Apparatus and process for automatically taking up a continuously supplied yarn

An automatic transfer device and process for the transfer of a continuously supplied yarn from a first take-up tube, which usually has a full package thereon, to a second take-up tube, which has usually no yarn thereon. In carrying out this process, the apparatus automatically cuts and aspirates the continuously supplied yarn, and an actuator arm applies the yarn to the second take-up tube by moving the continuously-supplied yarn into contact with a yarn snagging device.

BACKGROUND OF THE INVENTION 
A. Field of the Invention 
This invention relates to an apparatus and process for automatically 
winding of the continuously-supplied yarn. 
B. Description of the Prior Art 
Modern winders, for winding yarn onto yarn packages on take-up tubes, 
generally include two or more tube holders, each supporting one or more 
take-up tubes. While one holder is being rotated for winding yarn onto 
tubes mounted thereon, empty take-up tubes are placed on a second tube 
holder then in a standby condition. When full packages have been wound on 
the first tube, the full package is removed therefrom. It is then 
necessary to thread the yarn for winding onto the tube on the second tube 
holder. 
The threading of the yarn can be effected by feeding the end of the yarn 
onto an aspirator or the like, and then using a "doffer" to engage the 
yarn in traverse guides for proper winding on the tubes. Such rethreading 
of the yarn requires a considerable amount of time. In addition, such a 
rethreading procedure produces a considerable amount of waste, 
particularly when yarns are fed at very high speeds. 
Attempts have been proposed to reduce the amount of time required for 
rethreading yarn. For instance, U.S. Pat. No. 4,083,505 discloses a 
winding machine with a device for bringing yarn to be applied in operative 
connection with a driven bobbin and a thread-capturing device so that the 
yarn is seized and spool formation began independently. One of the 
problems associated with this device is that thread guides are required 
which, in turn, must be manually threaded. 
The present invention provides an apparatus and process for automatically 
winding a continuously-supplied yarn. 
SUMMARY OF THE INVENTION 
The apparatus of the present invention is designed to transfer a winding 
operation from a first take-up tube, which is full, to a second take-up 
tube, which is empty. In making this transfer, the apparatus must cut the 
continuously-supplied yarn in order to remain in control of the 
continuously-supplied yarn. Control is maintained by aspirating the 
upstream end of the continuously-supplied yarn. The apparatus must next 
position an empty take-up tube and apply the continuously-supplied yarn to 
the empty tube, followed by breaking the yarn so that a waste section of 
yarn is retained by the aspirator. The apparatus and process of the 
present invention are designed to apply the yarn to the empty tube and 
form a "transfer tail" thereon, in order to improve further downstream 
process operations which utilize the bobbin produced. 
The process of the present invention comprises the following steps: 
(a) catching a yarn in a yarn catcher, the yarn catcher catching the yarn 
at a point within a yarn traversing triangle; 
(b) cutting the yarn in a yarn cutter; 
(c) aspirating the upstream end of the yarn; 
(d) moving a first take-up arm from a yarn winding position to a first 
doff-donn position; 
(e) moving a second take-up arm from a second doff-donn position to a 
yarn-winding position; 
(f) moving the path of yarn travel with an actuator means, wherein the 
continuously-supplied yarn is snagged and held by a yarn snagger, the yarn 
path then being oriented thereby so that the yarn upstream of the snag 
point begins to wind upon the second take-up tube; 
(g) breaking the yarn at a point downstream of the snag point; and 
(h) returning the yarn catcher to a nonengaged position. 
The apparatus of the present invention comprises a yarn catcher, a yarn 
cutter, an aspirator, a first take-up arm, a first tube holder, a first 
take-up tube, a second take-up arm, a second tube holder, a second take-up 
tube, a rotatable take-up cam, a yarn traversing means, a movable actuator 
means, a rotatable yarn snagger, and a yarn breaking means. 
OBJECTS OF THE INVENTION 
It is an object of the present invention to reduce the degree of manual 
manipulation of a yarn being wound. If the present invention is utilized 
in its least automated embodiment, the present invention allows an 
operator to more easily transfer the winding of a continuously supplied 
yarn from a full bobbin to an empty tube. If the present invention is 
utilized in its most automated embodiment, no operator is required during 
the process of transferring the winding of the continuously-supplied yarn 
from the full bobbin to the empty tube. 
It is a further object of the present invention to form a transfer tail for 
each yarn bobbin in order to improve further downstream process 
operations. 
It is a further object of the present invention to enable the formation of 
a package of uniform length. 
It is a further object of the present invention to make a yarn package 
having a higher density. 
It is a further object of the present invention to enable accurate 
production records of package numbers, yarn lengths per package, package 
defect levels, and short and long term machine performance. 
It is a further object of the present invention to waste a minimal amount 
of yarn during the transferring of the winding from a full bobbin to an 
empty tube. 
It is a further object of the present invention to improve the uniformity 
of transfer tail length among the yarn packages.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
The process and apparatus of the present invention are designed to reduce 
or eliminate manual operations in the process of transferring a 
continuously-supplied yarn from a first take-up tube to a second take-up 
tube. Usually, the first take-up tube is full while the second take-up 
tube is empty. In addition, in the most preferred embodiment of the 
present invention, which is fully automated, the amount of yarn waste 
(accumulating during the transfer process) is kept to a minimum. Some 
other benefits of the most preferred embodiment of the process and 
apparatus are: 
(1) a reduction in operating personnel (in comparison with completely 
manual transfer processes); 
(2) a reduction in the risk of injury to operating personnel, due to the 
need for fewer manual operations. 
FIGS. 1 through 15 illustrate, in perspective view, the apparatus (20) used 
for carrying out the process of the present invention. The sequence of 
operations is cyclic, i.e., after the step occurring in FIG. 15, the 
process continues by carrying out the steps shown in FIG. 1, then FIG. 2, 
etc. Therefore, in describing the process, one must simply "cut-in" at any 
particular moment and describe the process from that point onward. 
FIG. 1 illustrates a point in the cycle of the process in which the winding 
of a yarn (5) on a first yarn package (1) is nearing completion. The yarn 
(5) is continuously supplied. Thus, in FIG. 1 the yarn package (1) has 
just about reached a desired maximum size. The first yarn package (1) is 
formed on a first take-up tube (2), the first take-up tube being held by a 
first take-up tube holder (3). The tube holder (3) is freely rotatable and 
is attached to a first take-up arm (4). FIG. 1 indicates that the yarn (5) 
is coming from a source of continuous supply (not shown), the yarn being 
threaded under a yarn traverse guide bar (6) and into the helical grooves 
of a traverse roll (8), after which the yarn is wound onto the surface of 
the first yarn package (1). 
A second point in the process is illustrated in FIG. 2. Once the first yarn 
package (1) reaches a desired size, a yarn catcher assembly (9) slides 
across the machine (20) in a direction which is parallel to the axis of 
the traverse roll (8), the yarn catcher assembly (9) sliding from a 
nonengaged position (FIG. 1) to an engaged position (FIG. 3A). The yarn 
catcher slides from the side of the machine (20) on which the take-up arm 
(4) is mounted to the opposite side of the machine (20). The yarn catcher 
assembly (9) is suspended from and slides on a yarn catcher guide bar (54, 
as shown in FIG. 19A and 19B) the guide bar (54) being rectangular in 
cross-section. The yarn catcher assembly (9) has thereon a lower 
yarn-contact member (12) and an upper yarn-contact member (11), each of 
these members being positioned to intersect the yarn path upon catcher 
assembly (9) moving from the nonengaged position to the engaged position. 
As it is shown in FIG. 2, the yarn-catcher assembly (9) is in transit from 
the nonengaged position to the engaged position. In FIG. 2, the catcher 
assembly has gone about sixty percent of the way across, and has caught 
the traveling yarn (5) with yarn contact members (11) and (12). [NOTE: In 
FIG. 2, it appears as if a yarn transfer guide (13) might obstruct the 
movement of yarn (5) when the catcher assembly (9) moves into the engaged 
position. This is only an illusion, as the transfer guide (13) is well in 
front of the yarn contact members (11) and (12), and the yarn (5).] 
FIG. 3A illustrates a next point in the cyclic process. The yarn contact 
members (11) and (12) hold a section of traveling yarn in a substantially 
straight line therebetween. When the yarn catcher assembly (9) slides into 
the engaged position, this straight section of traveling yarn is held in a 
position so that the yarn is forced into a yarn cutter guide (15) and a 
yarn cutter (16), as clearly shown in FIG. 17, and an upstream portion of 
the straight section of yarn which is held between members 11 and 12 
[i.e., a portion of the straight section of yarn immediately below the 
cutter (16), as shown in FIG. 17] is forced into the proximity of an 
aspirator (7) which is taking in air at a high rate of speed. After 
achieving this position momentarily, an automatic device actuates the 
electronic yarn cutter (16), resulting in the process as depicted in FIG. 
3B. It should be understood that FIG. 3B is a high speed "stop-action" 
illustration of what the inventors conceive of the yarn looking like 
immediately after the cutting process. In FIG. 3B, the upstream portion of 
the yarn (5) has just entered into an aspirator (7) and the downstream 
portion of the yarn (5) is free to finish winding on the first yarn 
package (1). 
FIG. 4 illustrates a next point in the process. Note that in comparing FIG. 
3B with FIG. 4, the first take-up arm (4) has been swung away from the 
yarn-winding position (FIG. 3B) to the doff-donn position (FIG. 4). In the 
most preferred embodiment, the swinging of the arm (4) is performed by 
pneumatic piston means, the piston being automatically actuated. [For 
clarity of illustration, pneumatic pistons are not shown in FIGS. 1 
through 15; however, the pistons are shown in FIGS. 20 and 22]. In FIG. 4, 
a second take-up arm (17) is shown, the second arm (17) being now only 
partially obscured by the first yarn package. The second take-up arm (17) 
has a second tube holder (18) [tube holders (18) and (3) are better 
illustrated in FIG. 18]. The second tube holder (18) has a second take-up 
tube (19) thereon. The second tube holder (18) and the second take-up tube 
(19) are both identical to the corresponding first tube holder (3) and the 
first take-up tube (2). However, the second take-up arm (17) is the mirror 
image of the first take-up arm (4). 
In FIG. 5, a next point in the process is shown. The second take-up arm 
(17) has been moved from a doff-donn position (FIG. 4) to a yarn-winding 
position (FIG. 5). During the steps depicted by FIGS. 1 through 15, the 
traverse roll (8) never ceases to spin at the desired winding speed. Thus, 
upon applying the second take-up tube (19) to the traverse roll (8), the 
tube (19) immediately receives power from the rotating traverse roll (8), 
the tube (19) quickly coming to match the surface speed of the rotating 
traverse roll (8). 
In FIG. 6, the next step of the process has begun. After the surface speed 
of the second take-up tube (19) has matched the surface speed of the 
traverse roll (8), an actuator lever (21) rotates counter-clockwise in a 
quick motion. FIG. 6 is a stop-action view as the lever has made about 50% 
of its counter-clockwise rotation. The actuator lever (21) is in the 
inactive position as shown in FIG. 5, the inactive position being "at 
about five o'clock" in the most preferred embodiment. In FIG. 6, the lever 
is "at about 3 o'clock", and in FIG. 7 the actuator lever is in the active 
position, a position which is "at about one o'clock". The actuator lever 
(21) has an actuator arm (22) thereon. The actuator arm (22) has a hook 
(23) therein, the hook (23) being positioned so that the 
continuously-supplied yarn, which is being aspirated, is held therein 
during the rotation of the actuator lever. 
FIG. 7 shows the actuator lever (21) upon completion of its 
counter-clockwise motion. The yarn (5) loops over the actuator arm (22), 
the yarn being positioned in the hook (23) on the actuator arm. The motion 
of the actuator lever (21) causes the path of yarn travel to be 
moved--i.e., altered. When the actuator lever (21) is in the nonengaged 
position (i.e., the "5 o'clock" position), the arm (22) is positioned 
completely out of the way of the yarn (5) during the normal yarn winding 
operation. However, once the yarn is being aspirated, the yarn path is in 
a position to be affected by the arm (22) upon a counter-clockwise 
rotation of the actuator lever (21), if the actuator lever is in the 
inactive position, as it should be at this point (i.e., as shown in FIG. 
5). Once the actuator lever (21) has rotated counter-clockwise a few 
degrees from the inactive position, the yarn (5) is contacted by the hook 
(23), and the yarn path to the aspirator is thereby altered by the further 
rotation of the actuator lever (21) as shown in FIG. 6. Thus, the path of 
yarn travel is moved. The movement of the path of yarn travel is initiated 
from a point in space, that point in space being the point at which the 
yarn contacts the hook (23) located on the actuator arm (22). Of course, 
this "point in space" changes with the movement of the actuator arm (22). 
The yarn path is moved both upstream and downstream of the point in space. 
The yarn path is moved between a last point of restrictive yarn contact 
(in the preferred embodiment, the last point of restrictive yarn contact 
is the lower yarn contact member (12)) and the point at which the yarn 
enters the aspirator (7). In the counterclockwise rotation of the actuator 
assembly, the lever (21) rotates in a plane which is approximately 
9.degree. off of the plane of rotation of the yarn snagging teeth (24). 
This allows a portion of the traveling yarn which is both upstream of the 
"point in space" and downstream of the last point of restrictive contact 
to cross the plane of rotation of the snagging teeth (24) and to be 
brought into contact with the snagging teeth (24). FIG. 7 shows the 
position of the yarn immediately after a snagging tooth (24) has snagged 
the yarn (5) and made about 1/8 of a revolution thereafter. Thus, the yarn 
is caught at a snag point. This snag point is an actual point on the yarn, 
i.e., a point with respect to which the yarn is not travelling, to be 
contrasted with the last point of restrictive yarn contact and the "point 
in space". 
Although it cannot be clearly seen in FIG. 7, once the yarn (5) is snagged, 
that portion of the yarn (5) which is downstream of the snag point (i.e., 
between the snag point and the hook 23) rests upon an extension (25) of 
the second tube holder, the extension (25) being provided in order to keep 
the yarn from coming off of the snagging tooth once the snagging tooth has 
rotated approximately one half turn after snagging the yarn. Thus, the 
yarn which is downstream of the snag point is kept on top of the extension 
(25), and in this way the yarn is prevented from flipping off of the 
snagging tooth (24). 
As soon as the yarn is snagged, the yarn tension downstream of the snag 
point increases rapidly because both the snagging teeth (24) and the 
aspirator (7) are competing for yarn. In the preferred process of the 
present invention, the yarn is being supplied (and thus wound) at about 
1800 meters per minute. If the yarn strength is small enough and the 
equipment used powerful enough, shortly after the yarn is snagged the 
tension increase alone will cause the yarn to break. If the yarn is strong 
relative to the equipment used, it may be necessary to introduce some 
second yarn cutting means into the system, as is shown in FIG. 17, in 
which yarn retreating from the aspirator is cut by a blade (120) which is 
installed inside of the aspirator (7). FIG. 8 depicts the result of the 
yarn snagging operation, FIG. 8 illustrating the case of a yarn transfer 
operation being carried out on a yarn which is weak enough to break, as 
opposed to the yarn being cut (which is necessary for relatively strong, 
heavy yarns). Note the yarn end (5') going into the aspirator (7) in FIG. 
8. Note also in FIG. 7 that the yarn "positions" which are upstream and 
downstream of the snag point are separated from one another by the yarn 
actuator guide (13). In FIG. 7, the yarn remains against the lower yarn 
contact member (12), and the yarn between the contact member (12) and the 
position of the hook (23) when the lever is in the active position aligns 
the yarn so that the yarn must contact the moving teeth (24) which are 
used to snag the yarn. 
In FIG. 8, the continuously supplied yarn (5) has formed a transfer tail 
(31) near the end of the second take-up tube (19). The transfer tail (31) 
is formed on an end of the take-up tube (19), the position of the transfer 
tail (31) being outside of the yarn traverse range on the tube, so that 
the transfer tail is accessible on the full package after yarn winding is 
completed. Once enough yarn is wound for the transfer tail (31), the yarn 
catcher assembly (9) is moved across the machine, back to its nonengaged 
position. In so doing, the continuously supplied yarn (5), being held on 
lower contact member (12), is allowed to move into traverse grooves (8V) 
of the traverse roll (8), and the yarn begins to traverse. It is preferred 
that the yarn catcher assembly (9) be moved from the engaged to the 
nonengaged position quickly enough that the assembly (9) will not 
interfere with normal yarn traversal. It is also preferred to wait until a 
desired length of yarn has accumulated for the transfer tail before 
sliding the assembly (9) back to the nonengaged position. FIG. 9 shows the 
assembly (9) moving back to the nonengaged position, the yarn (5) entering 
the traverse groove (8V), and the actuator assembly (21, 22, and 23) 
moving back to the inactive position. 
FIG. 10 illustrates a point in the process in which the second take-up tube 
(19) has a partially full package which is being wound thereon. Also, the 
first take-up tube (2), which had a full package (1) thereon in FIG. 9, 
has been doffed, exposing the first take-up tube holder (3). The 
continuously-supplied yarn (5) is traversing and the yarn catcher assembly 
(9) is completely removed from the yarn traversing triangle. The actuator 
assembly (21 and 22) has returned to the inactive position. 
FIG. 11 illustrates a further point in the process. An operator has 
manually replaced the first bobbin (1), along with and the first take-up 
tube (2), with a fresh first take-up tube (2') which has no yarn wound 
thereon at this stage. Note that the second bobbin (26) has more yarn 
wound thereon than in FIG. 10. 
FIG. 12 is analogous to FIG. 1, except that the condition and position of 
both of the take-up arms (4 and 17) are reversed. FIG. 12 is included in 
order to illustrate the full cycle of the process. FIG. 12 shows the yarn 
catcher assembly (9) in transit from the nonengaged position to the 
engaged position, as shown in FIG. 2. 
FIG. 13 is analogous to FIG. 4, except that the take-up arms are again 
reversed in condition and position. In FIG. 13 (as in FIG. 4), neither the 
bobbin (26) nor the fresh take-up tube (2') is in contact with the 
traverse roll (8). FIG. 13 illustrates the continuously supplied yarn (5) 
being aspirated and the yarn-catcher assembly (9) in the fully engaged 
position, as is shown in FIG. 4. 
FIG. 14 is analogous to FIG. 7. In carrying the process out between points 
illustrated in FIG. 13 and FIG. 14, the first take-up tube (2') has been 
brought into contact with the traverse roll (8) and has come up to speed. 
The actuator lever (21) has rotated counterclockwise into the "one 
o'clock" position and the traveling yarn has just been snagged by a tooth 
(24) of the yarn snagger. 
FIG. 15 is analogous to FIG. 10, again except that the condition and 
position of the take-up arms is reversed. In carrying out the process 
between the points illustrated in FIGS. 14 and 15, the transfer tail (31') 
has been wound, the yarn (5) has been cut or broken downstream of the snag 
point, the actuator lever (21) has returned to the inactive position, the 
yarn catcher assembly (9) has been moved from the engaged position to the 
nonengaged position, allowing the yarn to begin traversing, and as shown 
in FIG. 15, a partial yarn package has been built up on the fresh take-up 
tube (2'). In addition, the second bobbin (26) and its associated take-up 
tube (19) have been doffed, and a new take-up tube (19') has been donned. 
At this point, the process completes a single cycle. Thus, FIG. 1 
represents a next point in the process, FIG. 1 then being the point at 
which a fresh yarn package (now, 1') has reached the desired maximum size. 
In the present invention, the yarn (5) may be continuously supplied from 
bobbins which are attached to one another via transfer tails or the yarn 
may be continuously supplied from a source of filament extrusion, e.g., a 
melt spinning process, wet spinning process, etc. The 
continuously-supplied yarn is preferably run through the nip between two 
feed rolls which are in rotary contact with one another (the nip rolls are 
not shown in FIGS. 1-15). The yarn then runs under the yarn traverse guide 
bar (6). During winding of the yarn, the yarn runs from the guide bar (6) 
into the groove of the rotating traverse roll (8). While traversing, the 
path of yarn travel sweeps out two planes, a first plane being between the 
nip rolls and the traverse guide bar and a second plane between the guide 
bar and the traverse roll groove. These two planes together form a yarn 
traversing triangle. The function of the guide bar (6) is to ensure that 
the yarn approaches the machine (20) from the proper angle so that the 
operations of winding and transferring can be carried out successfully. If 
the nip rolls were located so that the yarn approaches the machine from 
the same angle as afforded by the guide bar (6), the guide bar (6) would 
become unnecessary. The yarn catcher catches the yarn at a point within 
the yarn-traversing triangle. If a traverse guide bar (6) is used (as 
shown in the drawings), the yarn catcher must catch the yarn at a point 
which is downstream of the traverse guide (6) (i.e., between the traverse 
guide and the traverse roll) so that the yarn need not again be threaded 
under the traverse guide bar (6), before the winding operation is resumed. 
In the present invention, there are preferably two take-up arms. This 
allows for the manual doffing of a full yarn package from a first take-up 
tube-holder (while the take-up arm is in a first doff-donn position), 
followed by the donning of a new take-up tube on the first tube-holder. 
The phrase "first doff-donn position" refers simply to the doff-donn 
position of a first take-up arm. The "second doff-donn position" is simply 
the doff-donn position of a second take-up arm. Most preferably, both 
doff-donn positions are as shown in FIG. 1 and FIG. 4. Likewise, the 
phrase "first yarn-winding position" refers to the position of the first 
tubeholder during the process of winding yarn on the first tubeholder, a 
position which changes as the first yarn package grows in size. The same 
holds for the phrase: "second yarn-winding position". Most preferably, 
both yarn-winding positions are located vertically above the traverse 
roll, but neither take-up arm need be in this exact position, nor must the 
take-up arms contact the traverse roll in exactly the same position. 
As used herein, the terms "upstream" and "downstream" are used with respect 
to the direction of yarn flow or movement, and are intended to refer to 
the yarn (5) movement from the source of continuous supply towards the 
machine (20). The yarn is generally being wound upon a bobbin or drawn 
into an aspirator. The only exception to these generalities occurs between 
the time at which the yarn is snagged by the rotating yarn snagger and the 
time at which the yarn is thereafter either cut or broken. Before this 
time period, the yarn has been continuously supplied from a source and has 
been either wound or aspirated until the yarn was snagged by the rotating 
yarn snagger. Immediately after that point in time at which the yarn is 
snagged, the yarn which is emerging from the source of continuous supply 
begins to bewound as a transfer tail, the winding occurring upon one end 
of the take-up tube. The direction of rotation of the yarn snagger also 
pulls yarn (which has been traveling into the aspirator, i.e., yarn 
between the aspirator and the snagger, this yarn being considered 
downstream of the snag point) back towards the snagger momentarily, until 
the yarn breaks or is cut. 
As shown in FIG. 7, in order that the yarn is snagged, the actuator arm 
(22) positions the yarn so that the yarn comes into contact with one of 
the teeth (24) of the yarn snagger. Once the yarn is caught at a snag 
point, the yarn is held on the snag point (i.e., not allowed to flip off 
of the tooth (24) by yarn immediately downstream of the snag point being 
held on an extension (25) of the tube holder. The extension is believed to 
be an absolute necessity in the present invention, as it is believed that 
the yarn would flip off of the tooth (24) if there were no extension (25) 
on the tube holder. Both tube holders (3 and 18) have extensions (31 and 
25, respectively) thereon for the purpose of winding yarn thereon during 
the process of snagging the yarn and winding a transfer tail. 
As described herein, after the yarn is snagged, the yarn breaks by either 
pulling apart from a tension increase or by cutting by means of a blade. 
The yarns pulls apart or is cut downstream of the snag point. Yarn 
downstream of the snag point and upstream of the aspirator then winds 
around the extension (e.g., 25) or the teeth, etc. This yarn is cut away 
(manually) immediately before doffing the bobbin. The yarn upstream of the 
snag point winds around the first half inch or so of the tube. This yarn 
becomes the transfer tail. Preferably, there are five or more wraps of 
yarn constituting the transfer tail. As used herein, the phrase "breaking 
the yarn at a point downstream of the snag point" is meant to include both 
pulling the yarn apart with a tension increase as well as utilizing a 
blade (in the aspirator, for example) to cut the yarn at this stage of the 
process. 
The mechanism (20) of the present invention is preferably powered, the 
powering means most preferably being pneumatic. The 
activation/deactivation of the powering means is preferably performed 
automatically, most preferably by a programmable controller. All of the 
moving parts associated with the mechanism (20) are powered by either 
pneumatic devices or the motor which powers the powered roll (8), the only 
exception being the yarn cutter (16), which is powered by an 
electromagnetic device. The powered roll (8) traverses the yarn. The 
pneumatic devices move the yarn catcher, the actuator arm, and the take-up 
arms. The programmable controller (not illustrated) is discussed 
immediately below, while the preferred pneumatic arrangement is discussed 
in detail immediately after the discussion of the controller. 
The process of the present invention requires that the movements of the 
various parts of the apparatus be carried out in a specific order. 
Furthermore, it is most preferable to carry out the process as quickly as 
is practical, so that a minimal amount of yarn waste is created. However, 
the process steps should not become too close together in time, so that 
the yarn transfer process does not become subject to an undesirable number 
of failures. 
A programmable controller is programmed to trigger solid state relays 
which, in turn, trigger solenoid valves which, in turn, control the 
pneumatic devices discussed below. It has been found that the mechanism 
(20) operates most efficiently with the following sequence of operations: 
(a) turn on he aspirator (7) control relay; 
(b) wait one second; 
(c) turn on the yarn catcher (9) control relay and thereafter activate the 
yarn cutter; 
(d) wait 4.0 seconds; 
(e) turn on the relay which reverses the position of the transfer arms by 
first removing the full bobbin from the drive roll and thereafter applying 
the fresh tube to the drive roll; 
(f) wait 1.5 seconds; 
(g) turn off the relay which reverses the positions of the transfer arms, 
thereby applying the proper pressure to the drive roll with the fresh tube 
which contacts the roll, while simultaneously activating the rotary 
actuator from the nonengaged position to the engaged position; 
(h) wait 1 second; and 
(i) deactivate the actuator arm relay and simultaneously turn off the 
aspirator (7) relay, as well as return the yarn catcher to the nonengaged 
position. 
Most preferably, the programmable controller used to automate the machine 
is a Texas Instrument TMS 990/U 89 single board computer. 
FIGS. 18, 19A, and 19B illustrate the yarn catcher assembly (9) and the 
mechanism by which it moves. The yarn catcher assembly (9) is comprised of 
a bracket (50) having an upper yarn-contact member (11) and a lower 
yarn-contact member (12) thereon. 
FIG. 18 illustrates a detailed perspective view of the yarn catcher 
assembly (9) and its associated support assembly. FIG. 19A illustrates the 
bracket (50), the upper and lower yarn contact members (11 and 12, 
respectively), the guide plate (51), the guide rod (54), and the slide 
member (53). 
FIG. 19A is a cross-sectional illustration of the yarn catcher assembly (9) 
and its support assembly. The bracket (50) slides on a horizontal guide 
plate (51). The bracket (50) has an upper surface (52) to which is bolted 
a slide member (53). The slide member (53) has a rectangular passageway 
through which a guide rod (54) is directed. 
Although FIGS. 1 through 15 illustrate the yarn catcher assembly (9) in 
perspective view, FIGS. 1 through 15 do not illustrate the guide rod (54) 
and the slide member (53) because both are obscured from view by the 
powered tranversing roll (8) shown in FIGS. 1 through 15. However, if the 
mechanism (20) is viewed from the side which is opposite that shown in 
FIGS. 1 through 15, one may see the rod (54) and the slide (53), as well 
as other parts which enable the movement of the yarn catcher assembly (9). 
FIG. 19B illustrates, in perspective view, this "backside" view of the 
mechanism (20). FIG. 19B illustrates the guide rod (54) which is "behind" 
and slightly above the "bottom" of the powered traverse roll (8). FIG. 19B 
also illustrates the slide member (53), to which is attached a slide pin 
(62) (the pin 62 is shown only in FIG. 19A). Also shown in FIG. 19B is a 
lever arm (56). On its lower end, the lever arm (56) is connected to a 
pneumatic piston (58), the piston (58) having a piston rod (59) 
terminating in a connector (60), the connector (60) being pivotally 
connected to the lower end of the lever arm (56) with a pin (61). An upper 
end of the lever arm (56) has an elongated hole therein, the elongated 
hole allowing the lever arm (56) to pass under a cap (55) of the slide pin 
(62), causing the upper end of the lever arm (56) to be held between the 
cap (55) of the slide pin (62) and the slide member (53). The lever arm 
(56) slides freely between the cap (55) and the slide member (53). The 
lever arm (56) rotates freely around a fulcrum pin (57) (see both FIGS. 
19B and 19A), the fulcrum pin (57) having a fulcrum pin support (64) which 
is attached to a frame plate (65), and a fulcrum pin cap (63) holds the 
lever arm (56) on the fulcrum pin (57). FIG. 19B illustrates a piston rod 
(59) in its fully extended position, which corresponds with the yarn 
catcher assembly (9) being in the nonengaged position. When the piston rod 
(59) is fully retracted by the pneumatic action within the piston (58), 
the lever arm (56) rotates around fulcrum pin (57), causing the slide 
member (53) to move the yarn catcher assembly (9) into the engaged 
position. FIG. 20 illustrates a perspective end-on view of the mechanism 
(20) from behind the device. FIG. 20 illustrates two pneumatic pistons (72 
and 66) which are mounted on a horizontal base (67). The associated piston 
rods (68 and 69) are each attached to corresponding connecting rods (70 
and 71) which in turn are connected to the "backside" of each of the 
take-up arms (4 and 17) with pins and connectors (not shown). Each piston 
rod (68 and 69) is in a fully extended position when its associated 
take-up arm is in the doff-donn position. Each piston rod (68 and 69) is 
fully retracted when its associated take-up arm (4 and 17) is holding an 
empty take-up tube (2 and 19) against the traverse roll (8). As a yarn 
package is built upon a take-up tube, the piston rod associated therewith 
is gradually extended, allowing the take-up arm to rise in conjunction 
with the buildup of yarn on the associated take-up tube. 
FIG. 21 illustrates an enlarged perspective view of the actuator assembly 
and additional closely associated positions of the apparatus. The actuator 
arm (22) has a "hook" (23). The actuator arm (22) is secured to an 
actuator lever (21). The actuator lever rotates around an actuator pivot 
(125). The hydraulic rotary actuator (see in FIG. 22) is held within a 
housing (124). The actuator lever (21) rests upon a first rubber "bumper" 
(123) when the actuator assembly is in the inactive position, as shown in 
FIG. 21. The actuator lever (21) rests upon a second rubber "bumper" (121) 
when the actuator assembly is in the active position. The second bumper 
(121) is supported by a mounting bracket (122). 
FIG. 22 is a schematic of the pneumatic system employed in the present 
invention. The schematic shown in FIG. 22 illustrates the pneumatic system 
in one of its most probable states: that state in which the yarn is being 
wound onto one of the take-up tubes. The circuit will first be described 
in the state illustrated in FIG. 22, followed by a description of the 
operation of the circuit during the yarn transfer process. 
At bottom center of FIG. 22, the symbol SA/90 refers to a 90 PSI air which 
is supplied to the line extending from the symbol. Moving down this line, 
the symbol refers to valve number 1 designated , the valve solenoid 
being the first voltage signal applied in the process of automatic 
transfer, the solenoid of valve number 1 being activated by a potential of 
120 volts applied thereto: hence the symbol . As shown, the aspirator (7) 
connected to valve number 1 is not operating because the solenoid has 
not been activated. The 90 PSI air next travels through a valve , this 
composite valve serving to both filter the air and reduce the output air 
pressure to 75 PSI, as is shown by the symbol immediately downstream of 
valve . The 75 PSI air emitted from valve is the air whip used to move 
the pneumatic pistons used in the pneumatics associated with the mechanism 
(20). 
The 75 PSI air next goes to several different locations simultaneously, one 
of which is a lubricator, symbolized by , this lubricator supplying 
lubricant to the entire pneumatic system. The 75 PSI air also travels 
through the lubricator to valve (15) (designated ), then through valve 
(15) and on to the rotary actuator piston (designated ). This 75 PSI air 
is keeping the rotary actuator in the inactive position. The 75 PSI air 
also travels to a dead-end in valve number 4 (designated ). The 75 PSI 
air also travels to a pressure regulator (102) which drops the pressure to 
5 PSI on its output side. The 5 PSI air from the pressure regulator (102) 
travels to a shuttle valve (101) and will be further discussed below. The 
75 PSI air also goes to, and through, valve number 2, designated . The 
air passes through valve 2 and on to the yarn-catcher piston, designated 
. The yarn-catcher piston is shown fully extended, indicating that the 
yarn catcher assembly (9) is being held in the nonengaged position. A line 
(103), coming out of the other end of the yarn catcher piston (designated 
) goes into line "A" of valve 2, this line leading to an exhaust port 
("R"), rendering the pressure inside of line 103 to be 1 atmosphere (i.e., 
ambient). The shuttle valve (101) has a 5 PSI input from the pressure 
regulator (102), and the shuttle valve (101) therefore admits 5 PSI air 
into line 104. The shuttle valve admits pressure to line 104 from 
whichever line (either line 103 or the 5 PSI from pressure regulator 
(102)) has the greater pressure. In the schematic as shown in FIG. 22, the 
shuttle valve (101) allows the 5 PSI line coming from the pressure 
regulator (102) to go into line 104 because line 103 is open to the 
atmosphere (at valve 2). Thus, the 5 PSI air flows up to the binary valve 
(designated ), and through the binary valve on the "B" side. After 
passing through the binary valve, the 5 PSI air reaches a junction (105), 
and is then directed into both line 106 and line 107. From line 107, the 5 
PSI air goes through a valve (108) and into the forward end of a first 
pneumatic piston (72), this piston being held in the yarn-winding position 
(as shown in FIG. 20). From line 106, the 5 PSI air also goes to the 
rearward end of a second position (66), keeping the corresponding piston 
rod (69) in the fully extended position, which is the doff-donn position 
(see piston 65 in FIG. 20). Piston (66) has line 109 connected to the 
forward end thereof, line 109 leading to valve 110. In the schematic, line 
109 leads to an exhaust port in valve 110, leaving the 5 PSI air in line 
106 holding position rod (69) in the extended position. Note that valve 
110 has a bumper switch (111) which is depressed. Valve 110 is actually 
located at the rearward end of piston 72, and it is the movement of piston 
rod 68 to the retracted position which causes bumper switch 111 to be 
depressed. Also note that valve 108 has a bumper switch (112) which is 
extended. Bumper switch 112 is actually located at the rearward end of 
piston (66), the piston rod (69) of which is not depressing bumper switch 
112 because piston rod 69 is in the extended position. Thus, one can see 
the operation of the pneumatic system during winding. 
The computer triggers relays which in turn trigger the solenoids which in 
turn trigger the pneumatic valves used to directly affect the positions of 
the piston rods, etc., used in the mechanism (20). The computer first 
turns on the aspirator by activating valve number 1 (designated ). The 
computer then waits 1 second and then activates valve number 2 (designated 
), which causes the yarn catcher assembly (9) to move to the engaged 
position. The retraction of the piston rod (59) associated with the yarn 
catcher mechanism triggers a magnetic proximity switch (designated ), 
which causes the electric yarn cutter to be triggered, which severs the 
yarn therein. The activation of valve number 2 also causes 75 PSI air to 
enter line (103), through which line (103) the 75 PSI air enters shuttle 
valve (101), the 75 PSI air shutting off the 5 PSI air side of shuttle 
valve (101). The 75 PSI air then exits the shuttle valve through line 
(104), the 75 PSI air traveling through the binary valve, and into the 
pistons (72 and 66). The 75 PSI air maintains the pistons in their 
positions as shown. The computer waits 2.5 seconds after activating valve 
number 2 and then activates the valve by triggering solenoid . This 
allows 75 PSI air to travel up through line 113 (dashed line) into the 
binary valve, causing valve 114 to be activated. This in turn allows 75 
PSI air from line 104 to travel through the "A" side of valve 114, and 
causes the 75 PSI air that was in lines 106 and 107 to exhaust through "S" 
of valve 114. The 75 PSI air traveling through the "A" side of valve 114 
moves into lines 115 and 116. From line 115, the air causes piston rod 68 
to extend fully (i.e., move to the doff-donn position), thus releasing the 
bumper switch (111), which in turn allows the 75 PSI air in line 116 to 
move through valve 110 and through line 109, causing the piston rod (69) 
to fully retract (i.e., moving the associated transfer arm to the 
yarn-winding position), which in turn depresses bumper switch 112 of valve 
108. After activating valve (4), the computer waits 1.5 seconds and then 
turns off valve (4), which exhausts the 75 PSI air in line (113) (this has 
no effect on valve 114). Simultaneously with the deactivation of valve 
(4), the computer actuates valve (15) by triggering solenoid . This 
causes the rotary actuator assembly (21, 22, and 23) to rotate from the 
inactive position to the active position. After deactivating valve 4 and 
activating valve (15), the computer waits 1 second and deactivates valve 
(15) and simultaneously deactivates valve (1) (the aspirator control 
valve) and valve (2), causing the yarn catcher piston rod (59) to extend 
(the yarn catcher assembly (9) moves from the engaged to the nonengaged 
position) and further causing 5 PSI air to fill lines 109, 115, and 116. 
Thus, piston rod (69) is held in the yarn winding position by 5 PSI air. 
The winding operation is continued until the yarn transfer process is 
desired, at which time valve 1 is again activated, etc. 
The invention is not limited to the above-described specific embodiments 
thereof; it must be understood therefore, that the detail involved in the 
descriptions of these embodiments is presented for the purposes of 
illustration only, and that reasonable variations and modifications, which 
will be apparent to those skilled in the art, can be made of this 
invention without departing from the spirit and scope thereof.