Patent Publication Number: US-2010107590-A1

Title: Device for producing a rope lap

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application claims priority under 35 U.S.C. §119(a) of German Patent Application No. 10 2008 053 762.4 filed Oct. 29, 2008, the disclosure of which is expressly incorporated by reference herein in its entirety. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention relates to a device for producing a rope lap with a creel in which a plurality of thread bobbins is arranged, a rope-forming device for combining threads drawn off from the creel to faun a rope, and a bobbin carriage. 
     2. Discussion of Background Information 
     To produce specific textile precursors, threads are combined to form thread strands, which are also called “ropes.” These ropes are then subjected to a further treatment, for example, a dyeing process. A different appearance results when a rope is dyed than when threads arranged next to one another are dyed. One example of the use of ropes is the indigo rope-dyeing method, in which approx. 300 to 500 threads are drawn off from a creel and combined to form a rope or cable. 
     The rope-dyeing method is described in the BASF Technical Information “Continuous dyeing with indigo,” September 1995, page 4. 
     The rope is wound up before the further processing. To this end, a so-called ascending batch winder is used, in which a lap roller lies in a winding bed that is formed by two lapper rollers. At least one of the lapper rollers is driven and transfers the drive power by friction to the lap roller and the rope lap forming thereon. The axis of the lap roller is guided laterally in vertical slide rails. With increasing diameter of the lap roller or of the rope lap, the lap roller rises in the slide rails. 
     The rope is wound up on the lap roller in the manner of a cross-bobbin winding, i.e., a laying device is used which displaces the rope parallel to the axis of the lap roller during the rotation of the lap roller. In order to achieve a stable build-up of the rope lap, relatively high displacement speeds are necessary thereby. A stable lap build-up is decisively dependent on the angle of intersection and the ratio between the circumferential speed and displacement speed. In order to avoid windings of the rope falling down at the axial ends of the rope lap, extremely rapid reverse movements of the laying device are necessary at the axial ends of the rope lap. 
     Through the constant acceleration and braking of the laying device, enormous dynamic forces act on the laying device which limit the production speed. An ascending batch winder of this type is designed for a production speed of no more than 500 m/min as a rule. In a normal production, however, a speed of only 300-350 m/min. is generally used. 
     An additional problem lies in that changing contact points of the rope lap on the lap rollers form through the changing displacement of the rope. This constant change produces vibrations and oscillations that likewise have a negative impact on the production speed. 
     SUMMARY OF THE INVENTION 
     Accordingly, the invention renders possible a high production speed. 
     According to embodiments of the invention, a device of the type mentioned at the outset includes a bobbin carriage having a warp beam with side disks. A traversing device with a rope guide, through which the rope is guided, is arranged adjacent to the warp beam. 
     With an embodiment of the device of this type, production speeds can be achieved that are at least twice as fast as the production speed of an ascending batch winder. As a rule, a warp beam can be operated at a speed of 1000-1500 m/min, when threads are wound up lying next to one another directly from a creel. The rope can also be wound up at this speed. Since the warp beam has side disks, a traversing device with a rope guide can be used which can be moved relatively slowly and thus also exerts relatively low lateral forces on the rope. In particular, it is no longer necessary for a rapid movement reversal of the rope guide at the axial ends of the warp beam. The dynamic forces can thus be kept low, which has a favorable effect on the production speed as well as on the service life of the bobbin carriage. 
     Preferably, the warp beam is in positive engagement with a rotary actuator. The drive power of the rotary actuator can thus be transferred directly to the warp beam, thus to a shaft on which the rope lap then forms. With a positive engagement, large torques can be transferred in a controlled manner. High winding speeds can thus also be achieved, which is associated with certain uncertainties in the case of a frictional transfer of drive forces. 
     It is preferred hereby that the bobbin carriage is embodied or formed as a center wind. The warp beam is thus held in the area of its rotational axis. The laying of the rope lap on changing contact points is thus omitted. This leads to a substantial stabilizing of the warp beam during winding. This in turn has a positive effect on the winding speed, so that higher winding speeds can be achieved. Furthermore, the service life of the device is increased. 
     It is also preferred that the warp beam is connected to a braking device in a non-slip manner. The braking device can then act directly on the warp beam and thus transfer high braking forces. Even a warp beam with a virtually completed rope lap and a correspondingly large mass can then be braked in a relatively short time. This has advantages when a thread breakage occurs. The warp beam can then be braked so quickly that the broken thread is not yet incorporated into the rope lap. The thread can then be joined again and the production can be continued. 
     Preferably, the traversing device has a drive control that displaces the rope guide by a maximum of five times the thickness of the rope parallel to the axis of the warp beam for each revolution of the warp beam. In principle it is sufficient if the thread guide is displaced by one thickness of the rope for each revolution of the warp beam. In this case, the individual windings of the rope are placed next to one another on the warp beam. However, a somewhat higher traversing speed is not harmful. However, it is expedient to keep the traversing speed relatively low. 
     Preferably, the warp beam has a diameter detection device which is connected to a rotary actuator. The diameter detection device detects the diameter of the rope lap forming on the warp beam. This diameter is crucial for the speed at which the rope is drawn onto the warp beam or the rope lap forming thereon. Since this speed should be kept constant, the diameter detection device can be coupled to the rotary actuator in order to ensure in a simple manner that the circumferential speed of the rope lap remains constant. 
     Preferably, at least one pressure roller is provided, which can be brought to bear with a predetermined pressure on the circumference of the rope lap forming on the warp beam. The pressure roller, several pressure rollers or pressure rolls can also be provided, ensures that the rope is wound on the rope lap with a certain tension, without the individual threads being excessively strained in the rope, as would be the case with the use of a trumpet unit. Furthermore, the rope lap is homogenized. The rope lap has a certain elasticity on its outer circumference, so that the pressure roller can impress the currently wound up rope into the surface somewhat and thus can build up a uniform winding pressure. 
     Alternatively or additionally it can be provided that a rope braking device is arranged upstream of the bobbin carriage. With the rope braking device a certain tension can be produced in the rope, which then is lapped in the rope lap. 
     Preferably, a winding area of the bobbin carriage is encapsulated. This has two advantages. On the one hand, soiling to a greater extent of the environment of the bobbin carriage by particles that are spun off from the rope during winding is avoided. On the other hand, contamination from outside being inserted into the rope lap can also be avoided. 
     Preferably, in addition to a first thread path, which is guided through the rope-forming device, a second thread path is provided, which circumvents the rope-forming device and the rope guide, wherein the threads from the creel to the warp beam can be optionally guided through the first thread path or the second thread path. This results in a combination device, i.e., the threads from the creel can be wound up either in the form of a rope or with parallel thread guidance. The warp beam is likewise suitable for the winding up of a thread sheet with parallel thread guidance. 
     Embodiments of the invention are directed to a device for producing a rope lap. The device includes a rope-forming device structured and arranged to combine threads drawn off from a plurality of thread bobbins in a creel to form a rope, and a bobbin carriage having a warp beam with side disks and a traversing device with a rope guide arranged adjacent to the warp beam. The rope is guided through the rope guided. 
     According to features of the embodiments, the device can further include a rotary actuator arranged in positive engagement with the warp beam. 
     In accordance with other features of the embodiments, the bobbin carriage can be embodied as a center wind device. 
     According to further features of the embodiments of the present invention, a braking device can be coupled to the warp beam in a non-slip manner. 
     Moreover, the traversing device can include a drive control structured and arranged to displace the rope guide parallel to an axis of the warp beam by a maximum of five times a thickness of the rope for each revolution of the warp beam. The warp beam may include a diameter detection device connected to the rotary actuator. 
     In accordance with further embodiments of the invention, at least one pressure roller may be structured and arranged to bear a predetermined pressure on a circumference of a rope lap forming on the warp beam. 
     Further still, the device can include a rope braking device arranged upstream of the bobbin carriage. 
     According to still further features of the embodiments of the instant invention, a winding area of the bobbin carriage can be encapsulated. 
     Further, the threads from the creel through the rope forming device and from the rope forming device to the rope guide can form a first thread path, and a second thread path may be arranged to circumvent the rope-forming device and the rope guide. In this manner, the threads from the creel to the warp beam can be selectively guided along one of the first and second thread path. 
     The device can further include a preparation device structured and arranged to suction off a thread sheet formed between the creel and the bobbin carriage. 
     Still further, a fan reed can be positioned between the creel and the bobbin carriage. 
     Further embodiments of the invention are directed to a method of producing a rope lap. The method include drawing off threads from a plurality of bobbins in a creel, forming a rope from the drawn off threads, and guiding the rope to a warp beam with side disks through a guide of a traversing device. 
     In accordance with features of the embodiments, the method can include displacing the guide parallel to an axis of the warp beam by a maximum of five times a thickness of the rope for each revolution of the warp beam. The method can also include detecting a diameter of the rope lap. 
     According to features of the embodiments of the instant invention, the method can include exerting a predetermined pressure on a circumference of a rope lap forming on the warp beam. 
     The method can further include braking progression of the rope upstream of the bobbin carriage. 
     In accordance with still yet other features of the embodiments of the present invention, the threads from the creel through the rope forming device and from the rope forming device to the rope guide can form a first thread path, and a second thread path may be arranged to circumvent the rope-forming device and the rope guide, and the method can further include selecting one of the first and second thread paths along which the threads from the creel to the warp beam will be guided. 
     Other exemplary embodiments and advantages of the present invention may be ascertained by reviewing the present disclosure and the accompanying drawing. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention is further described in the detailed description which follows, in reference to the noted plurality of drawings by way of non-limiting examples of exemplary embodiments of the present invention, in which like reference numerals represent similar parts throughout the several views of the drawings, and wherein: 
         FIG. 1  illustrates a side view of a device for producing a rope lap; 
         FIG. 2  illustrates a plan view of the device; 
         FIG. 3  illustrates a side view of a bobbin carriage; and 
         FIG. 4  illustrates a plan view of the bobbin carriage. 
     
    
    
     DETAILED DESCRIPTION OF THE PRESENT INVENTION 
     The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to show structural details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the present invention may be embodied in practice. 
       FIG. 1  shows a device  1  for producing a rope lap from a rope. 
     The device  1  has a creel  3  in which a plurality of bobbins  4  are arranged. A thread can be drawn off from each bobbin  4 . Bobbins  4  are arranged on both sides of a central plane  5 , so that two thread sheets  6 ,  7  are drawn off from creel  3 . For example, in the order of magnitude of 300-500 threads can be drawn off from creel  3  if a corresponding number of bobbins  4  is available. 
     Two partial thread sheets  6 ,  7  are combined to form a thread sheet  8  and run through a preparation device  9  in which thread sheet  8  for example can be suctioned off. A preparation device  9  of this type is optional. 
     Thread sheet  8  can subsequently run through a fan reed  10 , which is also optional, i.e., it can be omitted. 
     Thread sheet  8  can then be guided to a deflection device  11 , which is arranged in the area of a warping mill  12 , which is explained in more detail in connection with  FIGS. 3 and 4 . Deflection device  11  has, for example, a diversion roller  13  for diverting thread sheet  8 . Thread sheet  8  is then guided back to a rope-forming device  14 , which forms a rope  2  from thread sheet  8 , in that it combines the thread sheet  8  laterally. The rope  2  is fed in turn to warping device  12 . 
     In warping device  12 , a warp beam  15 , i.e., a mechanically stable shaft which is provided at its two axial ends with side disks  16 ,  17 , is arranged. Warp beam  15  is supported in the area of its axis  18  and is in positive connection with a drive motor  19 , shown only diagrammatically. The output of drive motor  19  is transferred to warp beam  15  in a non-slip manner. Warping device  12  is embodied as a center wind. 
     A rope lap  20 , shown only in  FIG. 3 , is formed on warp beam  15 . To this end, rope  2  is guided through a rope guide  21  of a traversing device  22 , which is symbolized by a double arrow in  FIG. 4 . After running through rope guide  21 , rope  2  is also guided over a diversion roller  23 , before it is wound up on warp beam  15  or rope lap  20  forming thereon. 
     Traversing device has a guide  24  on which rope guide  21  can be moved parallel to the axis of warp beam  15 . A drive control, not shown in further detail, ensures that rope guide  21  is displaced by a maximum of five times the thickness of rope  2  parallel to axis  18  of warp beam  15  for each rotation of the warp beam  15 . In most cases, the drive control will even ensure that rope guide  21  is displaced only by the thickness of rope  2  for each revolution of warp beam  15 . A lateral displacement by twice, three times or four times the thickness of rope  2  is also possible. 
     For example, the thickness can be adjusted through rope guide  21 , which to this end is embodied or formed as an eyelet, through which rope  2  is guided. The inside diameter of rope guide  21  can then be used as a gauge of the thickness of rope  2 . Alternatively thereto, the thickness of rope  2 , i.e., the extension thereof parallel to axis  18 , can also be determined with a measuring device not shown in further detail. Rope  2  can also be placed under the tension prevailing during winding up and then the thickness of the rope can be measured by hand. To this end, one measurement per rope lap can be sufficient as a rule if the winding conditions do not change substantially. 
     Rope guide  21  can thus be moved relatively slowly parallel to axis  18  of warp beam  15  during the winding up of rope  2 . As soon as rope  2  reaches one of the side disks  16 ,  17 , the direction of movement of rope guide  21  is reversed. This change of direction can also be carried out at a comparatively low speed, however, so that the dynamic forces that act on rope guide  21  and thus on rope  2  can remain relatively low. 
     In  FIG. 3 , a pressure roller  25  is shown diagrammatically which bears against the circumference of rope lap  20  with a predetermined force, which is indicated by an arrow  26 . Pressure roller  25  ensures that rope  2  is wound up on rope lap  20  with a certain tension without the threads forming rope  2  being excessively strained. The threads of rope  2  thus are given a certain tension reserve, i.e., an overstretching of the threads can be avoided. 
     The pressure roller can also be used to determine the current diameter of rope lap  20 . This diameter is then reported back to drive motor  19 , which is then controlled such that the circumferential speed of rope lap  20  remains constant. 
     Instead of pressure roller  25 , of course, a different sensor could also be used for determining the diameter, for example, a laser sensor, which scans the position of the circumference of rope lap  20  continuously or in a time-selective manner. 
     Alternatively or additionally to the use of a pressure roller, a rope brake  27  can also be used, which is arranged upstream of the bobbin carriage embodied or formed as a warping device  12 . With rope brake  27  a certain tension can be produced in rope  2 , which then is wound into rope lap  20 . 
     Warp beam  15  is connected in a non-slip manner to a braking device  28 , which is shown only diagrammatically. Because braking device  28  can act on warp beam  15  in a non-slip manner, high braking forces can be produced which lead to a very rapid braking of warp beam  15  in the event of an error. For example, warp beam  15  can be braked so quickly that in the event of a thread breakage in creel  3 , the torn thread end has not yet run through rope-forming device  14  when warp beam  15  comes to a stop. Accordingly it is possible to join the thread again. 
     As can be discerned in particular from  FIG. 3 , warping device  12  can have a housing that encloses the winding area, that is, warp beam  15 . For the sake of clarity, the corresponding housing parts have been removed in  FIG. 4 . Only one opening is necessary in the housing, through which thread sheet  8  can be guided onto warp beam  15  or thread sheet lap  20  forming thereon. A capsule of this type or a housing of this type on the one hand prevents dirt from outside being wound into thread sheet lap  20 . It also prevents dust that is produced during winding of the thread sheet  2  from being released into the environment and distributed there. 
       FIG. 1  shows a first thread path that runs through rope-forming device  14  and rope guide  21 . In a manner not shown in further detail, device  1  can also be operated with a second thread path in which thread sheet  8  is guided directly to warp beam  15 . In this case, warping device  12  operates in a conventional manner to wind up a thread sheet  8  from threads fed parallel to a plane. 
     It is noted that the foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention. While the present invention has been described with reference to an exemplary embodiment, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Changes may be made, within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the present invention in its aspects. Although the present invention has been described herein with reference to particular means, materials and embodiments, the present invention is not intended to be limited to the particulars disclosed herein; rather, the present invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims.