Abstract:
A spinning-drawing-texturing machine for producing crimped threads is described, comprising a spinning device, a drawing device, a texturing device, and a take-up device. A plurality of threads spun by the spinning device is assigned to the drawing device, the texturing device, and the take-up device. According to the present invention, the drawing device and the texturing device are arranged in a processing module and the take-up device in a winding module underneath the spinning device. The processing module and the winding module are erected side by side and form one long side of the machine. This ensures a configuration divided by functional groups, which facilitates operation and increases operational reliability.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    The present invention relates to a spinning-drawing-texturing machine for producing crimped threads.  
           [0002]    Spinning-drawing-texturing machines for producing crimped threads are generally known in the art and are essentially used for producing carpet yarns. To this end, the spinning-drawing-texturing machine comprises a spinning device, a drawing device, a texturing device, and a take-up device. A plurality of parallel threads is spun from a polymer melt, jointly drawn, and textured in parallel. The threads, which are crimped after texturing, are wound up in parallel by the take-up device. For this purpose, the spinning device, the drawing device, the texturing device, and the take-up device are arranged vertically one underneath the other. Such machines have the drawback, however, that the threads must be guided over several tiers for spreading.  
           [0003]    European publication EP 0 718 424 A1 discloses a spinning-drawing-texturing machine which remedies the drawback of poor threading means by combining the drawing device, texturing device and take-up device in a single machine unit for texturing and winding up a single thread. A plurality of such machine units is arranged side by side. This type of drawing-texturing machine, however, has the general drawback that a corresponding number of machine units is required to process a plurality of threads in parallel. Furthermore, the integration of the functional components into a single machine unit has the disadvantage that mutual influences, for instance in case of a spool change, are unavoidable.  
           [0004]    Accordingly, there is a need in the art for a spinning-drawing-texturing machine for producing crimped threads, which has a user-friendly compact structure.  
           [0005]    There is a further need in the art to make the processing and take-up of the threads as flexible as possible.  
         BRIEF SUMMARY OF THE INVENTION  
         [0006]    These objects are attained by a spinning-drawing-texturing machine wherein the devices required for performing the essential process steps to produce the crimped threads are separated by their function and are combined into individual machine modules. Thus, the drawing device and texturing device, which are necessary to process the spun threads, together form a processing module. This processing module is arranged underneath the spinning device, such that the freshly spun threads can feed directly into the processing module for processing. After the threads have been spun and processed, they are wound onto spools. For this purpose, the take-up device is arranged in a winding module, which is erected directly adjacent to the processing module and thus forms a long side of the machine. The texturing machine according to the present invention thus has the particular advantage of a small overall height, so that the drawing device and the texturing device in the processing module as well as the take-up device in the winding module can be operated from a single level by the operator personnel. The separation into the functional groups according to the present invention provides a further advantage. Spool changes in the take-up device can be performed without significantly influencing the devices arranged in the adjacent processing module.  
           [0007]    Another advantage of the present invention is that the threads that exit from the processing module at a close thread distance to one another can be wound up without any substantial spreading. The drawing device, texturing device and take-up device essentially form a single common control level for the processing and take-up of the threads. As a result, tension differences in the individual threads due to increased spreading can advantageously be avoided.  
           [0008]    The present invention further provides a particularly flexible configuration of the spinning-drawing-texturing machine. Here, the take-up units of the take-up device, which are tiered one over the other, are independently driven and controlled. Each crimped thread can be individually wound onto a spool. The take-up rates are the same. A particular advantage of this embodiment is that if a thread breaks in one take-up unit, the process does not have to be interrupted, so that high machine utilization is ensured.  
           [0009]    The take-up units can each be provided with a driven spindle, which receives the spool. To ensure continuous take-up of the threads, the take-up units can each be provided with two driven spindles that alternately receive the spool.  
           [0010]    When crimped threads are produced, additional processing after spinning of the threads is required as a function of the yarn type. For instance, if stuffer box texturing devices are used, an additional cooling device is used to cool the compressed thread. Likewise, swirling of the threads before or after texturing may be necessary to improve cover. A further advantage of the present invention is that it is possible to integrate the additional processing devices in the processing module.  
           [0011]    According to a preferred embodiment of the present invention, a broken-end collecting device is assigned to the take-up device to ensure that the process is not interrupted if there is a malfunction in the take-up device. This broken-end collecting device has a respective suction port upstream of each take-up unit. This ensures that the threads are continuously drawn off from the processing module even if a thread breaks in one of the take-up units.  
           [0012]    Another advantage of the present invention is its high degree of automation. A robot is provided for thread guidance during thread spreading at the start of the process and a doffer for changing the spool in the take-up units. The robot or doffer is preferably guided so as to be displaceable along the long length of the machine to enable thread guidance from the spinning device up to the take-up unit.  
           [0013]    A further advantage of the present invention is its high operational reliability. It also provides protection from volatile components during operation, e.g., related vapors. 
       
    
    
     BRIEF DESCRIPTION OF THE FIGURES  
       [0014]    The present invention will now be described in greater detail, by way of example, with reference to some embodiments depicted in the figures, in which:  
         [0015]    [0015]FIG. 1 is a schematic front view of a first embodiment of the inventive spinning-drawing-texturing machine of the present invention;  
         [0016]    [0016]FIG. 2 is a schematic top view of the embodiment of FIG. 1; and  
         [0017]    [0017]FIG. 3 is a schematic view of a second embodiment of the inventive spinning-drawing-texturing machine of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0018]    Unless express reference is made to one of the figures, the following description applies to both embodiments.  
         [0019]    The spinning-drawing-texturing machine comprises a spinning device  1 , which is supported in a processing module  6 . The spinning device comprises a melt feed  2 , a spinning beam  3 , a plurality of spinnerets  4  arranged on the underside of the spinning beam  3 , and a spinning chamber  5 .  
         [0020]    The processing module  6  is configured as a machine frame for carrying a drawing device  11  and a texturing device  14 . A winding module  10  is erected adjacent to the processing module  6 . The winding module  10  is also configured as a frame to receive a plurality of take-up units  17 . 1 ,  17 . 2  and  17 . 3  and together with the processing module  6  forms a long side  38  of the machine.  
         [0021]    The processing module  6 , in addition to the drawing device  11  and the texturing device  14 , comprises a finishing device  9  assigned to the outlet of the spinning device  1 , a deflection roller  12 . 1  arranged between finishing device  9  and drawing device  11 , and a delivery device  16  arranged downstream of the texturing device  14 . A plurality of thread guides  8  for forming threads  7  is assigned to finishing device  9 . Finishing device  9  is advantageously coupled with a broken end collecting device and a cutting device (not depicted). The drawing device  11  is formed by two godet units  13 . 1  and  13 . 2 . Godet unit  13 . 1  is formed, for instance, by two driven godets. Godet unit  13 . 2 , by way of example, is depicted as a driven godet and a deflecting roller, around which the threads loop several times. The texturing device  14 , which is arranged downstream of the drawing device  11  comprises a texturing nozzle  39  and a plurality of discharge pipes  40 . The texturing nozzle  39  comprises a plurality of guide channels and stuffer boxes in which one thread  7  each is crimped into a compressed thread  35  (not depicted in FIGS. 1 and 2). Between texturing device  14  and delivery device  16 , a deflection roller  12 . 2  is arranged.  
         [0022]    The take-up device  15  in winding module  10  comprises a plurality of tiered take-up units  17 . 1  to  17 . 3 . Each of the take-up units  17 . 1  to  17 . 3  has a spindle carrier  18  on which two projecting spool spindles  37 . 1  and  37 . 2  are arranged. Spindle carrier  18  is rotatably supported such that the spool spindles  37 . 1  and  37 . 2  can alternately be swung into a winding position and a changing position. In the winding position, a spool  41  is wound onto winding spindle  37 . For this purpose, the take-up unit  17  is provided, respectively, with a dancer arm control  21 , a changing unit  20 , and a contact roll  19 . Dancer arm control  21  controls the drive of spool spindle  37  in such a way that the take-up speed remains constant. Spool spindle  37  can be driven either directly by a spindle drive or indirectly by a driven contact roll  19 . Threads  7  are guided to the take-up units  17 . 1  to  17 . 3  in the take-up module  10  via a deflection roller  12 . 3  and a plurality of thread guides  46 . The thread guides  46  can also be configured as a deflection roller.  
         [0023]    In the spinning device of the embodiment of the spinning-drawing-texturing machine shown, a polymer melt is delivered to spinning device  1 , e.g., by means of an extruder, and is supplied to spinning beam  3  via melt feed  2 . Through spinnerets  4  the polymer melt is extruded in three filament bundles exiting side by side. Thread guides  8  combine each filament bundle into one thread  7 . Threads  7  are pulled out of spinning device  1  by drawing device  11 . Threads  7  are finished in finishing device  9  and are then guided to drawing device  11  via deflection rollers  12 . 1 . The parallel threads  7  are thereby rotated by 90° in their plane of travel. In drawing device  11 , threads  7  are drawn between godet units  13 . 1  and  13 . 2 . For this purpose, godet units  13 . 1  and  13 . 2  are driven at a differential speed. To support the drawing process, godet units  13 . 1  and/or godet unit  13 . 2  may be designed to be heatable. After drawing, threads  7  are pulled in parallel into texturing device  14 . In texturing nozzle  39 , each thread  7  accumulates into a compressed thread  35 . At the end of texturing device  14 , the compressed threads  35  are untangled to threads  7 , which are now crimped, and are guided to take-up device  15  via delivery device  16 . Delivery device  16 , by way of example, is configured as a godet unit, around which threads  7  loop several times.  
         [0024]    In take-up device  15 , threads  7  are distributed among the individual take-up units  17 . 1 ,  17 . 2  and  17 . 3  and on each tier are wound onto a spool  41 . For this purpose, take-up units  17  can be driven either jointly via group drives or independently via individual drives. In either case, a control mechanism, in this case, for instance, a dancer arm control  21  ensures that each of the threads  7  is wound up at the same winding speed. Due to the inventive separation of the functional components, a doffer  26  for performing spool changes is assigned to winding module  10 . To this end, doffer  26  is guided in a guide rail  27  parallel to the long side  38  of the machine in the area of the winding module  10 . Doffer  26  is provided with a carrier  28 , which is guided in guide rail  27  along the floor. A holder  29  is formed on carrier  28  and is provided with the gripper arms required to change the spool. The doffer is  26  capable of executing the entire sequence of motions, such as placing the empty bobbins, removing the full spools, and possibly also spreading the threads in the take-up unit.  
         [0025]    To spread threads  7  at the start of the process, the exemplary embodiment according to FIGS. 1 and 2 comprises a robot  22 , which is guided parallel to the long side  38  of the machine in a guide rail  23 . Guide rail  23  is arranged above processing module  6  and winding module  10 . A carrier  24 , which is provided with a holder  25  that is designed to be movable, is guided in guide rail  23 . Holder  25  comprises all the necessary gripper arms and drives to enable it to spread the threads.  
         [0026]    During operation, processing devices  9 ,  11 ,  14  in processing module  6  as well as take-up device  15  in winding module  10  are shielded toward the outside. As may be seen in FIG. 2, processing module  6  is provided with a carrier  42  having sidewalls  43 . 1  and  43 . 2 . Processing devices  9 ,  11  and  14  are arranged on carrier  42 . The side walls  43 . 1  and  43 . 2  and a protective covering  36 . 1 , which can be displaced parallel to the long side  38  of the machine, form an enclosure, which protects the processing devices  9 ,  11  and  14  toward the outside relative to the long side  38  of the machine. Likewise, winding module  10  is formed by a carrier  44  and sidewalls  45 . 1  and  45 . 2 . Sidewalls  45 . 1  and  45 . 2 , on the side opposite carrier  44 , are interconnected by a protective covering  36 . 2 , which can be moved parallel to the longitudinal side  38  of the machine. Here, too, protective covering  36 . 2  forms an enclosure together with sidewalls  45 . 1  and  45 . 2 . Protective coverings  36 . 1  and  36 . 2  are each configured as a closed, e.g., transparent wall, which together with a top cover (not depicted) forms a complete enclosure so as to reduce, for example, dust accumulation and noise as well as to protect the operator personnel from the rotating components and to make it possible to provide air conditioning for sensitive materials.  
         [0027]    [0027]FIG. 3 is a schematic front view of a further exemplary embodiment of the inventive spinning-drawing-texturing machine. Components with like functions are provided with identical reference numerals.  
         [0028]    The construction of this embodiment is substantially identical to the preceding embodiment. Insofar, only the differences will be described below. For the rest, reference is made to the preceding description regarding FIGS. 1 and 2.  
         [0029]    Underneath spinning device  1 , processing module  6  and winding module  10  are erected side by side to form a long side of the machine. Arranged consecutively in the travel direction of the thread, processing module  6  comprises a finishing device  9 , a deflection roller  12 . 1 , a delivery device  30 , a drawing device  11 , a texturing device  14 , a cooling device  31 , two delivery devices  16 . 1  and  16 . 2 , and a swirling device  32 , which is arranged between delivery devices  16 . 1  and  16 . 2 . In this embodiment, in contrast to the preceding embodiment, threads  7  are pulled from spinning device  1  by an additional delivery device  30  and are guided to the subsequent drawing device  11 . The drawing device is formed by two godet units  13 . 1  and  13 . 2 , each of which comprises two driven godets. Threads  4  are guided parallel to one another in several loops around the respective godet units  13 . 1  and  13 . 2 . Godet units  13 . 1  and  13 . 2  are driven at a differential speed to draw the threads. After drawing, the threads are crimped in texturing device  14 . For this purpose, texturing device  14  is provided with a texturing nozzle  39 . Arranged downstream of texturing nozzle  39  is a cooling device  31 , which is provided with side-by-side circumferential grooves, one per thread, to receive the compressed threads  35  exiting from the texturing device  14 . The cooling device  31  is configured as a drum, along the circumference of which the compressed threads  35  are cooled. To untangle the compressed threads  35 , threads  7  are pulled from the cooling device  31  by the downstream delivery device  16 . 1 . Between delivery devices  16 . 1  and  16 . 2 , a swirling device  32  is arranged in processing module  6 . Here, the threads are swirled to increase cover. This concludes the processing of the threads. The threads are delivered to winding module  10  and are distributed among the individual take-up units  17 . 1 ,  17 . 2  and  17 . 3  of take-up device  15 . The take-up units  17  each have a spindle carrier  18  with a spool spindle  37  held on the circumference of a driven contact roll  19 . Spindle carriers  18  are pivotable. In front of contact roll  19 , as seen in the travel direction of the thread, a changing unit  20  is provided, which receives the thread running off a thread guide  46 , preferably via a deflecting roller, and guides it back and forth substantially parallel to spool  41 .  
         [0030]    Take-up device  15  is associated with a broken-end collecting device  33 , which comprises a plurality of suction ports  34 . One suction port  34  is assigned to each of the take-up units  17 . 1  to  17 . 3 . The broken-end collecting device  33  is connected with a yarn container (not depicted). If a spool has to be changed or if a thread breaks in one of the take-up units  17 . 1  to  17 . 3 , the incoming thread is guided to the broken-end collecting device  33  via the associated suction port  34  and is deposited in a yarn container. This ensures that the processing devices in processing module  6  can continue to operate without interruption. The process does not have to be turned off.  
         [0031]    In the spinning-drawing-texturing machine shown in FIG. 3, on the side of winding module  10 , a servicing passage is formed in which doffer  26  is guided. Doffer  26  is configured identically to the preceding embodiment and takes care of spool changes in take-up units  17 . 1  to  17 . 3 .  
         [0032]    Robot  22  is movably guided parallel to the long side of the machine to spread threads  7  in the processing devices of processing module  6 . The configuration of robot  22  is identical to that of the preceding embodiment, so that reference can be made to the preceding description.  
         [0033]    The exemplary embodiments depicted in FIGS.  1  to  3  are given by way of example with respect to the structure and the arrangement of the processing devices and the take-up device. For instance, all the required components in the area of thread feeding as well as godets, texturing units, cooling drum and detangling unit can be arranged in a clear layout in processing module  6 . The lateral arrangement of the take-up device in the winding module results in a highly compact arrangement with an overall height that can measure less than 2 m. This ensures simple and easy service accessibility of both the processing devices and the take-up device.  
         [0034]    Individual processing units can also be removed from, or replaced in the processing module, for instance to produce uncrimped FDY [Fully Oriented Yarn] or POY [Partially Oriented Yarn].  
         [0035]    In the drawing devices shown in the exemplary embodiments, the number and configuration of the godets can basically be freely selected. The configuration of the drawing device depends on the production process and the overall type.  
         [0036]    Likewise, the number of parallel-guided and processed threads is given by way of example (three threads are shown). Single threads or a plurality of threads can be guided, processed and wound without problem. To wind up the threads, the take-up units could also be formed by two winding stations, which can be alternately used to wind the thread. Single thread guidance in the take-up area produces identical take-up conditions on each take-up unit. This ensures gentle and uniform winding of the threads. The take-up units can be arranged either vertically one above the other or horizontally side by side, as a function of the number of the threads.  
         [0037]    Robots and doffers can advantageously be used to automate the process. For instance, to spread the threads, a robot can be assigned exclusively to the processing devices of processing module  6 . Such a robot is capable of performing all the required sequences of motion and spreading procedures. For this purpose, the processing devices of the processing module, e.g., the finishing device and the swirling device, can be provided with corresponding auxiliary devices. A second robot could be used spread the threads in the take-up device as well as change the spools.  
                                             List of Reference Numerals                                    1   spinning device           2   melt feed           3   spinning beam           4   spinneret           5   spinning chamber           6   processing module           7   thread           8   thread guide           9   finishing device           10   winding module           11   drawing device           12   deflection roller           13   godet unit           14   texturing device           15   take-up device           16   delivery device           17   take-up unit           18   spindle carrier           19   contact roll           20   changing unit           21   dancer arm control           22   robot           23   guide rail           24   carrier           25   holder           26   doffer           27   guide rail           28   carrier           29   holder           30   delivery device           31   cooling device           32   swirling device           33   broken-end collecting device           34   suction port           35   compressed thread           36   protective cover           37   spool spindle           38   long side of machine           39   texturing nozzle           40   discharge pipe           41   spool           42   carrier           43   sidewall           44   carrier           45   sidewall           46   thread guide