Data processing: generic control systems or specific application – Specific application – apparatus or process – Product assembly or manufacturing
Reexamination Certificate
2001-12-21
2004-06-01
Nerbun, Peter (Department: 3765)
Data processing: generic control systems or specific application
Specific application, apparatus or process
Product assembly or manufacturing
C700S143000, C057S332000
Reexamination Certificate
active
06745097
ABSTRACT:
TECHNICAL FIELD
The present invention relates to a management method and a manufacturing apparatus for fiber-processing which can promptly accurately investigate problems of yarns or machines, even going upstream to a fiber forming process, by detecting something wrong from the occurrence of events prescribed as monitoring events, and thereafter by classifying the detected monitoring events during a fiber manufacturing process, a false-twisting process, a yarn twisting process, and others.
BACKGROUND ART
A fiber of a thermoplastic synthetic resin (hereafter, referred to as “polymer”) such as polyester, polyamide, and so forth is generally formed continuously into a fibrous state in a fiber forming process (melt spinning process). Subsequently, it is treated in a draw texturing process, a false twist-texturing process, a yarn twist-texturing process and the like, and then, depending on its use, for example, when the textured yarn is to be used as a fiber for clothes, the yarn is supplied to a weaving or knitting machine, or the like.
Here, the abovementioned fiber forming process (melt spinning process) is explained referring to a figure.
FIG. 1
is a rough explanatory diagram schematically expressing a melt spinning apparatus
100
to be used in a melt spinning process to produce a partially oriented yarn (POY). In
FIG. 1
, at first, a polymer, the starting material, is melted in an extruder (not shown in the figure) or the like. Then, the polymer is fed to a spinneret
101
under metering the polymer for prescribed volume by a gear pump (not shown in the figure) or the like in a molten state, the polymer is discharged into a fibrous state through spinning holes having a small diameter drilled in the spinneret
101
. Subsequently, filaments Y thus spun in the fibrous molten state are optionally treated for delayed cooling in a heated state with a heating device (not shown in the figure) set up below the spinneret
101
, or cooled with cooling air brown on in the direction of the arrowhead in
FIG. 1
by a cooling device
102
. During this process, the polymer spun in the fibrous state is getting thinned under being in the control of the degree of orientation or the degree of crystallization that is caused by the air resistance during the heating or the cooling, or during the passing through the spinning box
103
. Then, after the thinning is completed, an oil is applied on the filaments by an oiling apparatus
104
or the like which is a guide type oiling apparatus having an oil-supplying hole, and it is imparted with an adequate amount of entanglement by an entangling apparatus
105
or the like, and thereafter, if required, the filament is drawn at an adequate draw ratio. And, it is needless to say that the draw ratio is determined by the ratio between the spun speed of the polymer discharged from the spinneret
101
and the speed of rotation of a pair of rotating rollers
106
a
and
106
b
. Subsequently, a winder
107
continuously winds up the filaments Y as a filament packages P
1
and P
2
one after another. As the winder
107
for winding up the filament into the filament packages P
1
and P
2
one after another, a known automatic changeover winder can be used. An example of such winder is a turret-type automatic changeover winder in which a pair of bobbin holders are placed on a freely rotatable turret board, and when a fully wound filament package is formed on a bobbin holder, the turret board rotates, and the filaments to be wound are changed over to an empty bobbin placed on the other bobbin holder, and thereby the winding is continuously carried on. The filament packages P
1
and P
2
and the like which have been wound up in the above process are doffed by an automatic doffing machine (not shown in the figure) or the like. For the filament packages P
1
and P
2
and the like which have been doffed by the automatic doffing machine (not shown in the figure), managing information (in concrete terms, the number of the manufacturing machine, the number of the position of the manufacturing machine and the number of the doffing machine, or fiber forming management information such as the time of manufacturing) needed in the subsequent fiber-processing treatment is recorded on the management card attached to each package in the form of bar cord information or the like.
It is known that, in a melt spinning process of polymer, filaments consisting of an undrawn yarn (UDY), a partially oriented yarn (POY), a fully oriented yarn (FOY) or the like are obtained by the various conditions such as the kind of the polymer, the melt spinning conditions for heating and cooling the polymer, a winding-up speed, and the like. Further, it is known that the abovementioned filament such as an undrawn yarn (UDY), a partially oriented yarn (POY) or a fully oriented yarn (FOY) is fed to a draw-texturing machine, a false twist-texturing machine, a yarn twist-texturing machine, or the like (hereafter, these apparatus are collectively referred to as “fiber-processing machine”) depending on the physical properties of each of the filaments to produce a textured yarn.
As mentioned above, in the manufacturing process of filaments (hereafter, referred to as “yarn”), the yarn Y firstly spun out from the discharging holes of the spinneret
101
receives various forces in the course where it is drawn or twisted as shown above. Naturally, the yarn is heated for thermal plasticization or softening in these texturing processes. Further, whenever the polymer discharged from the spinneret
101
is cooled to solidify, or whenever the thermally plastisized yarn Y is cooled again, thermal stress is generated, and this acts on the yarn. The physical forces, which have been applied in the abovementioned process, are therefore internally stored as stress or strain in a yarn Y that is finally supplied to a fiber-texturing process. Further, the abovementioned factors affect large influence on fiber structure or physical property of fiber such as the degree of orientation or the degree of crystallization of fiber molecules, or thermal stress property. Accordingly, as going down from the melt spinning process to the texturing processes at the downstream side, the yarn has received more physical forces. Due to this, these physical forces also affect the tension of yarn, which is given under the processing of the yarn Y, and it is expressed as a complex force that these combined forces are superimposed to each other.
Under the circumstances explained above, in a conventional method for managing a fiber-processing machine and a conventional apparatus thereof, the tension of yarn is not grasped as a combined force that the various processing factors are superimposed to each other. That is, in a conventional technology, it is extremely difficult to separate and extract the superimposed processing factors from the generated tension while the yarn moves, so that it is not completely expected to realize such separation and extraction.
Now, conventional technologies will be briefly surveyed in the following. At first, in various fiber forming processes, trials to use the tension of yarn for managing the conditions of the process have been proposed. However, these trials are based on a basic technical concept that processing conditions are controlled in order for the tension of yarn to fall into a desirable range that is empirically or experimentally predetermined in each process of various kinds of fiber manufacturing processes.
A false twist-texturing machine that is commonly used for performing POY-DTY processing is cited as a representative example of a fiber-processing machine which embodies the conventional technical concept, and the abovementioned management method and an apparatus for carrying out the management will be explained. Further, needless to say, the following explanation is applicable not only to a false twist-texturing machine but also all of the abovementioned fiber-processing machines. That is, we can make explanation on all of the abovementioned fiber-processing machines without limiting to a false twi
Hamasu Bunji
Imamura Yoshiharu
Kusuzono Hiroaki
Sasaki Mitsumasa
Nerbun Peter
Rader & Fishman & Grauer, PLLC
Teijin Limited
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