The present invention relates to a process for loading socks onto finishing templates. The invention also relates to an apparatus usable for loading socks onto finishing templates in implementation of the aforesaid process. The invention is conveniently usable in the field of the industrial production of socks on a large scale.

In the production processes of socks, it is usually envisaged that socks produced by means of weaving are subjected to adequate finishing processes before implementing the final packaging thereof for placement on the market.

These finishing processes generally include the execution of an ironing step in which the socks, previously fitted on respective finishing templates, are subjected to a vaporization and ironing treatment, typically by means of two plates which can be approached on opposite sides with respect to the finishing template interposed therebetween.

Each finishing template is normally defined by a substantially flat metal plate in the profile of which, consistent with the anatomical shape of the sock, an end portion corresponding to the foot is identifiable, from which a longiform support portion corresponding to the leg portion extends.

In large-series production processes, a plurality of finishing templates are suitably distributed, normally with the end portions facing upwards, along a sort of transport chain which translates step-by-step along a closed circuit passing through at least one loading station, one or more processing stations and at least one unloading station.

The loading of the socks on the respective finishing templates is typically entrusted to at least one person who picks up each sock from a basket or other supply warehouse and manually arranges it onto the finishing template. In performing this operation, the operator must grasp the sock near the terminal edge of the leg portion, insert it around the tip of the finishing template, and slide it along the template, stretching it along the same template until the tip of the sock reaches the tip of the foot defined in the finishing template. During this operation, the operator must also pay attention to correctly orient the sock so that the toe and the heel of the foot are correctly positioned in the corresponding areas defined in the finishing template.

A certain training and experience is therefore required of the operator so that he/she is capable of correctly performing the required operations repetitively at a rate such as to meet the production needs.

The time required for the correct execution of the manual loading of the socks onto the finishing templates also tends to limit the operating rate of the production line. The current market demands target production rates in the order of 1200 pairs of socks per hour, i.e., one sock every 1 .5 seconds. Reaching and maintaining production rates of these values, if not lower, currently requires the use of more than one operator responsible for loading the socks on the same line.

The operating rate in the production lines of modern design is in any case such as to impose a considerable effort on the operators to correctly load the socks onto the finishing templates in a sufficiently short time.

It has also been found that loading the templates forces the operator to raise their arms cyclically up to the height of the shoulders and beyond, with a hardly ergonomic movement which can cause early fatigue, and induce serious complications in terms of health due to the consequent fatigue and/or overloading of the joints.

The object of the present invention is to overcome the limitations of the prior art by simplifying the operations imposed on the operator for the purpose of loading socks onto the finishing templates. In particular, the aim is to propose a technical solution which allows the operator to significantly simplify the operations required for loading the socks, limiting the execution of movements which, in the long run, could compromise the articular functionality of the organs involved. It is also intended to create a system in which the sock can be prepared for loading onto the finishing template by means of a few simple operations which can be performed quickly and intuitively even by inexperienced operators, benefiting productivity.

More in particular, the invention relates to a process for loading socks onto finishing templates according to claim 1 .

In a further aspect, the invention relates to an apparatus for loading socks onto finishing templates according to claim 7.

In at least one of the aforesaid aspects, convenient embodiments of the invention can comprise at least one of the following preferred features.

Conveniently, the terminal edge of the leg portion is fitted around the support member in an elastic tensioning condition.

Conveniently, the support member can be inscribed in a peripheral line having greater extension than a circumferential extension of the terminal edge of the leg portion under resting conditions.

Conveniently, the action of removing the sock is performed by rotating the sock for one or more complete turns around a longitudinal axis of the leg portion, partially removing it from the support member upon the completion of each turn.

Conveniently, the orientation of the sock is performed by stopping the rotation thereof when a reference index carried by the sock reaches a predetermined position around the longitudinal axis of the leg portion.

Conveniently, it is also envisaged to monitor the positioning of the terminal edge with respect to the reference plane during the rotation of the sock.

Conveniently, it is envisaged to enable monitoring the reference index when the terminal edge has reached the reference plane.

Conveniently, after the terminal edge has reached the reference plane, a monitoring of the position of the reference index during the rotation of the sock is enabled.

Conveniently, the sock is picked up from a feeding support located at a lower height with respect to the support member. Conveniently, the sock is fitted onto the support member with a movement from below.

Conveniently, the sock is engaged to the support member starting from the terminal edge of the leg portion.

Conveniently, part of the sock engaged to the support member hangs below it. More in particular, at least one part of the leg portion hangs from the support member. Conveniently, the part of the sock hanging from the support member results in a resting condition, i.e., in the absence of elastic tension, while the terminal edge of the leg portion is engaged to the support member in an elastic tensioning condition.

Conveniently, the sock is picked up from the support member at the terminal edge of the leg portion and inverted with a rotation motion in a vertical plane before being fitted onto the finishing template.

Conveniently, said at least one support member engages the terminal edge of the leg portion while maintaining the terminal edge in an elastic tensioning condition.

Conveniently, the positioning devices comprise movement members acting on the sock engaged to the support member to rotate the sock around a longitudinal axis of the leg portion.

Conveniently, the positioning devices comprise first reading devices configured to monitor the position of the terminal edge of the leg portion with respect to the geometric reference plane.

Conveniently, the movement members cooperate with the support member to rotate the sock by partially removing it from the support member upon the completion of each turn.

Conveniently, the orientation devices comprise second reading devices configured to locate a reference index carried by the sock.

Conveniently, the orientation devices comprise second reading devices configured to control the stop of the movement members when a reference index carried by the sock reaches a predetermined position around the longitudinal axis of the leg portion. Conveniently, the second reading devices are activatable after the terminal edge has reached the reference plane.

Conveniently, the second reading devices are activatable in response to a signal emitted by the first reading devices.

Conveniently, the support member comprises two or more rollers mutually spaced apart according to axes parallel to each other.

Conveniently, the rollers are arranged according to axes parallel to the longitudinal axis of the leg portion.

Conveniently, the rollers are rotatably idle.

Conveniently, the support member extends below, preferably cantilevered, from a support bracket.

Conveniently, the support member has a small terminal frame rotatably engaging the ends of the rollers opposite the support bracket.

Conveniently, the small terminal frame defines a substantially convex surface facing downwards and/or away from the support bracket.

Conveniently, at least one of said rollers has a circumferential groove.

Conveniently, the circumferential groove is positioned between said geometric reference plane and one end of the support member opposite the support bracket.

Conveniently, the movement members comprise a motorized wheel movable towards said rollers transversely to the axes of the latter.

Conveniently, the motorized wheel is movable between a rest position in which it is spaced from the rollers, and a working position in which it acts against the leg portion of the sock in a thrusting relation towards one or more of said rollers.

Conveniently, the motorized wheel acts at said circumferential groove.

Conveniently, a plurality of said support members are included, distributed along a flexible conveyor, movable along a closed loop movement circuit to sequentially carry each support member through a plurality of operating stations.

Conveniently, said operating stations comprise a loading station in which the socks are engaged to said support members, at least one control station in which at least one of said positioning devices and orientation devices operate, and at least one transfer station in which said gripping devices operate.

Conveniently, the flexible conveyor is configured to translate the support members with a step-by-step movement along the movement circuit.

Conveniently, at each movement step two of said respective adjacent support members are positioned at one of said work stations.

Conveniently, the positioning devices and the orientation devices operate respectively in a first and a second control station.

Conveniently, the gripping devices comprise at least one gripping member provided with a pair of mutually facing grippers.

Conveniently, the grippers are activatable for gripping the terminal edge of the leg portion in respective diametrically opposite areas.

Conveniently, the grippers of the gripping member are movable towards and away from each other, preferably along one or more guide bars.

Conveniently, said gripping member is mounted on a support rotatable around a horizontal overturning axis.

Conveniently, the rotatable support is interposed parallel between the movement circuit and a lying plane of the finishing template.

Conveniently, the rotatable support is movable with alternating rotations, preferably 180°, around the overturning axis, to bring said at least one gripping member between a first operating condition in which it directs the grippers towards the support member, and a second operating condition in which the grippers are turned towards the finishing template.

Conveniently, at least in the first operating condition the grippers of said at least one gripping member have a substantially horizontal orientation.

Conveniently, the rotatable support is also movable from the first operating condition in which the grippers of said at least one gripping member have a substantially horizontal orientation, to a third operating condition, in which the grippers have an orientation tilted downwards. Conveniently, the gripping devices further comprise a crossbar carrying the rotatable support.

Conveniently, the crossbar is movable along a pair of uprights, to translate said at least one gripping member between a lowered position and a raised position.

Conveniently, the gripping devices comprise two or more gripping members each simultaneously cooperating with one of said support members located in the transfer station.

Further features and advantages will become more apparent from the detailed description of a preferred, but not exclusive, embodiment of a process for loading socks onto finishing templates, and of an apparatus operating according to said process, in accordance with the present invention.

Such a description will be set out hereinafter with reference to the accompanying drawings given only for illustrative and, therefore, nonlimiting purpose, in which:

- figure 1 is a plan view of an apparatus for loading socks onto ironing templates, according to the present invention;

- figure 2 shows the apparatus in front perspective view;

- figure 3 is a perspective view highlighting a loading station;

- figure 4 is a perspective view highlighting a first control station;

- figure 5 is a perspective view highlighting a second control station;

- figure 6 shows a detail of the apparatus in perspective view from behind, highlighting a transfer station;

- figure 7 is an enlarged detail of one of the gripping elements operating in the transfer station;

- figure 8 schematically illustrates the engagement of socks to the support members in the loading station;

- figure 9 schematically illustrates the execution of the vertical positioning of the socks in the first control station; - figure 10 schematically illustrates the execution of the rotational orientation of the socks in the second control station;

- figure 1 1 is an enlarged detail highlighting a reference index arranged near the terminal edge of the sock;

- figures 12 to 17 show laterally a sequence of operating steps of the gripping devices in the transfer station, for the purpose of engaging the socks onto the finishing templates.

With reference to the mentioned figures, the number 1 globally indicates an apparatus for loading socks onto finishing templates, suitable for operating according to a loading process in accordance with the present invention.

The apparatus 1 is suitable for equipping a finishing line, not illustrated in detail as not relevant for the purposes of the present invention, in which a plurality of finishing templates 2 are advanced, preferably according to a step-by-step movement, along a closed loop advancement path P. The advancement path P passes at the loading apparatus 1 , by means of which a plurality of socks 3 being processed are fitted onto the finishing templates

2, to be subsequently transported through one or more processing stations responsible for executing the treatments required for the purposes of finishing and possibly the final packaging.

In a manner known per se, as better indicated in figure 8, each of the socks 3 being processed has a substantially tubular leg portion 4, extending starting from a terminal edge 5 normally integrating an elastic band and usually called a "cuff". On the opposite side to the terminal edge 5, a foot 6 extends from the leg portion 4, in which a toe 6a and a heel 6b can be identified. For the implementation of the process according to the invention, it is also preferably envisaged that at least one reference index 7, obtained or applied during the previous production steps, is arranged on each sock

3. The reference index 7 (figure 1 1 ) can be conveniently arranged inside the leg portion 4, in a predetermined position around a longitudinal axis Y of the latter, preferably adjacent to or near the terminal edge 5. The finishing templates 2 each have a plate-shaped body, for example in metallic material, of a substantially flat shape in the profile of which, consistent with the anatomical shape of the socks 3 being processed, an end portion 8 corresponding to the foot 6 is identifiable, from which a longiform support portion 9 corresponding to the leg portion 4 extends.

At least at the apparatus 1 , the finishing templates 2 are preferably arranged coplanar with each other, consecutively side by side in a vertical plane. Each of them substantially extends in a vertical direction starting from an attachment portion 10 to a movement chain (not shown) placed on the opposite side with respect to the end portion 8, the latter being, for example, facing upwards.

The apparatus 1 comprises one or more support members 11 distributed along a flexible conveyor 12, for example in the form of a chain or belt, movable along a closed loop movement circuit 13.

Preferably, each support member 11 comprises two or more rollers 14 mutually spaced apart according to axes parallel to each other, each extending cantilevered below from a respective support bracket 15 engaged to the flexible conveyor 12. In the example shown, four rollers 14, preferably idle, are included for each support member 1 1 , arranged according to the vertices of a rectangle.

A small terminal frame 16, defining a substantially convex surface facing downwards, rotatably engages the ends of the rollers 14 opposite the support bracket 15.

One or more of said rollers 14 can conveniently have at least one circumferential groove 17, preferably placed between the end opposite the support bracket 15, and a geometric reference plane N extending orthogonally through the support member 1 1 , at a predetermined distance from the support bracket itself.

In the illustrated example, the movement circuit 13 has a forward branch 13a and a return branch 13b (partially indicated in the outline in figure 1 ) which are substantially straight and parallel to each other. The flexible conveyor 12 is driven, for example with a step-by-step movement, to sequentially carry each support member 1 1 through a plurality of operating stations 18-21 , distributed along the movement circuit 13. More in particular, it is preferably envisaged that, at each movement step, two support members 11 are simultaneously positioned at each of the operating stations 18-21.

The operating stations 18-21 comprise at least one loading station 18 and one or more control stations 19, 20 aligned along the forward branch 13a of the movement circuit 13. One or more transfer stations 21 arranged on the return branch 13b are also included.

At each drive of the flexible conveyor 12, the socks 3 treated in each of the operating stations 18-21 are simultaneously advanced towards the next operating station.

In the loading station 18, a person responsible for loading the apparatus 1 picks up the individual socks 3, for example contained in a container C (diagrammed in figure 8) or provided by means of a belt conveyor or other feeding support conveniently placed at a lower height with respect to the support members 1 1 , to engage them each on one of the support members 1 1 located near the loading station itself. More in particular, as diagrammed in figure 4, the engagement of each sock 3 envisages that the terminal edge 5, together with the leg portion 4 closest thereto, is fitted around the rollers 14 forming the support member 1 1 .

The set of rollers 14 forming the support member 11 , arranged according to axes parallel to the longitudinal axis Y of the leg portion 4, can be inscribed in a peripheral line having greater extension than a circumferential extension of the terminal edge 5 in rest conditions, i.e., in the absence of elastic tension. Consequently, the terminal edge 5 is fitted around the support member 11 and held by the latter in an elastic tensioning condition, peripherally around the longitudinal axis Y of the leg portion 4.

The presence of the small terminal frame 16 facilitates the insertion of the terminal edge 5 around the support member 11 with a simple movement from below. The person responsible for loading can therefore perform the operation in an extremely simple, easy and immediate manner, carrying the terminal edge 5 of the leg portion 4 beyond the geometric reference plane N, i.e., near the support bracket 15 or in any position between the latter and the geometric reference plane itself, without having to pay attention to the exact positioning of the terminal edge 5 along the support member 1 1 and/or to the orientation of the sock 3 around the longitudinal axis Y of the leg portion 4. The height positioning of the support members 1 1 can be conveniently chosen so that the person responsible can reach them with the socks 3 without having to raise their arms excessively, even while sitting. It is also possible to suitably choose the positioning of the basket C or other feeding system with respect to the support members 1 1 in the loading station 18, so that the socks 3 can be manually transferred to the support members 1 1 with movements of limited excursion. Furthermore, nothing excludes the use of a robotic arm or other automated loading equipment.

As clearly diagrammed in figures 8 to 10, after engagement, the sock 3 hangs below the support member 11 in rest conditions, i.e., in the substantial absence of elastic tension with the exception of the terminal edge 5 and of a transition zone 5a immediately close thereto, where the elastic tension imposed on the terminal edge itself gradually decreases away from the support member 1 1 .

Once the engagement of two socks 3 on the respective support members 1 1 has been completed, the latter are transferred upon the action of the flexible conveyor 12 to a first control station 19 along the forward branch 13a of the movement circuit 13. In the first control station 19, vertical positioning devices 22-23 of the sock 3 operate, configured to partially remove the sock 3 from the respective support member 1 1 , so that the terminal edge 5 is suitably positioned with respect to the aforesaid geometric reference plane N.

Preferably, the positioning devices 22-23 comprise movement members 22 acting on each sock 3 engaged to the respective support member 1 1 . In the example better illustrated in figure 4, said movement members 22 comprise, for each of the support members 1 1 carried in the first control station 19, at least a first motorized wheel 22a movable towards said rollers 14 transversely to the axes of the latter, between a rest position in which it is spaced from the rollers 14, and a working position (diagrammed in figure 4) in which it acts against the leg portion 4 of the sock 3 in a thrusting relation against one or more of the rollers 14 themselves. More in particular, to offer greater control over the movement of the sock 3, the first motorized wheel 22a preferably acts at the circumferential groove 17.

The action of the first motorized wheel 22a forces the sock 3 to be continuously rotated for one or more complete turns around the longitudinal axis Y of the leg portion 4, accompanied by the rotation of the rollers 14 pulled by the sock 3 itself. The elastic tension imposed near the terminal edge 5 generates a tension gradient with respect to the remaining part of the sock 3, which hangs in the absence of tension away from the support member 11 . Consequently, a centripetal contraction of the sock is created in the transition zone 5a, which tends to remove it from the support member 1 1. Therefore, the cooperation between the first motorized wheel 22a and the rollers 14, together with the elastic tension imposed near the terminal edge 5, makes it so that with the rotation of the sock 3, the effects of a force component which tends to partially remove it from the rollers 14 are expressed, according to a certain quantity upon the completion of each complete turn.

The positioning devices 22-23 are also equipped with first reading devices 23, comprising for example photocells or equivalent systems, configured to monitor the position of the terminal edge 5 with respect to the geometric reference plane N during the rotation of the sock 3.

When the terminal edge 5 reaches the reference plane, or a predetermined position with respect thereto, the immediate stop of the first motorized wheels 22a and their distancing from the socks 3, in the rest position, is commanded. The socks 3 remain engaged to the respective support members 1 1 with the respective terminal edges 5 in a predefined position along the rollers 14, and a new activation of the flexible conveyor 12 determines the transfer of the support members 1 1 together with the socks 3 to a second control station 20.

In the second control station 20, orientation devices 24 of each sock 3 operate around the longitudinal axis Y of the respective leg portion 4. Preferably, as better seen in figure 5, the orientation devices 24 envisage, for each of the socks 3, the use of at least a second motorized wheel 24a positionable in a thrusting relation towards the respective support member 1 1 in the second control station 20, similarly to what has been said for the first motorized wheels 22a in the first control station 19. In fact, each second motorized wheel 24a is suitable for rotatably driving the respective sock 3 around the longitudinal axis Y of the leg portion 4, preferably at a reduced speed with respect to the rotation previously implemented in the first control station 19.

The orientation devices 24 also comprise second reading devices 25, for example cameras or equivalent systems, configured to recognize the reference index 7 arranged on each of the socks 3. For each of the socks 3 present in the second control station 20, the second reading devices 25 monitor the position assumed by the reference index 7 (figure 11 ) around the longitudinal axis Y of the leg portion 4, to control the stop of the second motorized wheel 24a, when the same reference index 7 reaches a predetermined position. The orientation of the socks 3 is thus fixed in a predetermined angular position, for example with the tip 6a of the foot 6 oriented to the right, suitable for the subsequent transfer to the finishing templates 2.

It should be noted that the angular excursion made in the rotation of the sock 3 so that the reference index 7 reaches the predetermined position can be advantageously contained within values lower than 360°. The reduced angular excursion, which can be implemented at a significantly reduced speed with respect to that implemented during the positioning step, allows to finalize the orientation of the sock 3 without significantly changing the longitudinal position of the terminal edge 5 along the support member 1 1 .

In a possible alternative embodiment not illustrated, a single control station can be included where both the positioning devices 22-23 and the orientation devices 24 operate, with the aid of a single motorized wheel for the execution of both steps of the process on each sock 3. In this case the second reading devices 25 can be activatable in response to a signal emitted by the first reading devices 23 after the terminal edge 5 has reached the geometric reference plane N.

Once the orientation has been completed, the flexible conveyor 12 is again operated to advance the socks 3 oriented towards the transfer station 21 placed along the return branch 13b.

Gripping devices 26 operate in the transfer station 21 , better depicted in figures 6 and 7, configured to pick up each sock 3 from the respective support member 1 1 and engage it on one of the finishing templates 2 arranged at the apparatus 1 .

The gripping devices 26 comprise at least one, preferably two gripping members 27 simultaneously cooperating with two of the support members 1 1 positioned in the transfer station 21 .

Each gripping member 27 is provided with a pair of mutually facing grippers 28, movable towards and away from each other along one or more guide bars 29, and activatable for grasping the terminal edge 5 of the leg portion 4 in two diametrically opposite areas, each between two abutments 28a, 28b which are movable towards each other.

The gripping members 27 are mounted on a rotatable support 30 around a horizontal overturning axis X, interposed parallel between the return branch 13b of the movement circuit 13 and the vertical plane in which the finishing templates 2 lie.

An actuator unit 31 operates on the rotatable support 30 to bring each gripping member 27, with alternating rotations of 180° around the overturning axis X, between a first operating condition (figure 12) in which it turns the grippers 28 towards the respective support member 1 1 , and a second operating condition (figures 15 and 16) in which the grippers 28 are turned towards the respective finishing template 2.

In the first operating condition, the actuator unit 31 is also suitable for bringing the rotatable support 30 in a third operating condition (figures 13 and 14), in which the grippers 28 of the gripping members 27 have an orientation tilted downwards, indicatively according to an angle between 45° and 60° for example in the order of 55° with respect to a horizontal plane, as indicated in figure 13.

A crossbar 32 supports the rotatable support 30 and is movable along a pair of uprights 33, preferably vertical, to translate the gripping members 27 between a lowered position (figures 12 and 13) and a raised position (figures 14 and 15).

When the support members 11 carrying the oriented socks 3 have reached the transfer station 21 , the gripping members 27 are brought into the lowered position with the grippers 28 in the first operating condition (figure 12). The grippers 28 are then activated for each grasping the terminal edge 5 of the respective sock 3 between the movable abutments 28a, 28b. A rotation of the rotatable support 30 is then controlled through the actuator unit 31 to bring the grippers 28 of the gripping members 27 into the third operating condition. The consequent downwards rotation of the grippers 28 causes the socks 3 to be disengaged from the respective support members 1 1 and brought outside the vertical encumbrance of the latter (figure 13). At this point, an appropriate mutual spacing of the grippers 28 of each gripping element can also be commanded, so as to maintain an adequate elastic tension along the terminal edge 5 of the leg portion 4, which assumes a substantially flattened configuration with a width suitable for the subsequent insertion onto the finishing template 2.

With an upwards movement of the crossbar 32 along the uprights 33, the gripping members 27 reach the raised position (Figure 14), at which a new angular rotation of the rotatable support 30 is commanded to bring the gripping members 27 into the second operating position (Figure 15). The end portion 8 of the leg 4 of each sock 3 is consequently overturned a rotation motion in a vertical plane, at the end of which the terminal edge 5 of the sock 3 is vertically aligned above the finishing template 2, or preferably fitted around the upper end of the latter.

With a new downwards movement of the crossbar 32 towards the lowered position (figure 16), the terminal edge 5 is moved downwards, dragging the sock 3 along the finishing template 2, until the foot 6 of the sock 3 reaches the end portion of the template itself. The complete insertion of each sock 3 around the respective finishing template 2 is thus determined, regardless of the length of the leg portion 4.

It can be conveniently envisaged that during the movement towards the lowered condition, the gripping members 27 translate horizontally along the respective guide bars 29 and/or the crossbar 32, spontaneously or on the command of the respective actuators, to follow the shape of the finishing templates 2. The insertion of the sock 3 is thus facilitated, even in laterally protruding areas such as, for example, at the heel 6b.