Winder machines are used to wind fibers, and in particular, molten fiberglass strands onto bobbins, or collets, in order to form what are known as packages. After being formed, the packages are used in applications or are subjected to further processing.

The bobbins are held on rotating spindles or collets. A device known as a shoe guides the fiber strand as the strand is wound onto the package, the shoe moving back and forth rectilinearly in front of the package such that the package is built up evenly during winding.

The shoe is carried in helical grooves provided in the traverse such that as the traverse, which is essentially an elongated spindle, rotates, the shoe oscillates back and forth in front of the package being wound.

In the prior devices, the drive relationship between the traverse and the collet was controlled by a series of gears and toothed belts. Thus, when it became necessary to wind a package differently, such as due to a different type of strand being wound, desired package sizes, customer preferences, etc., it was necessary to change the gears in the winder to achieve the proper speed relationships between the traverse and the collet. This could take several hours or more to do, and required shutting down the machine for an extended period of time.

Further, prior winders may use a hydraulic system for varying the distance between the traverse and collet as the package is built up. This is required in order to maintain working clearance for the shoe. This design, however, can be of complicated construction and introduces the potential of grease and oil escaping or spilling, thereby potentially contaminating fibers being wound and soiling of the machine or surrounding area.

Summary of the Invention It is, therefore, the principal object of the present invention to provide a winder machine for winding fibers onto a collet.

Another object of the present invention is to provide a winder machine for producing a variety of winding configurations without requiring the replacement of transmission components.

Still another object of the present invention is to provide a winder machine having an improved system for maintaining clearance between a package being wound and a moveable shoe.

Another object of the present invention is to provide an improved locking mechanism for locking the turret of a winder machine.

Yet another object of the present invention is to provide a winder machine having an improved system for moving a traverse assembly with respect to a package being wound.

Another object of the present invention is to provide a winder machine which can be digitally programmed to perform predetermined winding operations.

A still further object of the present invention is to provide a winding machine having reduced vibration during winding.

And still another object of the present invention is to provide a method of winding fibers in predetermined configurations.

Generally, the present invention includes a winder machine having two collets, each being driven by a separate motor. The traverse is separately driven using a servomotor. A software interface is provided for operation by the operator, who enters the desired winding style. These instructions are delivered to a digital programmable logic controller (PLC) which uses software from the interface terminal to create a program. The output from the PLC is connected to a modbus module connected to the PLC, which is essentially a protocol translator/converter. The modbus converts the instructions form the PLC into a language which can be understood by the servo drive system of the traverse. Inverters are also provided for allowing control of the drive speeds of the collet drive motors.

Attached to each of the drive motors and to the servomotor is a digital rotary encoder which outputs the exact rotational speed of the motors, this output bring monitored by the PLC.

The present invention allows for the drive relationship between the collet motors and the servomotor, and thus the winding speed of the package and the speed of oscillation of the traverse to be almost infinitely varied with respect to one another. This is significant in that rotational speed relationships between the traverse roller and collet vary as a package being wound builds up in diameter. Only a limited amount of tension can be applied to a fiber being wound in order to prevent breakage of the fiber. Further, because of the digital system used,

and the preciseness allowed by the rotary encoders, the predetermined winding styles are closely repeatable from one package to the next.

It is also noted that the traverse on the new machine is provided with a stationary outrigger which projects outwardly from the face of the winder to stabilize the traverse and to reduce vibration of the traverse during winding.

Another feature of the present invention is the fact that the traverse, which must be moved away from the collet during winding as the fiber strand builds up on the package being wound, is moved by a new system. The system uses an electrical stepping motor in combination with a linear variable displacement transformer (LVDT). The stepping motor is connected to a threaded rod such that as the motor turns, the threaded rod advances or retracts.

The threaded rod is in turn connected to the traverse assembly, and the LVDT is used to determine the position of the traverse. The stepping motor allows for precise movement of the threaded rod, such that the distance between the traverse (on which the shoe is carried) and the package can be accurately varied and maintained.

Brief Description of the Drawings The foregoing, as well as other objects of the present invention will be further apparent from the following detailed description of the preferred embodiment of the invention, when taken together with the accompanying specification and the drawings, in which: Figure 1 is a perspective view of a winding machine constructed in accordance with the present invention, illustrating two collets mounted on a turret, with a traverse assembly and an outrigger extending generally parallel to the collets; Figure 2 is a partial perspective view of the traverse assembly illustrated in Figure 1, illustrating in phantom the traverse slide mechanism, the traverse servomotor, and a proximity switch arrangement for determining the position of the traverse assembly; Figure 3 is a partial perspective view of the two collets of the winder machine illustrated in Figure 1, the right-most collet being in position for winding of fibers thereon; Figure 4 is a partial perspective view from the rear of the winder machine, illustrating the traverse slide assembly, the proximity switch arrangement (together with the counter- weight arrangement therefor), and the servomotor for the traverse;

Figure 5 is a partial perspective view illustrating the turret rotation system, including the turret motor, and also the traverse slide assembly, which includes a stepping motor for driving a threaded rod assembly; Figure 6A is a schematic representation of a collet of the winder machine of Figure 1 being wound with fibers to form the beginning of a package, illustrating a kiss roller and the associated T-bar arrangement located at an intermediate position between two proximity switches; Figure 6B is a schematic view illustrating a further buildup of the package, in comparison with Figure 6A, wherein the upright of the T-bar mechanism is activating one of the proximity switches; Figure 6C is a schematic view, illustrating outward movement of the traverse due to the activation of the proximity switch by the T-bar assembly, such outward movement of the traverse allowing clearance between the traverse assembly and the package being built up; Figure 7 is a perspective view of the winder of the present invention, from the rear, illustrating the drive connection of the two collet drive motors; Figure 8A is a schematic representation of the turret of the present invention showing the turret in an intermediate position; Figure 8B is a schematic representation of the turret latch mechanism of the present invention locking the turret in a predetermined position, pursuant to a predetermined arrangement of two turret limit switches; Figure 9 is a front elevational view of a control panel constructed in accordance with the present invention; Figure 10 is a schematic view of a control layout for the winder of the present invention.

Detailed Description The accompanying drawings and the description which follows set forth this invention in its preferred embodiment. However, it is contemplated that persons generally familiar with textile machinery will be able to apply the novel characteristics of the structures illustrated and described herein in other contexts by modification of certain details. Accordingly, the drawings and description are not to be taken as restrictive on the scope of this invention, but are to be understood as broad and general teachings.

Referring now to the drawings in detail, wherein like reference characters represent like elements or features throughout the various views, the winder machine of the present invention is indicated generally in the figures by reference character 10.

Turning to Figure 1, winder machine 10 includes a housing, generally 12 supported by legs, generally 14. Extending outwardly from the front, generally 16, of winder machine are two rotatable collets, generally 18 and 20. Collets 18 and 20 can be of conventional design.

Collets 18 and 20 are carried on a rotatable turret plate, generally 22. Turret plate 22, upon being indexed approximately 180 degrees, allows for either one of the collets 18,20 to be presented to a traverse assembly, generally 24, during winding of fibers, such as fiberglass fibers F, onto a tube T such as shown in Figures 6A through 6C. A curved generally S-shaped plate 25 divides and provides a shield between collets 18 and 20.

Traverse assembly 24 includes a traverse roll, 26 having a helical groove 28 provided along its length. A shoe, generally 30, is connected to the helical groove 28, such that as traverse roll 26 is rotated, shoe 30 oscillates back and forth in front of a collet being wound with fiber. This allows for an even buildup of fiber on the tube T, in order to form a package P, such as illustrated in Figure 6A through 6B.

Traverse roll 26 and shoe 30 can be of conventional design.

On one end of traverse roll 26 is an end plate 32. Also connected to end plate 32 is tie rod 34 and rod 36. Rod 34 provides support for a strand hold off guide 37 which supports a fiber as it is connected to a tube T. Rod 36 supports a kiss roll arrangement, generally K, which contacts a package P as it is being wound. Disposed at a lower end of end plate 32 is an outrigger tube 38 which serves to stabilize the traverse assembly 24 during winding operations. By such stabilization, vibration is significantly reduced during winding, such that uniformity of winding of fibers on the package is optimized. Prior to application of outrigger tube 38, noticeable manifestations of the vibration could be detected from examination of wound packages P.

At the opposite end of traverse assembly 24 (opposite from end plate 32), rods 34,36, traverse roll 26, and outrigger tube 38, are fixedly attached to a traverse slide assembly, generally 40 (Figure 4). Traverse slide assembly 40 allows for movement of traverse roll 26 to and fro with respect to a collet being wound. This is necessary in order to maintain proper

clearance between the traverse assembly and the package as it is wound to an ever-increasing diameter, to thereby provide proper clearance for operation of shoe 30.

Traverse slide assembly 40 is illustrated in phantom in Figure 2, as is a servomotor 42 which is directly connected to traverse roll 26. Also illustrated in phantom is a T-bar assembly 44 which rocks or pivots back and forth between proximity switches 46 and 48 (see Figures 6A through 6C).

In Figure 3 kiss rollers 48 are shown which is designed to contact the fiber package as the fiber package P is built up on a collet. Upon buildup of the collet, kiss roller 48 tends to pivot, causing kiss roller arms 50 to which kiss roller 48 is connected to rotate rod 36. Rod 36 is connected to kiss roll linkage 50 such that as kiss roll 48 moves, rod 36 causes corresponding movement of T-bar 44.

As shown in Figure 4, the traverse slide assembly 40 includes an elongated plate 60 having a lower bore 62 extending the width thereof, and upper bore 63 also extending through the width of plate 60, both bores receiving a shaft or rod 64 on which plate 60 is carried for sliding movement. It is noted that the ends of the traverse assembly are fixedly attached through a sliding cover plate 66 to plate 60, such that movement of plate 60 causes corresponding movement of the traverse assembly 24 and plate 66.

Figure 3 illustrates the front of the winder machine 10, and shows movement of the kiss roller 48 between an extended position, as shown in phantom, and a retracted position, as shown in solid lines. The movement of the kiss roll is more fully illustrated in Figures 6A through 6C. Movement of kiss roll 48 by a predetermined amount causes the traverse assembly 24 to back away from the collect being wound in order to provide clearance therebetween.

As noted above, the traverse slide assembly is allowed to move to and fro on bearing rods, or shafts, 64. Such motion of the traverse slide assembly is controlled by a stepping motor 70 and ball screw arrangement 72 more fully illustrated in Figure 5.

Carried on the traverse slide assembly is a servomotor 74 which is directly connected to the traverse roll 26 for rotating the traverse roll 26. It is an important factor of the present invention that the rotation speed of the traverse roll 26 can be controlled. The rotation of the traverse roll controls the speed of movement of the shoe, and the speed of movement of the shoe is dependent upon various factors, such as the instantaneous diameter of the package

being wound, the winding pattern, the actual fiber being wound, package configuration preferences, etc. Accordingly, the provision of the servomotor 74 allows for accurate control of the rotational speed of the traverse roll 26 and, accordingly, the traverse speed of the shoe 30. Connected to the servomotor is a rotary encoder 76, which provides an output indicating the rotational speed of the traverse roller 26, this output being fed to a feedback control system, generally C, to be discussed in more detail below.

Also carried on traverse slide assembly 40 is the T-bar rocker mechanism 44 mentioned above. The T-bar mechanism is fixedly attached to rod 36 which extends outwardly in the traverse roll assembly. Because T-bar assembly 44 is fixedly connected to rod 36, movement of the kiss roll 48 thus causes corresponding movement of the T-bar assembly. T-bar assembly 44 has an upright 78 which pivots between two proximity switches 46 and 48 through arc 84.

Carried on the two horizontal legs 86 and 88 of T-bar assembly 44 are counter-weight posts 90,92 for receiving cylindrical counter-weights 94. The counter-weights are used to properly balance T-bar assembly 44, depending on the winding operation to be performed.

Figures 6A through 6C illustrate the rocking, or pivoting, motion ofthe T-bar assembly between the proximity switches 46,48, Figure 6A showing a package P being built up, with the T-bar assembly in a balanced, steady state position. Figure 6B shows the package as it is built up further, with the T-bar assembly now leaning, such that the upright 78 is approaching proximity switch 46. Once proximity switch 46 receives a reflected signal from upright 78, a signal sent to the control system C, which thereby energizes stepping motor 70 to drive ball screw arrangement 72 (Figure 5). Ball screw arrangement 72 includes a threaded rod 98, the end of which is fixedly attached to plate 60 of traverse slide assembly 40. Threaded rod 98 thus controls movement of the traverse slide assembly along bearing rods 64. When the condition in Figure 6B occurs, the stepping motor 70 is actuated to advance the traverse slide assembly until the upright 78 of T-bar assembly 44 leans to the left, and proximity switch 48 receives a feed back signal. At this point, the stepping motor is de-energized, and traverse slide assembly 40 remains stationary, until the package P is built up further to the extent necessary to once again cause the condition illustrated in Figure 6B to arise.

Figure 5 further illustrates the turret driver arrangement for rotating turret plate 22.

During a winding operation, one collet is used to wind one or more packages thereon at a time.

Thus, when the packages are finished on that collet, the other collet is then rotated into position in front of the traverse assembly. This rotation is caused by rotation of the turret assembly, generally 100. The turret assembly 100 is rotated by a turret motor 101 having a toothed-belt pulley 102 which drives a toothed belt 104, the toothed belt 104 being in driving engagement with the teeth 106 provided on the periphery of turret plate 22. Two limit switches 108 and 110 are fixedly attached to the housing 12 of the winder 10 and sense when turret assembly 100 has been rotated the appropriate amount. When the turret actuator posts 112,114 are in a predetermined relationship with the limit switches, the turret assembly is locked into place and is in proper position for winding. Figures 8A and 8B illustrate this process.

Figure 8A illustrates the turret plate at an intermediate position, i. e., wherein neither collet is in a winding position. In this intermediate position, a turret latch mechanism, generally 116, which includes a latch member 118 actuated by a pneumatic cylinder 120 is in a release position, with the latch member 118 being in a retracted position. As shown in Figure 8B, the turret plate has rotated further such that turret actuator post 114 has contacted the first limit switch 108. This signals the turret motor to decelerate, and once the second limit switch 110 makes contact with the turret actuator post 114, the turret latch member 118 is then advanced in track 122, and locked into place in a keeper, or latch plate 124. The turret latch mechanism then securely holds the turret blade in position for the next winding operation.

Another important aspect of the present invention is the provision of individual collet motors 126,128. Collets 18,20 are driven independently from one another by motors 126 and 128, respectively. Motors 126 and 128 are industrial a. c. motors, and each are connected via belts 130,132, respectively, to a central shaft assembly, generally 136, provided on the turret assembly 100. Shaft assembly 136 includes concentric shafts 138 and 138A having pulleys which allow for each of the motors to be connected to shaft assembly 136, and each collet to be connected to the shaft assembly also. Pulleys 140,140A are on shaft 138 and drive collet 18, and pulleys 142,142A are on sleeve shaft 138A and drive collet 20. This allows for the drive connection between motors 124,126 and collets 18,20 to be maintained even as the turret assembly is rotated.

Each of the collet drive motors 126,128 includes a rotary encoder 146,148, such as manufactured by Lakeshore, connected thereto for monitoring the drive speed of the motors

126,128. The outputs from the rotary encoders pass to a quad relay 150 (Figure 10), and then on to a servo drive 152, such as a servo drive made by Pacific Scientific. Servo drive 152 and quad relay 150 are located in a waywind box 153 in housing 12. A discriminator 151 in communication with the control cabinet controls whether quad relay 150 forwards the output from rotary encoder 146 or 148 depending upon whether collet A or B is being wound.

The servo drive also receives an input from the traverse motor encoder 76. This information is communicated between the servo drive and a digital programmable logic controller (PLC) 154, such as manufactured by Allen-Bradley. The PLC 154 uses predetermined software to maintain the proper drive relationship between the collet motors and traverse motors during buildup of a package, these drive relationships ultimately being predetermined by an operator, depending on the type of package desired, the fiber being wound, and/or other production considerations. An operator inputs the desired package configurations, such inputs to be acted upon by the PLC, into an operator interface 156, such as manufactured by Maple Systems. A modbus module, such as manufactured by ProSoft, is provided in the PLC to translate instructions from the PLC to instructions readable by the servo drive. The operator interface 156, PLC and servo drive could be mounted within housing 12, or carried in a separate cabinet 158 such as illustrated in Figure 9.

Actuation of the collets can be controlled by a pneumatic floor switch 162, if desired.

While preferred embodiments of the invention have been described using specific terms, such description is for present illustrative purposes only, and it is to be understood that changes and variations to such embodiments, including but not limited to the substitution of equivalent features or parts, and the reversal of various features thereof, may be practiced by those of ordinary skill in the art without departing from the spirit or scope of the following claims.