needles or heddles of the loom. The process improves yarn uniformity, reduces breakage, and increases fabric quality, which is particularly useful in the production of carpets and artificial turf, where pre-twisting is not required in the final product but is necessary in the weaving process.The machine can accommodate up to 3,000 twisting devices, adjusted according to the number of needles on the loom. The twist can be in the "S" or "Z" direction, or a combination of both, depending on the product requirements. The twist is programmed and controlled by a central unit that adjusts parameters such as the number of twists per meter (from 2 to 2,000), the twist direction, and the speed. The invention allows for the integration of twisting devices in-line with the loom, eliminating or supplementing the need for prior processes such as the use of TFO (Twist-For-One) machines or tangle systems, commonly used in the textile industry to improve yarn compactness. This process and this multi-device machine not only increase loom efficiency by reducing downtime due to yarn breakage but also improve the quality of the final product by ensuring more compact and uniform yarns without defects.In short, this innovation restructures the online yarn twisting process between the creel and the loom, allowing its direct integration into the loom and improving both operational efficiency and the quality of the final product.

[0035] DESCRIPTION OF THE DRAWINGS

[0036] To complement the description being made and in order to help a better understanding of the characteristics of the invention, this descriptive document is accompanied, as an integral part thereof, by sheets of drawings in which the following has been represented for illustrative and non-limiting purposes:

[0037] Figure 1 shows a schematic perspective view of an example of the multi-device twisting machine of the invention mounted on a tufting needle loom, illustrating its arrangement and components. Figure 2 shows a side elevation view of the loom example with the multi-device twisting machine shown in Figure 1.

[0038] PREFERRED EMBODIMENT OF THE INVENTION

[0039] In view of the aforementioned figures, and in accordance with the numbering adopted, one can observe in them an example of a non-limiting embodiment of the multi-device torsion machine of the invention, which comprises what is described in detail below.

[0040] Thus, as can be seen in the figures, the multi-device twisting machine (100) of the invention, applicable for treating yarns (1) before being woven on looms (200), as shown in the figures, or needle knitting machines (8), essentially comprises:

[0041] - a frame (3) on which between 1 and 3000 torsion devices (4) are mounted, where each torsion device (4) comprises a torsion roller (4a) and a drive system (5) which may be pneumatic, mechanical, hydraulic or electromechanical; and

[0042] - wherein said twisting devices (4) are configured so as to apply twist to the yarn (1) in the “S” or “Z” direction or in a combination of both directions, with an amount of twists controlled by the drive system (5), such that the yarn (1) passes through the needle shaft (8) with sufficient twist to group the filaments, achieving a compact and uniform shape, which increases the efficiency of the loom by preventing yarn breakage.

[0043] In the preferred embodiment described, it should be understood as any one of the many that, in application of the present invention, can be put into practice, taking into account that the type of torsion device (4) or false torsion is not an essential part thereof and that any type of such device known in the art can be employed in any practical embodiment of the machine of invention.

[0044] The essential object of the invention being a process for generating twists in the yarn (1) or yarns, whether one or several and already twisted or not, coming from a creel (not shown) feeding the loom (200), at an intermediate point between said creel and the needle (8) of the loom (200) or knitting machine so that at the moment when said yarn (1) comes into contact with said needle (8) it has a certain number of twists per meter, thereby giving the yarn (1) greater regularity and roundness, thus avoiding problems of breakage due to the formation of defects, curls, loops or other causes derived from insufficient twisting.

[0045] The threads (1) from the feeder creel are guided to the frame (3) on which the twisting devices (4) or false twisting devices used are mounted, from among the various types known in the art, driven by its drive system (5).

[0046] In the embodiment shown in the figures, the torsion devices (4) are mechanical rollers all driven simultaneously by a belt (6) from an electric, mechanical, pneumatic, etc., motor of any type known to be suitable for implementing the invention. Likewise, it may or may not be necessary to use one or more direction-changing rollers (2) for the thread (1), depending on the distance and orientation chosen for each product.

[0047] The yarns (1) from the feed creel are directed towards the frame (3) that houses the multiple twisting devices (4). These twisting devices (4) are adjustable and can be selected from types known in the art. The twisting devices (4) are operated by a drive system (5) that can be pneumatic, mechanical, or electromechanical. In this embodiment, each twisting device (4) consists of a twisting roller (4a), driven simultaneously by a belt (6) connected to a motor, as the drive system (5), which can be electric or pneumatic. This drive system (5) allows for the controlled twisting of the yarns (1) as they pass through the twisting devices (4), ensuring uniform and precise twisting.

[0048] The drive system motor (5) is equipped with a conventional yarn control system for the degree and direction of false twist. A general program determines the yarn speed and rotation variables, including the movement sequence and the specific duty cycle for the type of yarn being processed.

[0049] It is important to emphasize that the essential characteristic of the multi-device twisting machine (100) is that it is mounted in line within the loom (200), knitting machine or main machine, that the operation of the twisting devices (4) is carried out as one more of the series of operations of said loom (200) or main machine, and that the operation of the twisting devices (4) does not in any way condition the speed of processing the yarn in the needle loom (200), needle knitting machine, etc., although it does increase the operating efficiency of said loom (200), knitting machine, etc.

[0050] In short, the in-line twisting process that is the subject of the invention, applicable to treating yarns (1) before being woven on a loom (200) or needle knitting machines or other weaving machines, is distinguished by essentially comprising the application of a provisional twist to each yarn (1) before being woven, by including a twisting device (4) located between the creel or feed bobbin of said yarn (1) and said machine, such that the yarn (1) passes through the needle shaft (8) with sufficient twist to group the filaments, achieving a compact and uniform shape of the same.

[0051] The torsion of the torsion device(s) (4) is applied to the wire (1) in one direction or the other, i.e., in the “S” or “Z” direction, or in a combination of both directions,

[0052] Furthermore, the process includes a central unit that controls the amount of twist applied by each twisting device (4). More specifically, this twist is preferably programmed and controlled by a central unit that adjusts parameters such as the number of twists per meter, from 2 to 2,000, applied to each yarn (1) by each twisting device (4), to adapt to the different types of yarn being processed.

[0053] In turn, preferably, the process contemplates that each twisting device (4) allows the independent or joint regulation of the twisting parameters, such as the degree of twist, the direction of rotation and the operating cycle, according to the characteristics of the yarn (1) to be processed.

[0054] Furthermore, according to the process of the invention, preferably, each twisting device (4) is arranged in an adjustable manner to allow variation in the arrangement and number of twisting devices (4) according to the characteristics of the loom (200) or knitting machine concerned in each case.

[0055] In a preferred embodiment of the process, the twisting device(s) (4) apply a false twist to the thread (1), so that it recovers its initial state.

[0056] In any case, preferably, the twisting devices (4) are configured so as to minimize the accumulation of twist before the thread (1) enters the needle (8), avoiding defects such as curls or knots in the thread.

[0057] Furthermore, the process optionally includes the use of more than one twisting device (4) inserted in series or in parallel on each thread (1) of the loom (200) or knitting machine.

[0058] And, also optionally, the process contemplates the possibility of combining the twisting devices (4) with other twisting systems incorporated in the yarn feed creel or bobbin (1), such as a motorized creel or those that rotate the yarn bobbin (1) or those of a static bobbin by means of double twisting.

[0059] And, for its part, the multi-device twisting machine (100) proposed by the invention, applicable for incorporation into a loom (200), a knitting machine or other weaving machine, between the creel or bobbin of the feed of said yarn (1) and said machine, such that the yarn (1) passes through the axis of the needle (8) to carry out the described process, basically comprises the following:

[0060] - a frame (3) on which between 1 and 3000 twisting devices (4) are mounted, which are configured to apply twist to the yarn (1), in the “S” or “Z” direction or in a combination of both directions, before it enters the loom (200) or knitting machine, and

[0061] - a drive system (5), which may be pneumatic, mechanical, hydraulic or electromechanical, configured to control the amount of torque applied by each torque device (4).

[0062] In addition, the machine comprises a central unit that controls the amount of torque applied by each torsion device (4).

[0063] More specifically, preferably, this twisting is programmed and controlled by the central unit which adjusts parameters such as the number of twists per meter from 2 to 2,000, applied to each yarn (1) by each twisting device (4), to adapt to the different types of yarn processed.

[0064] Preferably, each torsion device (4) comprises a torsion roller (4a) and a drive system (5).

[0065] Preferably, the frame (3) is arranged in an adjustable manner to allow variation in the arrangement and number of twisting devices (4) according to the characteristics of the loom (200) or knitting machine.

[0066] Preferably, each twisting device (4) is configured to allow independent regulation of twisting parameters, such as the degree of twist, direction of rotation, and operating cycle, according to the characteristics of the yarn (1) being processed. In one embodiment, the drive system comprises an electric motor (5) that controls the speed and direction of the twist applied to each yarn (1), this motor being adjustable to adapt to the different types of yarn being processed. The twisting device(s) (4) comprising the twisting machine (100) is preferably a so-called false-twist system, with different yarn guiding systems, such as Y-shaped clamps or others.

[0067] Finally, optionally, the twisting machine (100) comprises the incorporation of more than one twisting device (4) inserted in series or in parallel on each thread (1) of the loom (200).

[0068] Having sufficiently described the nature of the present invention, as well as the manner of putting it into practice, it is not considered necessary to make its explanation more extensive so that any expert in the field can understand its scope and the advantages that derive from it.

Claims

CLAIMS 1.- Online twisting process applicable to treating yarns (1) before being woven on a loom (200), needle knitting machines or other weaving machines, characterized by comprising applying a provisional twist to each yarn (1), before being woven, by including a twisting device (4) located between the creel or feed bobbin of said yarn (1) and said machine, such that the yarn (1) passes through the needle shaft (8) with sufficient twist to group the filaments. 2.- In-line twisting process, according to claim 1, characterized in that the twist of the twisting device or devices (4) is applied to the yarn (1) in the “S” or “Z” direction, or in a combination of both directions. 3.- Online torsion process, according to claim 1 or 2, characterized in that the amount of torsion applied by each torsion device (4) is controlled by a central unit 4.- Online twisting process, according to claim 5, characterized in that the twisting is programmed and controlled by a central unit that adjusts parameters such as the number of twists per meter from 2 to 2,000, applied to each yarn (1) by each twisting device (4), to adapt to the different types of yarn processed. 5.- Online twisting process, according to any of the preceding claims, characterized in that each twisting device (4) allows independent or joint regulation of the twisting parameters, that is, the degree of twist, the direction of rotation and the operating cycle, according to the characteristics of the yarn (1) to be processed. 6.- Online twisting process, according to any of the preceding claims, characterized in that the arrangement and number of twisting devices (4) varies according to the characteristics of the loom (200) or knitting machine concerned in each case. 7.- Online twisting process, according to any of the preceding claims, characterized in that the twisting device or devices (4) apply a false twist to the thread (1), so that it recovers its initial state. 8.- In-line twisting process, according to any of the preceding claims, characterized in that the twisting devices (4) are configured so as to minimize the accumulation of twist before the entry of the thread (1) into the needle (8), avoiding defects such as curls or knots in the thread. 9.- In-line twisting process, according to any of the preceding claims, characterized in that it comprises the use of more than one twisting device (4) inserted in series or in parallel on each thread (1) of the loom (200) or knitting machine. 10.- In-line twisting process, according to any of the preceding claims, characterized in that the combination of the twisting devices (4) with other twisting systems incorporated in the creel or feed bobbin of the yarn (1), consisting of a motorized creel or those that rotate the yarn bobbin (1) or those of a static bobbin by means of double twisting. 11.- Multi-device twisting machine (100), applicable for incorporation into a loom (200), a knitting machine or other weaving machine, between the creel or bobbin feed of said yarn (1) and said machine, characterized by comprising: - a frame (3) on which between 1 and 3000 twisting devices (4) are mounted, configured to apply twist to the yarn (1), in the “S” or “Z” direction or in a combination of both directions, before it enters the loom (200) or knitting machine, and - a drive system (5), pneumatic, mechanical, hydraulic or electromechanical, configured to control the amount of torque applied by each torque device (4). 12.- Multi-device torsion machine (100), according to claim 11, characterized in that each torsion device (4) comprises a torsion roller (4a) and a drive system (5) 13. Multi-device torsion machine (100), according to claim 11 or 12, characterized in that the frame (3) is adjustable to allow variation in the arrangement and number of twisting devices (4) according to the characteristics of the loom (200) or knitting machine. 14.- Multi-device torsion machine (100), according to any of claims 11 to 13, characterized in that each twisting device (4) is configured to allow independent regulation of the twisting parameters, i.e., the degree of twist, the direction of rotation and the operating cycle, according to the characteristics of the yarn (1) to be processed. 15.- Multi-device torsion machine (100), according to any of claims 11 to 14, characterized in that the drive system comprises an electric motor (5) that controls the speed and direction of the torque applied to each thread (1). 16.- Multi-device torsion machine (100), according to any of claims 11 to 15, characterized in that the twisting device or devices (4) is a false twisting system, with different thread guiding systems, clamps, Y-type, or others. 17.- Multi-device torsion machine (100), according to any of claims 11 to 16, characterized in that it comprises the incorporation of more than one twisting device (4) inserted in series or in parallel on each thread (1) of the loom (200).

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