Automated Creel Assembly With Robotic Yarn Package Positioning
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Solution Overview
Problem
Existing tufting/creeling operations face challenges in improving safety, reducing process time, changeover time, labor, and creel variability.
Innovation Solution
An automated creel assembly with a movable platform, rotary actuator, and gripper system, equipped with cameras for yarn quantity detection, is integrated with a robotic arm and service robot to automate yarn package handling and positioning, enabling efficient creel loading and management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If automated creel assemblies are implemented, then safety is improved and labor is reduced, but device complexity increases
Solution Approach 1:
The automated creel assembly is divided into modular components including a movable platform, rotary actuator, gripper system, and camera subsystems. Each module performs a specific function and can be independently controlled, allowing complex automation tasks to be broken down into manageable segments that improve safety while maintaining reasonable system complexity
Solution Approach 2:
The movable platform is designed to perform multiple functions: it can move along the first axis to position yarn packages, rotate about the first axis via the rotary actuator to orient packages, and the gripper can both engage and release packages. This multi-functionality reduces the need for separate dedicated components, improving safety through automation without proportionally increasing device complexity
2Loss of time
If automated creel assemblies are implemented, then process time is reduced, but device complexity increases
Solution Approach 1:
The camera system captures images of yarn packages and measures their dimensions before the packages are fully processed. The system pre-determines package characteristics and positions, allowing the movable platform and gripper to execute precise operations without delays for measurement or adjustment during the main processing sequence, thereby reducing process time
Solution Approach 2:
The automated creel assembly operates continuously with the movable platform transitioning smoothly between positions along the first axis, the rotary actuator continuously adjusting package orientation, and the gripper maintaining engagement during transfers. This eliminates idle time and discontinuous operations, reducing overall process time while the integrated control system manages complexity
3Measurement precision
If camera systems are added for yarn quantity detection, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The camera system replaces manual visual inspection or mechanical measurement devices for detecting yarn package dimensions and quantity. The camera captures images that are processed to determine package metrics, providing more precise and consistent measurements without requiring complex mechanical measurement mechanisms, thus improving measurement precision while adding only a single camera component
Solution Approach 2:
The camera creates an optical copy or image of the yarn package, which can be analyzed to determine package dimensions, yarn quantity, and other characteristics. This optical copying approach provides precise measurement data without requiring physical contact or complex mechanical measurement systems, improving measurement capability with minimal added complexity
Data Source
AI summary
A creel assembly having an outer wall defines an interior space, a plurality of yarn package engagement locations distributed within the interior space, a gantry that is movable secured within the interior space, and at least one processor. The gantry is positioned to selectively engage yarn packages within the interior space. In use, the gantry can selectively access the plurality of yarn package engagement locations. The processor is communicatively coupled to the gantry and receives an input corresponding to a selected action by the gantry. Modular creel systems can be formed from a plurality of the disclosed creel assemblies. Methods of using and assembling the disclosed creel assemblies and modular creel systems are also disclosed.