Patent Description:
Patent Literature <NUM> (<CIT>) discloses an apparatus (yarn processor) configured to form a winding assembly (wound package) in such a way that a yarn is unwound from a yarn supply package (a supplying bobbin in Patent Literature <NUM>) formed by winding the yarn onto a yarn supplying bobbin and the processed yarn is wound onto a winding bobbin.

Among yarn layers formed by the yarn in the above-described yarn supply package, those on the inner side in the radial direction of the yarn supply package (i.e., those in the vicinity of the yarn supplying bobbin, which will be referred to as an inner layer part) may be lower in quality than a part on the outer side in the radial direction of the inner layer part. As described below, there are several reasons for this. The yarn supply package is typically formed by winding a yarn onto a yarn supplying bobbin having a circumferential surface in which slits are formed. When winding of a yarn onto such a yarn supplying bobbin starts, the yarn is treated in such a way that the tension of the yarn is higher than when the yarn is wound, in order to cause the yarn to be reliably held at a part of the yarn supplying bobbin, where the slits are formed. Furthermore, at the start of winding of a yarn onto a yarn supplying bobbin that is typically harder than the yarn, the yarn tends to be damaged due to, for example, contact with the yarn supplying bobbin. When a wound package which is to be sold as a product is contaminated with such a low-quality yarn in the inner layer part, the grade of the wound package may be decreased.

An object of the present invention is to avoid a wound package sold as a product from being contaminated with a low-quality yarn.

According to a first aspect of the invention, a yarn processor capable of processing a yarn unwound from a yarn supply package and winding the yarn onto a winding bobbin comprises: a yarn supply package retaining portion which is configured to retain the yarn supply package; a winding device which is capable of forming a wound package by winding the yarn onto the winding bobbin; a cutting unit which is capable of cutting the yarn before the yarn is wound onto the winding bobbin; a bobbin replacement unit which is capable of replacing the wound package formed by the winding device with a new winding bobbin as the winding bobbin and which is capable of performing yarn threading to the new winding bobbin; and a controller which is capable of performing: a formation termination process of cutting the yarn by controlling the cutting unit and terminating formation of the wound package by controlling the winding device; and a replacement process of replacing the formed wound package with the new winding bobbin and threading a yarn to the new winding bobbin by controlling the bobbin replacement unit, the controller performing the formation termination process and the replacement process when determining that an amount of the yarn in the wound package in formation reaches a predetermined target wound amount, the control unit generating, by calculation, remaining amount-related information that is numerical information regarding a remaining amount of the yarn remaining in the yarn supply package which is retained by the yarn supply package retaining portion and from which the yarn is being unwound, and when determining in remaining amount reduction determination that a numerical value of the remaining amount-related information is not larger than a predetermined value, the control unit performing the formation termination process to cause the winding device to form a formation forcible termination wound package that is a wound package having a smaller amount of the yarn than the target wound amount.

According to this aspect, when the remaining amount of the yarn in the yarn supply package becomes not larger than the predetermined value, i.e., when unwinding of the yarn in the inner layer part from the yarn supply package starts, the formation of the formation forcible termination wound package is terminated. This makes it possible to avoid the inclusion of the low-quality yarn in the formation forcible termination wound package that is a product. It is therefore possible avoid the contamination of the low-quality yarn in the wound package that is a product.

According to a second aspect of the invention, the yarn processor of the first aspect is arranged so that the controller stores individual information of the formation forcible termination wound package and information regarding the remaining amount reduction determination, in association with each other.

According to this aspect, it is possible to discern the formation forcible termination wound package from the other wound packages by utilizing the information stored in the controller.

According to a third aspect of the invention, the yarn processor of the first or second aspect is arranged so that the yarn supply package retaining portion is capable of retaining, as the yarn supply package, a first yarn supply package and a second yarn supply package different from the first yarn supply package and is capable of uninterruptedly supplying the yarn when a yarn connecting portion is formed by connecting a start end portion of a yarn in the first yarn supply package with a terminal portion of a yarn in the second yarn supply package, a detection unit is provided to be able to detect information indicating occurrence of yarn supply package switching in which unwinding of the yarn from the first yarn supply package finishes at the yarn supply package retaining portion, the yarn connecting portion starts to move, and unwinding of the yarn from the second yarn supply package starts, when the remaining amount reduction determination is performed while the yarn is being unwound from the first yarn supply package, the controller terminates formation of the formation forcible termination wound package by performing the formation termination process, the controller performs the replacement process after the formation of the formation forcible termination wound package, and the controller causes the winding device to form an inner-layer-part-inclusive wound package that is a wound package and includes the yarn unwound from the first yarn supply package after the remaining amount reduction determination, by winding the yarn unwound from the first yarn supply package and processed after the remaining amount reduction determination onto the new winding bobbin attached to the winding device in the replacement process that is performed after the formation of the formation forcible termination wound package, and when switching determination is performed based on a result of detection by the detection unit to determine whether the yarn supply package switching occurs while the inner-layer-part-inclusive wound package is being formed, the control unit terminates formation of the inner-layer-part-inclusive wound package by performing the formation termination process, the control unit performs the replacement process after the formation of the inner-layer-part-inclusive wound package, and the control unit performs the replacement process after the formation of the inner-layer-part-inclusive wound package to wind the yarn unwound from the second yarn supply package and processed after the switching determination onto the new winding bobbin attached to the winding device.

According to this aspect, the yarn can be uninterruptedly supplied because unwinding of the yarn from the second yarn supply package starts when unwinding of the yarn from the first yarn supply package ends. With this arrangement, however, the formation of the inner-layer-part-inclusive wound package may continue even after the end of the unwinding of the yarn in the inner layer part of the first yarn supply package from the first yarn supply package. In such a case, a large amount of the high-quality yarn in the outer layer part of the second yarn supply package may be disadvantageously wound onto the inner-layer-part-inclusive wound package, with the result that the high-quality yarn may be wasted. According to the aspect, at the execution of the switching determination, the inner-layer-part-inclusive wound package is replaced with a new winding bobbin. With this arrangement, it is possible to immediately wind the yarn in the second yarn supply package onto the new winding bobbin after the occurrence of the yarn supply package switching. It is therefore possible to suppress a large amount of the high-quality yarn in the second yarn supply package from being included in the inner-layer-part-inclusive wound package.

According to a fourth aspect of the invention, the yarn processor of the third aspect is arranged so that the controller stores individual information of the inner-layer-part-inclusive wound package and information regarding the switching determination, in association with each other.

According to this aspect, it is possible to discern the inner-layer-part-inclusive wound package from the other wound packages by utilizing the information stored in the controller.

According to a fifth aspect of the invention, the yarn processor of the third or fourth aspect is arranged to further comprise a marking unit which is capable of performing a marking operation of providing a mark on the wound package that is being formed by the winding device, when the switching determination is performed, the controller controlling and causing the marking unit to perform, as the marking operation, an inner layer part inclusive marking operation of providing a mark on the inner-layer-part-inclusive wound package.

According to this aspect, the inner layer part inclusive marking operation makes it possible to discern a wound package without a mark from the inner-layer-part-inclusive wound package by appearance.

According to a sixth aspect of the invention, the yarn processor of any one of the first to fourth aspects further comprises a marking unit which is capable of performing a marking operation of providing a mark on the wound package that is being formed by the winding device, when the remaining amount reduction determination is performed, the controller controlling and causing the marking unit to perform, as the marking operation, an inner layer part avoiding marking operation of providing a mark on the formation forcible termination wound package.

According to this aspect, the inner layer part avoiding marking operation makes it possible to discern a wound package without a mark from the formation forcible termination wound package by appearance.

According to a seventh aspect of the invention, the yarn processor of the fifth aspect is arranged so that, when the remaining amount reduction determination is performed, the controller controlling and causing the marking unit to perform, as the marking operation, an inner layer part avoiding marking operation of providing a mark on the formation forcible termination wound package.

According to an eighth aspect of the invention, the yarn processor of the seventh aspect is arranged so that the marking unit is capable of performing the marking operation so that the formation forcible termination wound package is discerned from the inner-layer-part-inclusive wound package, and the controller controls and causes the marking unit to perform the inner layer part inclusive marking operation and the inner layer part avoiding marking operation so that the formation forcible termination wound package is discerned from the inner-layer-part-inclusive wound package.

According to this aspect, it is possible to easily discern the formation forcible termination wound package from the inner-layer-part-inclusive wound package by appearance. On this account, it is possible to discern the formation forcible termination wound package from the inner-layer-part-inclusive wound package even if they are unintentionally mixed.

According to a ninth aspect of the invention, the yarn processor of any one of the fifth to eighth aspects is arranged so that the marking unit includes the winding device, the winding device includes: a rotational driving unit which is configured to rotationally drive the wound package about a central axis of the wound package; and a traverse unit including a traverse guide configured to traverse the yarn and a guide driving unit configured to reciprocally drive the traverse guide along the axial direction of the wound package, and the controller causes the winding device to perform the marking operation in such a way that the controller controls the traverse unit to stop the traverse guide at a predetermined position in the axial direction while controlling the rotational driving unit to rotate the wound package.

According to this aspect, as the marking operation, it is possible to form a so-called straight winding on the wound package. This makes it possible to achieve the marking operation by a simple means.

The following will describe an embodiment of the present invention. The following will outline a yarn processing facility <NUM> including a false-twist texturing machine <NUM> (described later) of the present embodiment, with reference to the block diagram of <FIG>. As shown in <FIG>, the yarn processing facility <NUM> includes false-twist texturing machines <NUM> (yarn processors of the present invention) and a management device <NUM>. The false-twist texturing machines <NUM> are, for example, aligned along a predetermined base longitudinal direction (see e.g., <FIG>). Each false-twist texturing machine <NUM> can perform false twisting of yarns Y (see e.g., <FIG>) made of, for example, synthetic fibers such as polyester or nylon (polyamide fibers). Each yarn Y is, for example, a multi-filament yarn formed of filaments (not illustrated). As described below, each false-twist texturing machine <NUM> is configured to process yarns Y supplied from a yarn supplying unit <NUM> by a processing unit <NUM> and form wound packages Pw by winding the yarns Y onto winding bobbins Bw attached to a winding unit <NUM>. Each false-twist texturing machine <NUM> is controlled by a machine controller <NUM> that is a computer device provided in each false-twist texturing machine <NUM>.

The management device <NUM> is a host computer configured to integrally manage information obtained by the machine controllers <NUM>. The management device <NUM> includes a management input unit 101a (e.g., a keyboard), a management output unit 101b (e.g., a display), and a management storage unit 101c (e.g., a hard disk). The information management unit <NUM> of the present embodiment is equivalent to a combination of the management device <NUM> and the machine controllers <NUM>.

Now, the overall structure of a false-twist texturing machine <NUM> will be described with reference to <FIG> and <FIG>. <FIG> is a profile of the false-twist texturing machine <NUM>. <FIG> is a schematic diagram of the false-twist texturing machine <NUM>, expanded along paths of yarns Y (yarn paths). Hereinafter, a vertical direction to the sheet of <FIG> is defined as the above-described base longitudinal direction, and a left-right direction to the sheet is defined as a base width direction. The direction orthogonal to the base longitudinal direction and the base width direction is defined as the up-down direction (vertical direction) in which the gravity acts. A direction in which a yarn Y runs will be referred to as a yarn running direction. The false-twist texturing machine <NUM> includes a yarn supplying unit <NUM> for supplying the yarns Y, a processing unit <NUM> which processes (false-twists) the yarns Y supplied from the yarn supplying unit <NUM>, a winding unit <NUM> which winds the yarns Y processed by the processing unit <NUM> onto a winding bobbins Bw, and the machine controller <NUM> (a controller of the present invention).

The yarn supplying unit <NUM> includes a creel stand <NUM> retaining yarn supply packages Ps, and supplies the yarns Y to the processing unit <NUM>. The processing unit <NUM> is configured to unwind the yarns Y from the yarn supplying unit <NUM> and process the yarns Y. In the processing unit <NUM>, the following members are provided in this order from the upstream in the yarn running direction: first feed rollers <NUM>; a twist-stopping guide <NUM>; a first heater <NUM>; a cooler <NUM>; a false-twisting device <NUM>; second feed rollers <NUM>; a second heater <NUM>; and third feed rollers <NUM>. These constituent features of the processing unit <NUM> are provided in, for example, each of later-described spindles <NUM> (see <FIG>). The winding unit <NUM> includes plural winding devices <NUM>. Each winding device <NUM> winds the yarn Y for which the false winding has been performed at the processing unit <NUM> onto the winding bobbin Bw, and forms a wound package Pw. The winding part <NUM> is further provided with automatic doffers <NUM> which correspond to the respective winding devices <NUM> and are configured to replace completed wound packages Pw with new empty winding bobbins Bw.

The machine controller <NUM> is configured to be able to control each constituent feature of the yarn supplying unit <NUM>, the processing unit <NUM>, and the winding unit <NUM>. The machine controller <NUM> is, for example, a typical computer device. The machine controller <NUM> includes a machine input unit 5a, a machine output unit 5b, and a machine storage unit 5c (see <FIG>). The machine input unit 5a includes, for example, an unillustrated touch panel and/or a keyboard that are not illustrated, and is arranged to be operable by an operator. The display machine output unit 5b includes, for example, an unillustrated display and is capable of outputting information. The machine storage unit 5c is configured to store various sets of information for controlling the constituent features of the yarn supplying unit <NUM>, the processing unit <NUM>, and the winding unit <NUM>. The machine controller <NUM> is configured to control the constituent features of the yarn supplying unit <NUM>, the processing unit <NUM>, and the winding unit <NUM> based on the sets of information. Alternatively, the machine controller <NUM> may indirectly control the constituent features of the yarn supplying unit <NUM>, the processing unit <NUM>, and the winding unit <NUM> through controllers (not illustrated) for controlling these constituent features. The machine controller <NUM> is electrically connected to the management device <NUM> which is a host computer. The machine controller <NUM> is able to perform at least a formation termination process and a replacement process that will be described later.

The false-twist texturing machine <NUM> includes a main base <NUM> and a winding base <NUM> which are placed to be spaced apart from each other in the base width direction. The main base <NUM> and the winding base <NUM> are substantially identical in length in the base longitudinal direction. The main base <NUM> and the winding base <NUM> are arranged to face each other in the base width direction. The false-twist texturing machine <NUM> includes units which are termed spans each of which includes a pair of the main base <NUM> and the winding base <NUM>. In one span, each device is placed so that the yarns Y running while being aligned in the base longitudinal direction can be subjected to false-twist texturing at the same time. In the false-twist texturing machine <NUM>, the spans are placed in a left-right symmetrical manner to the sheet, with a center line C of the base width direction of the main base <NUM> as a symmetry axis (main base <NUM> is shared between the left span and the right span). The spans are aligned in the base longitudinal direction.

A group of constituent features through which a single yarn Y supplied from the yarn supplying unit <NUM> passes before reaching the winding unit <NUM> is termed a spindle. The false-twist texturing machine <NUM> includes spindles <NUM> (see <FIG>) that are identical in number with the winding devices <NUM>. Roughly speaking, the spindles <NUM> are aligned along the base longitudinal direction. The inclusion relation is as follows: the false-twist texturing machine <NUM> includes plural spans, and each span includes plural spindles <NUM>. The false-twist texturing machine <NUM> is able to false-twist the yarn Y in the spindle <NUM> to which the yarn Y is threaded.

The structure of the yarn supplying unit <NUM> will be described with reference to <FIG> and <FIG>. The creel stand <NUM> of the yarn supplying unit <NUM> includes yarn supply package retaining portions <NUM> (see <FIG>) which correspond to the respective spindles <NUM>. Each of the yarn supply package retaining portions <NUM> is arranged so that two yarn supply packages Ps are attached and detached to and from the portion. In other words, each yarn supply package retaining portion <NUM> has two package attachment units <NUM>. For the sake of convenience, one of the two package attachment units <NUM> is termed a first attachment unit <NUM>, whereas the other is termed a second attachment unit <NUM>. To and from each of the first attachment unit <NUM> and the second attachment unit <NUM>, a single yarn supply package Ps can be attached and detached. The attachment and detachment of the yarn supply packages Ps to and from the package attachment unit <NUM> are performed, by, for example, an operator.

Each yarn supply package retaining portion <NUM> of the yarn supplying unit <NUM> is arranged to be able to uninterruptedly supply the yarn Y by the arrangement described below. For example, as shown in <FIG>, a yarn supply package Ps1 that is one of the yarn supply packages Ps is attached to the first attachment unit <NUM>. On the other hand, another yarn supply package Ps2 different from the yarn supply package Ps1 is attached to the second attachment unit <NUM>. The yarn Y is unwound from the yarn supply package Ps1. A terminal portion of the yarn Y in the yarn supply package Ps1 is joined with (connected to) a start end portion of the yarn Y in the yarn supply package Ps2. Due to this, a node K (yarn connecting portion) is formed between the two yarns Y. This arrangement makes it possible to uninterruptedly supply the yarn Y from the yarn supply package Ps2 after the yarn supply package Ps1 becomes empty. To be more specific, immediately after the supply of the yarn Y from the yarn supply package Ps1 ends and the yarn supply package Ps1 becomes empty, the node K is pulled to the downstream side in the yarn running direction (i.e., to the winding device <NUM> side), with the result that the yarn Y is unwound from the yarn supply package Ps2. In other words, after the unwinding of the yarn Y from the yarn supply package Ps attached to one package attachment unit <NUM> finishes, unwinding of the yarn Y from the next yarn supply package Ps attached to the other package attachment unit <NUM> starts. For the sake of convenience, this action will be referred to as yarn supply package switching. Because of this, the yarn Y is uninterruptedly supplied. Thereafter, the yarn supply packages Ps (yarn supplying bobbin Bs) having become empty is replaced with a new yarn supply package Ps by, for example, the operator. Furthermore, a start end portion of the yarn supply package Ps2 is joined with a terminal portion of the new yarn supply package Ps by, for example, the operator. As these steps are repeated, the yarn Y is uninterruptedly supplied from the yarn supplying unit <NUM>.

On the downstream side in the yarn running direction of each yarn supply package retaining portion <NUM>, a yarn detection sensor <NUM> (a detection unit of the present invention) is provided. The yarn detection sensor <NUM> is configured to be able to detect from which one of the attachment units, the first attachment unit <NUM> and the second attachment unit <NUM>, the yarn Y is being supplied. As shown in <FIG>, the yarn detection sensor <NUM> includes a first detection unit <NUM> and a second detection unit <NUM>. The first detection unit <NUM> is configured to be able to detect whether the yarn Y is being supplied from the first attachment unit <NUM>. The second detection unit <NUM> is configured to be able to detect whether the yarn Y is being supplied from the second attachment unit <NUM>. Each of the first detection unit <NUM> and the second detection unit <NUM> is, for example, an optical sensor configured to optically detect the yarn Y. For further details of the yarn detection sensor <NUM>, see e.g., <CIT>. Alternatively, the first detection unit <NUM> and the second detection unit <NUM> may be contact sensors, for example.

In the yarn running direction, on the downstream of each yarn supply package retaining portion <NUM> and on the upstream of the first feed roller <NUM>, a cutter <NUM> capable of cutting the running yarn Y is provided. The cutter <NUM> is electrically connected to the machine controller <NUM>.

The structure of the processing unit <NUM> will be described with reference to <FIG> and <FIG>. For the sake of convenience, the following will describe only portions of the processing unit <NUM>, which correspond to one spindle <NUM>.

The first feed rollers <NUM> are arranged to unwind a yarn Y from a yarn supply package Ps attached to the yarn supplying unit <NUM> and feed the yarn Y to the first heater <NUM>. The first feed rollers <NUM> are provided on the upstream side in the yarn running direction of the twist-stopping guide <NUM>. The conveyance speed of conveying the yarn Y by the first feed rollers <NUM> is substantially identical with unwinding speed V (see <FIG>) at which the yarn Y is unwound from the yarn supply package Ps. Information of a set value of the conveyance speed of the yarn Y by the first feed rollers <NUM> is stored in, for example, the machine controller <NUM> in advance. On the upstream side in the yarn running direction of the first feed rollers <NUM>, the above-described cutter <NUM> is provided. When yarn breakage occurs, unfavorable winding of the yarn Y onto a rotationally-driven member such as the first feed rollers <NUM> can be prevented by cutting the yarn Y by the cutter <NUM>.

The twist-stopping guide <NUM> is provided to prevent twist of the yarn Y formed by the false-twisting device <NUM> from being propagated to the upstream in the yarn running direction of the twist-stopping guide <NUM>. The twist-stopping guides <NUM> are placed downstream of the first feed rollers <NUM> in the yarn running direction, and placed upstream of the first heater <NUM> in the yarn running direction.

The first heater <NUM> heats the yarns Y sent from the first feed rollers <NUM>. The first heater <NUM> is placed downstream of the twist-stopping guide <NUM> in the yarn running direction and upstream of the cooler <NUM> in the yarn running direction. In the present embodiment, the first heater <NUM> is arranged to heat a single yarn Y for the sake of simplicity. The disclosure, however, is not limited to this arrangement. The first heater <NUM> may be arranged to be able to simultaneously heat plural yarns Y.

The cooler <NUM> is configured to cool the yarn Y heated at the first heater <NUM>. The coolers <NUM> are placed downstream of each first heater <NUM> in the yarn running direction, and placed upstream of the false-twisting devices <NUM> in the yarn running direction. In the present embodiment, the cooler <NUM> is arranged to cool a single yarn Y for the sake of simplicity. The disclosure, however, is not limited to this arrangement. The cooler <NUM> may be arranged to be able to simultaneously cool plural yarns Y.

The false-twisting device <NUM> is configured to twist the yarn Y. The false-twisting device <NUM> is a so-called disc-friction-type false-twisting device, for example. The disclosure, however, is not limited to this arrangement. The false-twisting device <NUM> is placed downstream of the cooler <NUM> in the yarn running direction and upstream of the second feed rollers <NUM> in the yarn running direction.

The second feed rollers <NUM> are configured to send the yarns Y processed by the false-twisting device <NUM> to the second heater <NUM>. The conveyance speed of conveying the yarn Y by the second feed rollers <NUM> is higher than the conveyance speed of conveying the yarn Y by the first feed rollers <NUM>. The yarn Y is therefore drawn between the first feed rollers <NUM> and the second feed rollers <NUM>. Information of a set value of the conveyance speed of the yarn Y by the second feed rollers <NUM> is stored in, for example, the machine controller <NUM> in advance.

The second heater <NUM> heats the yarn Y sent from the second feed rollers <NUM>. The second heater <NUM> extends along the vertical direction. The second heater <NUM> is arranged to heat a single yarn Y for the sake of simplicity. The disclosure, however, is not limited to this arrangement. The second heater <NUM> may be arranged to be able to simultaneously heat plural yarns Y.

The third feed rollers <NUM> send the yarn Y heated by the second heater <NUM> to the winding device <NUM>. The conveyance speed of conveying the yarn Y by the third feed rollers <NUM> is lower than the conveyance speed of conveying the yarn Y by the second feed rollers <NUM>. The yarn Y is therefore relaxed between the second feed rollers <NUM> and the third feed rollers <NUM>. Information of a set value of the conveyance speed of the yarn Y by the third feed rollers <NUM> is stored in, for example, the machine controller <NUM> in advance.

In the processing unit <NUM> arranged as described above, the yarn Y drawn between the first feed rollers <NUM> and the second feed rollers <NUM> is twisted by the false-twisting device <NUM>. The twist formed by the false-twisting devices <NUM> propagates to the twist-stopping guide <NUM> but does not propagate to the upstream of the twist-stopping guide <NUM> in the yarn running direction. The yarn Y which is twisted and drawn is heated at the first heater <NUM> and thermally set. After that, the yarn Y is cooled at the cooler <NUM>. The yarn Y is untwisted at the downstream of the false-twisting device <NUM>. However, each filament is maintained to be wavy in shape on account of the thermal setting described above. After being false-twisted by the false-twisting device <NUM>, the yarn Y is thermally treated at the second heater <NUM> while being relaxed between the second feed rollers <NUM> and the third feed rollers <NUM>, and then the yarn Y is guided to the downstream side in the yarn running direction. Finally, the yarn Y sent from the third feed rollers <NUM> is wound onto the winding bobbin Bw by the winding device <NUM>. Accordingly, the wound package Pw is formed.

The structure of the winding unit <NUM> will be described with reference to <FIG> and <FIG>. The winding unit <NUM> includes winding devices <NUM> (marking units of the present invention) and automatic doffers <NUM> (see <FIG>; bobbin replacement units of the present invention) that are provided to correspond to the respective winding devices <NUM>. The winding devices <NUM> belong to the respective spindles <NUM> (see <FIG>). Each winding device <NUM> is configured to wind the yarn Y onto the winding bobbin Bw. Each winding device <NUM> includes, for example, a fulcrum guide <NUM>, a traverse device <NUM> (traverse unit of the present invention), a cradle <NUM>, and a winding roller <NUM>. The fulcrum guide <NUM> is a guide which functions as a fulcrum when the yarn Y is traversed. For example, the traverse device <NUM> can traverse the yarn Y by a traverse guide <NUM> which is attached to an endless belt driven in a reciprocating manner by a motor <NUM> (a guide driving unit of the present invention). That is to say, the traverse device <NUM> is configured to reciprocate the traverse guide <NUM> along the axial direction (hereinafter, a winding bobbin axial direction) of the winding bobbin Bw (wound package Pw). The cradle <NUM> is arranged to be able to support the winding bobbin Bw (wound package Pw) to be rotatable about the central axis of the wound package Pw. The winding roller <NUM> is arranged to rotate the wound package Pw about the central axis and to apply contact pressure to the surface of the wound package Pw. The winding roller <NUM> is rotationally driven by the motor <NUM> (a rotational driving unit of the present invention) while being in contact with the surface of the wound package Pw, for example. With this arrangement, the wound package Pw is passively rotated by the friction force and the shape of the wound package Pw is adjusted by the contact pressure applied to the surface of the wound package Pw. Instead of rotationally driving the winding roller <NUM>, the wound package Pw may be directly rotationally driven by an unillustrated motor.

The automatic doffer <NUM> is arranged to detach the wound package Pw from the winding device <NUM> and attach an empty winding bobbin Bw to the winding device <NUM>. To put it differently, the automatic doffer <NUM> is arranged to be able to replace the completed wound package Pw with an empty winding bobbin Bw in the winding unit <NUM>. The automatic doffer <NUM> is provided with an unillustrated cutter which is able to cut the yarn Y at around the wound package Pw. As the running yarn Y is cut by the cutter, the formation of the wound package Pw is completed. Even after the yarn is cut by the cutter, the yarn Y is unwound from the yarn supply package Ps at substantially the same speed as the winding onto the winding bobbin Bw, and is kept supplied to the winding device <NUM> side. The automatic doffer <NUM> includes an unillustrated suction which is able to suck, capture, and hold the running yarn Y supplied to the winding device <NUM>, after the finish of the formation of a wound package Pw and until the start of the winding of the yarn Y onto the next winding bobbin Bw. Before the yarn Y is threaded to the winding bobbin Bw to which the yarn Y is to be wound next, a part of the yarn Y sucked by the suction is removed. The automatic doffer <NUM> is configured to thread the yarn Y to an empty winding bobbin Bw attached to the winding device <NUM>. For details of the structure of the automatic doffer <NUM>, see <CIT>, for example.

In the winding unit <NUM> structured as above, the yarn Y which is sent from the third feed rollers <NUM> described above is wound onto the winding bobbin Bw by each winding device <NUM>, and the wound package Pw is formed (winding process). As the yarn Y is cut by the cutter of the automatic doffer <NUM> and the winding device <NUM> is stopped, the winding process of winding the yarn Y onto the winding bobbin Bw (i.e., formation of the wound package Pw) is finished. Almost at the same time, the yarn Y supplied to the winding device <NUM> is sucked and retained by the suction, and the wound package Pw having been formed is detached from the cradle <NUM> by the automatic doffer <NUM>. Immediately after this, a new empty winding bobbin Bw is attached to the cradle <NUM> by the automatic doffer <NUM>, and a yarn Y is threaded to the new winding bobbin Bw. As a result, it becomes possible to start winding of the yarn Y onto the new winding bobbin Bw. Hereinafter, for the sake of convenience, a process in which the machine controller <NUM> cuts the yarn Y by controlling the cutter of the automatic doffer <NUM> and terminates the formation of the wound package Pw by controlling the winding device <NUM> will be referred to as a formation termination process. For the sake of convenience, a process in which the machine controller <NUM> controls the automatic doffer <NUM> to replace the finished wound package Pw with a new winding bobbin Bw and to thread the yarn Y onto the new winding bobbin Bw will be referred to as a replacement process.

Among yarn layers formed by the yarn Y in the above-described yarn supply package Ps, those on the inner side in the radial direction of the yarn supply package Ps (i.e., those in the vicinity of the yarn supplying bobbin Bs, which will be referred to as an inner layer part) may be lower in quality than a part on the outer side in the radial direction of the inner layer part. As described below, there are several reasons for this. A yarn supply package Ps is typically formed by winding a yarn onto a yarn supplying bobbin Bs having a circumferential surface in which slits (not illustrated) are formed. When winding of a yarn onto such a yarn supplying bobbin Bs starts, the yarn Y is treated in such a way that the tension of the yarn Y is higher than when the yarn Y is wound, in order to cause the yarn Y to be reliably held at a part of the yarn supplying bobbin Bs, where the slits are formed. Furthermore, at the start of winding of the yarn Y onto the yarn supplying bobbin Bs that is typically harder than the yarn Y, the yarn Y tends to be damaged due to, for example, contact with the yarn supplying bobbin Bs. When such a low-quality yarn Y in the inner layer part is contaminated in a wound package Pw which is to be sold as a product, the grade of the wound package Pw may be decreased.

In the present embodiment, in order to avoid a wound package Pw which is to be sold as a product from being contaminated with a low-quality yarn Y, the machine controller <NUM> performs processes described below. Hereinafter, unless otherwise specified, the explanation deals with one specific spindle <NUM> among the spindles <NUM>.

As a premise, the machine controller <NUM> is configured to be able to calculate the remaining amount of a yarn Y in a yarn supply package Ps from which the yarn Y is being unwound (hereinafter, an unwinding-in-progress package) at a predetermined reference time. (Hereinafter, this will be referred to as remaining amount calculation. ) In the present embodiment, the reference time is a time at which the remaining amount calculation starts. Furthermore, the machine controller <NUM> is configured to be able to set in advance the content of a process performed when the remaining amount of the yarn Y in the yarn supply package Ps is reduced. (Hereinafter, this process will be referred to as an at-reduction process. ) The remaining amount calculation and the at-reduction process will be specifically described below.

The following will describe the remaining amount calculation. The machine controller <NUM> is configured to be able to calculate (i.e., estimate) the remaining amount of the yarn Y included in the unwinding-in-progress package at the reference time, based on initial amount information, unwinding unit amount information, and cumulative time information that are described below. For convenience, the initial amount information, the unwinding unit amount information, and the cumulative time information may be collectively termed basic information.

The initial amount information is information related to an initial amount (initial weight or initial length) of a yarn Y in a yarn supply package Ps before unwinding of the yarn Y starts. The initial amount information is, for example, set in advance in the machine controller <NUM> as information in common between all yarn supply packages Ps of all spindles <NUM> of a single false-twist texturing machine <NUM>. As more specific information, in the present embodiment, information of the above-described initial weight WF and information of fineness (i.e., weight per unit length) of the yarn Y are stored in the machine controller <NUM> as the initial amount information. The unit of the weight of the yarn supply package Ps is, for example, kilogram. The fineness of the yarn Y is represented as F. The unit of the fineness is, for example, decitex. Decitex indicates the weight (gram) of the yarn Y per <NUM> meters.

The unwinding unit amount information is information regarding the amount of a yarn Y unwound from a yarn supply package Ps per unit time. The unwinding unit amount information is, for example, information of the above-described unwinding speed V. In the present embodiment, for the sake of convenience, the unwinding speed V is substantially constant during a winding process. The unit of the unwinding speed is, for example, meter per minute. The unwinding unit amount information is, for example, set in advance in the machine controller <NUM> as information in common between all spindles <NUM> of a single false-twist texturing machine <NUM>. The machine controller <NUM> obtains information of the unwinding speed V based on, for example, the information of a set value of the rotation number of the first feed rollers <NUM>.

The cumulative time information is information regarding the total time of unwinding of a yarn Y from a yarn supply package Ps (cumulative time). For the sake of convenience, the cumulative time of a yarn supply package Ps from which a yarn Y is unwound is represented as tin. The cumulative time information is obtained in the following manner. To begin with, when, for example, unwinding of the yarn Y from the above-described yarn supply package Ps1 (see <FIG>) starts, the start of the unwinding of the yarn Y at the first attachment unit <NUM> is detected by the yarn detection sensor <NUM>. At this stage, the machine controller <NUM> sets tin at a predetermined initial time (reset process). The initial time is zero, for example. Thereafter, the machine controller <NUM> increases tin over time (updates tin) while the yarn Y is being unwound from the yarn supply package Ps. When the unwinding of the yarn Y from the yarn supply package Ps is temporarily stopped due to, for example, yarn breakage (i.e., when a stop time is generated), the machine controller <NUM> temporarily stops the update of tin. In this way, the machine controller <NUM> obtains only the time (detection time) during which the unwinding of the yarn Y from the yarn supply package Ps is detected by the yarn detection sensor <NUM>, as the cumulative time (tin). When a yarn Y is being unwound from a yarn supply package Ps, the machine controller <NUM> is able to obtain cumulative time information of that yarn supply package Ps.

During the winding process, the machine controller <NUM> determines whether yarn supply package switching with which the yarn supply package Ps supplying the yarn Y is switched has occurred, based on a detection result of the yarn detection sensor <NUM>. For example, in <FIG>, the yarn supply package switching is a matter in which unwinding of the yarn Y from the yarn supply package Ps1 ends (end of unwinding) and unwinding of the yarn Y from the yarn supply package Ps2 starts. When the state of the yarn detection sensor <NUM> is switched from a state in which the yarn Y is detected by one of the first detection unit <NUM> and the second detection unit <NUM> to a state in which the yarn Y is detected by the other of the first detection unit <NUM> and the second detection unit <NUM>, the machine controller <NUM> determines that the yarn supply package switching has occurred. When it is determined that the yarn supply package switching has occurred, the machine controller <NUM> sets tin at the predetermined initial time by performing the above-described reset process.

As described above, the machine controller <NUM> generates (i.e., obtains), by calculation, the initial amount information, the unwinding unit amount information, and the cumulative time information as the basic information.

When the remaining amount of the yarn Y in the unwinding-in-progress package at the reference time is WR, the machine controller <NUM> performs the remaining amount calculation by using the basic information and based on the equation below. In the equation, "<NUM>" and "<NUM>" are coefficients for converting the units of the numbers on the respective sides of the equation to kilogram.

When the ratio of the remaining amount of the yarn Y in the unwinding-in-progress package to the initial amount (hereinafter, this ratio will be referred to as a remaining amount ratio) is R, the machine controller <NUM> is able to calculate the remaining amount ratio based on the equation below. The machine controller <NUM> may calculate the remaining amount ratio as a percentage of WR to WF (i.e., a remaining amount percentage).

Alternatively, a machine controller <NUM> may calculate the remaining amount ratio by utilizing only the basic information, without utilizing WR.

When the remaining time during which the yarn Y can be supplied from the unwinding-in-progress package is tR, the machine controller <NUM> may estimate tR based on, for example, the equation below. The unit of tR is minute.

The following will describe an arrangement for the at-reduction process with reference to <FIG> illustrates items such as a selection screen for selecting a processing mode of the false-twist texturing machine <NUM>. For the sake of convenience, a display is provided as the machine output unit 5b and a touch panel is provided as the machine input unit 5a to overlap the display (see <FIG>). It is noted that the machine input unit 5a and the machine output unit 5b may be arranged differently.

The machine controller <NUM> stores information of plural options of the at-reduction process in the machine storage unit 5c. The machine controller <NUM> is, for example, configured to be able to display the options of the at-reduction process on the machine output unit 5b (see a screen S1 in <FIG>). The machine controller <NUM> is configured to be able to set in advance the content of the at-reduction process in accordance with an input to the machine input unit 5a by the operator. For example, options "Nothing" and "Formation of Inner-Layer-Part-Inclusive Wound Package" are displayed in an upper part of the screen S1. "Nothing" indicates that no particular process is performed when the remaining amount of the unwinding-in-progress package is reduced. "Formation of Inner-Layer-Part-Inclusive Wound Package" indicates that, when the remaining amount of the unwinding-in-progress package is reduced, a later-described inner-layer-part-inclusive wound package is formed. Furthermore, for example, an entry field for inputting a processing condition is displayed in a lower part of the screen S1. The processing condition indicates what condition must be satisfied to start the execution of the at-reduction process. In the example shown in <FIG>, the machine controller <NUM> is arranged to execute the at-reduction process when the above-described remaining amount ratio (R) becomes equal to or less than <NUM> %. As the at-reduction process, the machine controller <NUM> executes a process of forming a later-described inner-layer-part-inclusive wound package when the "Formation of Inner-Layer-Part-Inclusive Wound Package" is selected in advance and a predetermined processing condition is satisfied.

For facilitating the understanding of the explanation below, with reference to <FIG>, the following will describe unwinding of the yarn Y from each yarn supply package Ps and formation of each wound package Pw when the at-reduction process is not performed (i.e., when the above-described option "Nothing" is selected). <FIG> are graphs showing the relationship between a yarn amount in a known processing mode in which the at-reduction process is not performed and a time. To be more specific, <FIG> is a graph showing the relationship between the remaining amount (vertical axis) of a yarn Y in a yarn supply package Ps (specifically, a yarn supply package Ps1, Ps3) attached to the first attachment unit <NUM> and a time (horizontal axis). <FIG> is a graph showing the relationship between the remaining amount (vertical axis) of a yarn Y in a yarn supply package Ps (specifically, a yarn supply package Ps2) attached to the second attachment unit <NUM> and a time (horizontal axis). <FIG> is a graph showing the relationship between the wound amount (vertical axis) of a yarn Y on a winding bobbin Bw (specifically, a winding bobbin Bw1, Bw2, Bw3, Bw4, Bw5) and a time (horizontal axis). In all of the graphs in <FIG>, a time t0 at which unwinding of the yarn Y from the yarn supply package Ps1 starts is the origin. In the present embodiment, in a state in which the yarn Y has not been unwound from each yarn supply package Ps at all (i.e., each package is fully wound), the weight (initial weight) of each yarn supply package Ps is WF.

To begin with, prior to the time t0, a fully-wound yarn supply package Ps1 is attached to the first attachment unit <NUM>. The initial weight of the yarn Y in the yarn supply package Ps1 is WF. Prior to the time t0, a fully-would yarn supply package Ps2 is attached to the second attachment unit <NUM>, too. A terminal portion of the yarn Y in the yarn supply package Ps1 is joined with a start end portion of the yarn Y in the yarn supply package Ps2 so that a node K is formed. At the time t0, yarn threading to the sections of a predetermined spindle <NUM> starts. In accordance with this, at the time t0, unwinding of the yarn Y from the fully-wound yarn supply package Ps1 starts. Thereafter, at a time ts1 immediately after the time t0, the yarn threading to the winding bobbin Bw1 attached to the winding device <NUM> finishes, and winding of the yarn Y onto the winding bobbin Bw1 starts (i.e., formation of the wound package Pw1 starts). Between the start of unwinding of the yarn Y from the yarn supply package Ps1 to the finish of yarn threading to the winding bobbin Bw1, the yarn Y is sucked and captured by the suction of the automatic doffer <NUM>. In the present embodiment, the unwinding speed of the yarn Y when the yarn threading is performed is substantially identical with the unwinding speed (V described above) when the yarn Y is wound onto the winding bobbin Bw.

As time passes, the remaining amount (remaining weight) of the yarn Y in the yarn supply package Ps1 decreases whereas the wound amount (wound weight) of the yarn Y wound onto the winding bobbin Bw1 increases. In other words, the amount of the yarn Y in the wound package Pw1 increases over time. The machine controller <NUM> counts the time elapsed from the start of the formation of the wound package Pw1. By utilizing this information of the time, the machine controller <NUM> calculates the amount of the yarn Y in the wound package Pw1. When determining that the amount of the yarn Y in the wound package Pw1 reaches a predetermined target wound amount, the machine controller <NUM> terminates the formation of the wound package Pw1 (i.e., executes the formation termination process). To be more specific, for example, at a time te1, as the machine controller <NUM> causes the cutter of the automatic doffer <NUM> to cut the yarn Y, the winding process of winding the yarn Y onto the winding bobbin Bw1 is terminated. On this account, the time te1 is the winding end time at which winding of the yarn Y onto the winding bobbin Bw1 ends (i.e., formation of the wound package Pw1 is terminated). Onto the winding bobbin Bw1, only the yarn Y supplied from the yarn supply package Ps1 has been wound. Cutting of the yarn Y by the cutter and suction and capture of the yarn Y by the suction (i.e., start of sucking and removal of the yarn Y) are almost simultaneously performed. Furthermore, the machine controller <NUM> executes a replacement process by controlling the automatic doffer <NUM>. In other words, the machine controller <NUM> controls the automatic doffer <NUM> to detach the winding bobbin Bw1 (wound package Pw1) from the cradle <NUM>, to attach the winding bobbin Bw2 to the cradle <NUM>, and to perform yarn threading to the winding bobbin Bw2. As a result, at a time ts2 immediately after the time te1, attachment of the winding bobbin Bw2 to the cradle <NUM> by the automatic doffer <NUM> is completed and a winding process of winding the yarn Y onto the winding bobbin Bw2 starts. There is a slight time lag tL (see <FIG>) between the winding end time (te1) of the winding bobbin Bw1 and the winding start time (ts2) of the winding bobbin Bw2 onto which the yarn Y is to be wound next to the winding bobbin Bw1. As described above, even when the winding bobbin Bw is being replaced, the yarn Y is unwound from the yarn supply package Ps at a substantially same speed as the yarn Y wound onto the winding bobbin Bw. At a time te2, the winding process of winding the yarn Y onto the winding bobbin Bw2 ends (formation of the wound package Pw2 finishes) and a winding process of winding the yarn Y onto a winding bobbin Bw3 starts at a time ts3.

At a time ta1 (see <FIG>) after the time ts3, the yarn supply package Ps1 attached to the first attachment unit <NUM> becomes empty. Therefore the time ta1 is the unwinding end time at which unwinding of the yarn Y from the yarn supply package Ps1 ends. At the same time as the yarn supply package Ps1 becomes empty, at a time tb1 (= the time ta1), the node K formed by joining the yarn Y in the yarn supply package Ps1 with the yarn Y in the yarn supply package Ps2 is pulled toward the winding device <NUM> side. As a result, unwinding of the yarn Y from the yarn supply package Ps2 attached to the second attachment unit <NUM> starts. Therefore the time tb1 is the unwinding start time at which the yarn Y is unwound from the yarn supply package Ps2 for the first time (i.e., unwinding of the yarn Y from the yarn supply package Ps2 starts). Thereafter, at a time te3, the winding process of winding the yarn Y onto the winding bobbin Bw3 ends (formation of the wound package Pw3 finishes). On a winding bobbin Bw3, both the yarn Y unwound from the yarn supply package Ps1 and the yarn Y unwound from the yarn supply package Ps2 are wound. The wound package Pw3 includes a node K. Thereafter, at a time ts4, a winding process of winding the yarn Y onto a winding bobbin Bw4 starts. At a time te4, the winding process of winding the yarn Y onto the winding bobbin Bw4 ends (formation of the wound package Pw4 finishes). Onto the winding bobbin Bw4, only the yarn Y unwound from the yarn supply package Ps2 has been wound.

After the time ta1 and before the yarn supply package Ps2 becomes empty (e.g., at the time ta2), the operator detaches the empty yarn supply package Ps1 from the first attachment unit <NUM> and attaches a new fully-wound yarn supply package Ps3 to the first attachment unit <NUM> (yarn supply package replacement). The remaining weight of the yarn supply package Ps3 at this stage is WF. Thereafter, at an appropriate timing, a terminal portion of the yarn Y in the yarn supply package Ps2 is joined (connected) by the operator with a start end portion of the yarn Y in the yarn supply package Ps3 so that a node K (see <FIG>) is formed. The operator may manually join (connect) the end portions. Alternatively, the operator may join the end portions by operating an unillustrated portable joining device, for example.

Thereafter, from a time ts5 to a time te5, the yarn Y is wound onto a winding bobbin Bw5 (a wound package Pw5 is formed). At a time tb2 between the time ts5 and the time te5, the yarn supply package Ps2 attached to the second attachment unit <NUM> becomes empty. At the same time when the yarn supply package Ps2 becomes empty, at a time ta3 (= the time tb2), unwinding of the yarn Y from the yarn supply package Ps3 attached to the first attachment unit <NUM> starts.

When the at-reduction process is not performed, the yarn Y is unwound from each yarn supply package Ps as described above and each wound package Pw is formed.

With reference to <FIG>, the following will describe the steps of the formation of an inner-layer-part-inclusive wound package when the "Formation of Inner-Layer-Part-Inclusive Wound Package" is selected as the mode in the at-reduction process. <FIG> is a flowchart showing the steps of replacement of a winding bobbin Bw, which is performed when the remaining amount of a yarn Y in a yarn supply package Ps is reduced. <FIG> are graphs showing the relationship between a yarn amount and a time in a processing mode for forming an inner-layer-part-inclusive wound package. Being similar to <FIG>, <FIG> is a graph showing the relationship between the remaining amount (vertical axis) of a yarn Y in a yarn supply package Ps attached to the first attachment unit <NUM> and a time (horizontal axis). Being similar to <FIG>, <FIG> is a graph showing the relationship between the remaining amount (vertical axis) of a yarn Y in a yarn supply package Ps attached to the second attachment unit <NUM> and a time (horizontal axis). Being similar to <FIG>, <FIG> is a graph showing the relationship between the wound amount (vertical axis) of a yarn Y on a winding bobbin Bw and a time (horizontal axis). Each of <FIG> is a schematic diagram of a wound package Pw. <FIG> illustrates information regarding the rank of a wound package Pw. <FIG> shows a screen S2 regarding information of a wound package Pw displayed on the machine output unit 5b, for example.

In an initial state, being similar to the above-described case where the at-reduction process is not performed, a yarn supply package Ps1 is attached to the first attachment unit <NUM> and a yarn supply package Ps2 is attached to the second attachment unit <NUM>, for example. Furthermore, the yarn Y unwound from the yarn supply package Ps1 is processed by the processing unit <NUM> and is wound onto a winding bobbin Bw1. The yarn supply package Ps1 is equivalent to a first yarn supply package of the present invention. The yarn supply package Ps2 is equivalent to a second yarn supply package of the present invention.

Each time a predetermined time elapses, the machine controller <NUM> calculates the remaining amount ratio of the yarn Y remaining in the yarn supply package Ps1, for example. Hereinafter, for the sake of convenience, information of a value of a remaining amount ratio will be referred to as remaining amount-related information. To put it differently, the machine controller <NUM> generates (obtains) the remaining amount-related information by calculation, each time the predetermined time elapses. The machine controller <NUM> determines whether the remaining amount ratio is not smaller than a predetermined value (S101). The predetermined value is a value that was set at the time of setting the above-described processing condition (see "<NUM>% or less" in <FIG>). Until the remaining amount ratio becomes equal to or smaller than the predetermined value (No in S101), the machine controller <NUM> forms a wound package Pw at a predetermined spindle <NUM>, in the same manner as in the case where the at-reduction process is not performed. In this example, the wound packages Pw1 and Pw2 are formed in order in the same manner as in the case where the at-reduction process is not performed. The machine controller <NUM> evaluates the wound packages Pw1 and Pw2 as wound packages Pw with the highest rank (e.g., "A1" in <FIG>). The machine controller <NUM> stores the individual information (see "ID" in <FIG>) and the rank of each wound package Pw in association with each other.

When it is determined that the remaining amount ratio becomes not larger than the predetermined value (remaining amount reduction determination; Yes in S101), the machine controller <NUM> controls and causes the winding device <NUM> to perform, for a wound package Pw in production, inner layer part avoiding marking operation that is described below (S102). For example, a time at which the remaining amount of the yarn Y in the yarn supply package Ps1 becomes W1 (see the time t1 in <FIG>) is a time at which the remaining amount ratio reaches the predetermined value. When the remaining amount ratio reaches the predetermined value, for example, the yarn Y is being wound onto a winding bobbin Bw3 and a wound package Pw3s is being formed (see <FIG>). When the remaining amount reduction determination is performed while the yarn Y is being unwound from the yarn supply package Ps1, the machine controller <NUM> performs an inner layer part avoiding marking operation in such a way that a motor <NUM> (see <FIG>) is controlled to passively rotate a wound package Pw3s and a motor <NUM> is controlled to stop the traverse guide <NUM> at a predetermined first position in the winding bobbin axial direction. As a result, so-called straight winding is formed on the wound package Pw3s, i.e., a mark M1 (see <FIG>) is formed on the wound package Pw3s. To put it differently, the wound package Pw3s is marked. The inner layer part avoiding marking operation is encompassed in a marking operation of the present invention.

The machine controller <NUM> controls the automatic doffer <NUM> to cut the running yarn Y and terminates the formation of the wound package Pw3s (formation termination process). Thereafter, the machine controller <NUM> controls the automatic doffer <NUM> to replace the wound package Pw3s with a new winding bobbin Bw4 at the winding device <NUM> (S103; replacement process) Furthermore, the machine controller <NUM> controls the automatic doffer <NUM> to perform yarn threading to the new winding bobbin Bw4 (new winding bobbin of the present invention). This makes it possible to avoid the contamination of the yarn Y in the inner layer part of the yarn supply package Ps1 into the wound package Pw3s. The wound package Pw3s is smaller than the wound packages Pw1 and Pw2 (see <FIG>). To put it differently, the formation of the wound package Pw3s is terminated in a state in which the amount of the yarn Y in this package is smaller than the above-described target wound amount. The wound package Pw3s is equivalent to a formation forcible termination wound package of the present invention.

Furthermore, the machine controller <NUM> evaluates the wound package Pw3s as a wound package Pw which is, for example, lower in rank than the wound packages Pw1 and Pw2 (see e.g., A2 in <FIG>), and stores the individual information and the rank of the wound package Pw3s in association with each other. In S103, the machine controller <NUM> stores the individual information of the wound package Pw3s and information indicating that the remaining amount reduction determination has been done during the formation of the wound package Pw3s (see e.g., inner layer part contamination avoidance in <FIG>), in association with each other.

Subsequently, the machine controller <NUM> controls the winding device <NUM> to start winding of the yarn Y onto a winding bobbin Bw4, i.e., to start formation of a wound package Pw4r. The machine controller <NUM> determines whether the above-described yarn supply package switching has occurred during the formation of the wound package Pw4r, based on a detection result of the yarn detection sensor <NUM> (S104). The machine controller <NUM> continues the formation of the wound package Pw4r until the occurrence of the yarn supply package switching (No in S104). When the yarn supply package switching occurs, the unwinding of the yarn Y from the yarn supply package Ps1 finishes, a node K is pulled, and unwinding of the yarn Y from the yarn supply package Ps2 starts (see <FIG>). When determining that the yarn supply package switching has occurred (switching determination; Yes in S104), the machine controller <NUM> executes a below-described inner layer part inclusive marking operation for the wound package Pw4r (S105). When the switching determination is performed while the yarn Y is being wound onto the winding bobbin Bw4, as the inner layer part inclusive marking operation, the machine controller <NUM> controls the motor <NUM> to passively rotate the wound package Pw4r and controls the motor <NUM> to stop the traverse guide <NUM> at a predetermined second position in the winding bobbin axial direction. As a result, straight winding is formed on the wound package Pw4r, i.e., a mark M2 (see <FIG>) is formed on the wound package Pw4r. To put it differently, the wound package Pw4r is marked. The inner layer part inclusive marking operation is encompassed in the marking operation of the present invention.

The machine controller <NUM> preferably controls the motor <NUM> so that the position of the mark M1 in the winding bobbin axial direction is different from the position of the mark M2 in the winding bobbin axial direction. For example, in the winding bobbin axial direction, the mark M1 may be positioned at around an equidistant position between an end face of the wound package Pw3s and the center of the wound package Pw3s. The mark M2 may be provided at around the center in the winding bobbin axial direction of the wound package Pw4r. This makes it easy to discern the wound package Pw3s from the wound package Pw4r by appearance.

In addition to the above, the machine controller <NUM> controls the cutter of the automatic doffer <NUM> at a predetermined timing to cut the running yarn Y so that, for example, the node K is included in the wound package Pw4r, and terminates the formation of the wound package Pw4r (formation termination process). As a result, the yarn Y in the inner layer part of the yarn supply package Ps1 and the node K are wound into the winding bobbin Bw4, and the wound package Pw4r is formed. Alternatively, the machine controller <NUM> may cause the cutter of the automatic doffer <NUM> to cut the running yarn Y at a timing at which the node K is not included in the wound package Pw4r and is sucked and removed by the suction of the automatic doffer <NUM>.

Thereafter, the machine controller <NUM> controls the automatic doffer <NUM> to replace the wound package Pw4r with a new winding bobbin Bw5 (a new winding bobbin of the present invention) at the winding device <NUM> (S106; replacement process). In the same manner as the wound package Pw3s, the wound package Pw4r is smaller than the wound packages Pw1 and Pw2 (see <FIG>). The wound package Pw4r is intentionally formed as a wound package Pw that is inferior to the other wound packages Pw in quality, in order to remove the yarn Y in the inner layer part of the yarn supply package Ps1. The wound package Pw4r may be discarded. Alternatively, the wound package Pw4r may be treated as a low-ranked wound package Pw. The wound package Pw4r formed by winding the yarn Y onto the winding bobbin Bw4 is equivalent to the inner-layer-part-inclusive wound package of the present invention. Furthermore, the machine controller <NUM> controls the automatic doffer <NUM> to perform yarn threading to a new winding bobbin Bw5. The machine controller <NUM> controls the winding device <NUM> to start winding of the yarn Y onto the winding bobbin Bw5.

Furthermore, the machine controller <NUM> evaluates the wound package Pw4r as a wound package Pw which is, for example, lower in rank than the wound packages Pw1, Pw2, and Pw3r (see e.g., B in <FIG>). The machine controller <NUM> stores the individual information and the rank of the wound package Pw4r in association with each other. In S106, the machine controller <NUM> stores the individual information of the wound package Pw4r and information indicating that the switching determination has been done during the formation of the wound package Pw4r (see e.g., "including inner layer part" in <FIG>), in association with each other.

Furthermore, the yarn Y is wound onto a winding bobbin Bw5 and a wound package Pw5 is formed. Being similar to the wound packages Pw1 and Pw2, the wound package Pw5 is formed as a high-ranked wound package Pw (see <FIG>). Subsequent processes are not explained.

As described above, when the remaining amount of the yarn Y in the yarn supply package Ps1 becomes not larger than the predetermined value, i.e., when unwinding of the yarn Y in the inner layer part from the yarn supply package Ps1 starts, the formation of the wound package Pw3s is terminated (formation termination process). This makes it possible to avoid the inclusion of the low-quality yarn Y in the wound package Pw3s that is a product. It is therefore possible avoid the contamination of the low-quality yarn Y in the wound package Pw that is a product.

The machine controller <NUM> stores the individual information of the wound package Pw3s (formation forcible termination wound package) and information regarding the remaining amount reduction determination, in association with each other. It is possible to discern the wound package Pw3s from the other wound packages Pw by utilizing the information stored in the machine controller <NUM>.

At the execution of the switching determination, the wound package Pw4r is replaced with a new winding bobbin Bw5. With this arrangement, it is possible to immediately wind the yarn Y in the yarn supply package Ps2 onto the new winding bobbin Bw5 after the occurrence of the yarn supply package switching. It is therefore possible to suppress a large amount of the high-quality yarn Y in the yarn supply package Ps2 from being included in the wound package Pw4r.

The machine controller <NUM> stores the individual information of the wound package Pw4r (inner-layer-part-inclusive wound package) and information regarding the switching determination, in association with each other. It is possible to discern the wound package Pw4r from the other wound packages Pw by utilizing the information stored in the machine controller <NUM>.

The machine controller <NUM> causes the winding device <NUM> to perform the inner layer part inclusive marking operation. This makes it possible to discern the wound package Pw without the mark M2 from the wound package Pw4r by appearance.

The machine controller <NUM> causes the winding device <NUM> to perform the inner layer part avoiding marking operation. This makes it possible to discern the wound package Pw without the mark M1 from the wound package Pw3s by appearance.

The machine controller <NUM> causes the winding device <NUM> to perform the inner layer part avoiding marking operation and the inner layer part inclusive marking operation in order to make it possible to discern the wound package Pw3s from the wound package Pw4r. This makes it easy to discern the wound package Pw3s from the wound package Pw4r by appearance. On this account, it is possible to discern the wound package Pw3s from the wound package Pw4r even if they are unintentionally mixed.

In addition to the above, as the marking operation, it is possible to form a straight winding on the wound package Pw. This makes it possible to achieve the marking operation by a simple means.

Claim 1:
A yarn processor (<NUM>) capable of processing a yarn (Y) unwound from a yarn supply package (Ps) and winding the yarn (Y) onto a winding bobbin (Bw), comprising:
a yarn supply package retaining portion (<NUM>) which is configured to retain the yarn supply package (Ps);
a winding device (<NUM>) which is capable of forming a wound package (Pw) by winding the yarn (Y) onto the winding bobbin (Bw);
a cutting unit (<NUM>) which is capable of cutting the yarn (Y) before the yarn (Y) is wound onto the winding bobbin (Bw) ;
a bobbin replacement unit (<NUM>) which is capable of replacing the wound package (Bw) formed by the winding device (<NUM>) with a new winding bobbin (Bw4, Bw5) as the winding bobbin (Bw) and which is capable of performing yarn threading to the new winding bobbin (Bw4, Bw5); and
a controller (<NUM>) which is capable of performing: a formation termination process of cutting the yarn (Y) by controlling the cutting unit (<NUM>) and terminating formation of the wound package (Pw) by controlling the winding device (<NUM>); and a replacement process of replacing the formed wound package (Pw) with the new winding bobbin (Bw4, Bw5) and threading a yarn (Y) to the new winding bobbin (Bw4, Bw5) by controlling the bobbin replacement unit (<NUM>),
the controller (<NUM>) performing the formation termination process and the replacement process when determining that an amount of the yarn (Y) in the wound package (Pw) in formation reaches a predetermined target wound amount,
the control unit (<NUM>) generating, by calculation, remaining amount-related information that is numerical information regarding a remaining amount of the yarn (Y) remaining in the yarn supply package (Ps) which is retained by the yarn supply package retaining portion (<NUM>) and from which the yarn (Y) is being unwound, and
when determining in remaining amount reduction determination that a numerical value of the remaining amount-related information is not larger than a predetermined value, the control unit (<NUM>) performing the formation termination process to cause the winding device (<NUM>) to form a formation forcible termination wound package (Pw3s) that is a wound package (Pw) having a smaller amount of the yarn (Y) than the target wound amount.