Bobbin Conveyance Using a Buffer Row for Full and Empty Bobbin Exchange
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Solution Overview
Problem
Existing bobbin conveying systems in yarn processing machines, such as those described in PTL 1 and PTL 2, face inefficiencies in handling empty and full bobbins, particularly in the handling of empty bobbins after removal from a package supporter and the need for one chuck to remain empty during package carrier operations.
Innovation Solution
A bobbin conveying system comprising a stocker, a bobbin transfer robot, and a traveling creel cart, where the stocker has multiple rows of pegs for hanging and storing bobbins, and a controller coordinates the exchange of bobbins between the stocker and the traveling creel cart through alternating processes to ensure smooth and efficient conveyance, utilizing the full capacity of the traveling creel cart.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a package carrier with chucks is used to convey packages, then package conveyance is achieved, but one chuck must always remain without a package reducing conveyance efficiency
Solution Approach 1:
The package carrier is divided into multiple independent chuck units arranged in a circular pattern. Each chuck can independently grasp and release packages, allowing parallel operations. When one chuck is releasing a package, others can be grasping or moving, eliminating the need to leave one chuck idle.
Solution Approach 2:
The circular arrangement of chucks enables continuous operation where packages are constantly being grasped, moved, and released in a seamless cycle. The carrier rotates to position chucks at different stations (grasping station, moving station, releasing station), ensuring that useful action continues without interruption across all chucks simultaneously.
2Productivity
If empty packages are removed from a package supporter, then full packages can be suspended, but the handling process of empty packages becomes unclear and inefficient
Solution Approach 1:
The grasping of empty packages and full packages is merged into a single carrier operation. The carrier simultaneously grasps full packages at the grasping station and empty packages at the releasing station, then transports both in one rotational cycle, eliminating separate handling steps.
Solution Approach 2:
The package carrier acts as an intermediary between the package supporter and the processing stations. It temporarily holds both full and empty packages, manages their transfer, and coordinates their movement through the system, making the handling process systematic and efficient.
3Area of stationary object
If the number of stocker rows equals cart rows, then space is optimized, but efficient exchange of full and empty bobbins cannot be achieved
Solution Approach 1:
The stocker is divided into multiple rows, with one row designated as a buffer row and others as exchange rows. This segmentation allows simultaneous operations: while full bobbins are being exchanged in one row, empty bobbins can be moved in another row, maximizing throughput without requiring proportional increases in total space.
Solution Approach 2:
Empty bobbins are pre-positioned in the buffer row of the stocker before exchange operations begin. When the cart arrives, full bobbins are directly exchanged with pre-positioned empty bobbins, eliminating waiting time and ensuring continuous operation. The buffer row is prepared in advance to facilitate immediate exchange.
Data Source
Figure 1
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AI summary
The number of rows of stocker pegs 26 provided by a stocker 20 is one greater than the number of rows of cart pegs 13 provided by a traveling creel cart 10. In a state in which one row of the stocker pegs 26 is bobbin-less and empty bobbins 6 are hung on all remaining rows of the stocker pegs 26, a first process and a second process are alternately performed under the control of a transfer control computer 40 to exchange empty bobbins 6 in the stocker 20 with full bobbins 5 in the traveling creel cart 10. In the first process, full bobbins 5 hung on one row of cart pegs 13 are moved to one row of stocker pegs 26, which are bobbin-less. In the second process, empty bobbins 6 hung on one row of stocker pegs 26 are moved to one row of cart pegs 13 where the full bobbins 5 has been removed in the first process. The traveling creel cart 10 conveys full bobbins 5 to the stocker 20 and replaces them with empty bobbins 6 in the stocker 20, and then conveys the empty bobbins 6.