This application is a continuation-in-part of and claims priority to US Provisional Patent Application Serial Number 60/002,612, filed August 21, 1995.

BACKGROUND OF THE INVENTION

U.S. Patent No. 4,158,253, to Gaghan et al . (hereinafter

"the '253 patent") discloses a simplified yarn coiler. The

'253 patent attempts to achieve the laudable goals of trying to make a modular yarn coiler that is easy to construct and repair.

The device of the '253 patent, however, has many drawbacks. One of these drawbacks concerns the '253 patent's use of a crank and gear transmission. Due to this transmission, the '253 device cannot be easily modified to change the pattern of the yarn coil which is made. Accordingly, it is not easy to go from making large diameter coils to smaller diameter coils. In the '253 device, this would require changing the various gears and cranks shown in the '253 patent to achieve a different final drive ratio, which controls coil size. This gear and crank system also makes it difficult and costly to run and synchronize multiple yarn coiling stations in a single factory because each station needs its own gear and crank transmission. Furthermore, the use of gears, themselves, carries inherent problems. For example, gears are subject to mechanical wear, which after time could cause the machine to function improperly, such as when gear teeth break off or there becomes substantial play between deformed teeth. Thus, there is room for improvement within the art.

OBJECTS OF THE INVENTION It is an object of the invention to provide a yarn coiler that is substantially simpler than prior art yarn coilers.

It is a further object of the invention to provide a yarn coiler that uses substantially less parts than prior art yarn coilers.

It is yet a further object of the invention to provide a yarn coiler that is not subject to the problems inherent with gear and crank-based mechanical drives.

It is still yet a further object of the invention to provide a yarn coiler that can be easily programmed to coil yarn in large or small diameter cans or any other configuration. It is still yet a further object of the invention to provide a yarn coiler that can be easily coordinated and synchronized with other identical yarn coilers to produce a yarn coiling factory.

It is still yet a further object of the invention to provide an improved yarn coiler that can be retro-fitted out of a prior art yarn coiler.

These and other objects of the invention are achieved by a yarn coiler comprising at least one swivelly mounted depending yarn tube and an adjustable moving mechanism connected to the tube for moving the tube along a predetermined path. The depending tube can thereby be made to move along a variety of predetermined paths by adjusting the moving mechanism. The adjustable moving mechanism preferably comprises a programmable controller into which a program representing the predetermined path is placed, together with first and second linear moving mechanisms, each independently controlled by the programmable controller, for moving the tube in first and second linear directions, these directions being perpendicular to and coplanar with each other. Furthermore, a frame may connect a plurality of yarn tubes such that the depending yarn tubes move along the same path, the frame being connected to the adjustable moving mechanism for being moved along a predetermined path.

BRIEF DESCRIPTION OF THE DRAWINGS Figures IA and IB are elevational views of a yarn coiler according to the invention.

Figure 2 is a plan view of a yarn coiler according to the invention.

Figure 3A is a side elevation view of a second linear moving mechanism for use with a yarn coiler according to the invention.

Figure 3B is a front view of a first linear moving mechanism for use with the yarn coiler according to the invention.

Figure 4 is an elevational view of a second embodiment of a two-dimensional moving mechanism for use with the yarn coiler according to the invention.

Figure 5 is a view along line 5-5 of Figure 4. Figure 6 is a plan view of the first linear moving mechanism for use with the second embodiment of a two- dimensional moving mechanism for use with the yarn coiler according to the invention.

Figure 7 is an elevational view of a third embodiment of a two-dimensional moving mechanism for use with the yarn coiler according to the invention. Figure 8 is a view along line 8-8 of Figure 7. Figure 9 is a view along line 9-9 of Figure 8. Figure 10 is an elevation view of a fourth embodiment of a two dimensional moving mechanism for use with the yarn coiler according to the invention. Figure 11 is a plan view of the fourth embodiment of a two dimensional moving mechanism for use with the yarn coiler according to the invention.

Figure 12 is a view along line 12-12 of Figure 11. Figure 13 is a schematic view of a single controller connected to a plurality of yarn coiling stations.

DETAILED DESCRIPTION OF THE DRAWINGS Figures IA and IB show elevational views of a first embodiment of yarn coiler 5 according to the invention. Figure 2 shows yarn coiler 5 having the ability to simultaneously coil four cans of yarn 2. Although each yarn can must have the same diameter, that diameter may vary as shown by differing diameters 3, 3a of Figure 2.

Supported above the floor on which yarn cans 2 are placed are four depending hollow yarn tubes 10. There is one tube 10 per yarn can 2. Each yarn tube 10 has upper and lower ends.

At the upper end of each yarn tube 10, pivot 12 is attached.

Attached to the coiler support frame will be pivot mount 15.

In the preferred embodiment it is envisioned that pivot 12 will be a semispherical-shaped ball and pivot mount 15 will be a corresponding semispherical-shaped hole. The ball will have a hole therethrough for downwardly directed yarn to pass through. Other types of pivots and pivot mounts may be used. Furthermore, while four depending hollow yarn tubes 10 are shown in the preferred embodiment, it is possible for there to be as few as one, or more than four, depending hollow yarn tubes 10. Yarn strands are fed to yarn tubes 10 by yarn feed mechanisms 800, 800' . The yarn feed mechanisms are mounted to either overhead supports or legs to suspend them, as well as depending yarn tubes 10, above yarn cans 2, which will be resting on the factory floor. Side plates 812, 812' support pivot mounts 15. For feeding yarn strands S, a motor (not shown) rotates shafts 820, 820' . Mounted on ends of shafts 820, 820' are feed rolls 810, 810' . Against yarn strand S and feed rolls 810, 810' are idler rolls 815, 815' .

For moving the four yarn tubes 10 in an arcuate path for coiling the yarn, two-dimensional moving mechanism 50 connected to frame structure 80 is provided. Frame structure 80, which will later be described in greater detail, is used to cause each tube 10 to simultaneously move along the same path, at the same speed, as the other tubes 10, thereby producing four identically coiled cans of yarn 2.

As shown in Figures 1-3, two-dimensional moving mechanism 50 comprises first and second linear moving mechanisms 50a, 50b. First linear moving mechanism 50a is for moving depending tubes 10 in a first linear direction while second linear moving mechanism 50b is for moving depending tubes 10 in a second linear direction, perpendicular to and coplanar with the first. Each linear moving mechanism is independently controlled by programmable controller C, typically a conventional microprocessor-based digital device. Thus, by varying the program in controller C, it is possible to cause the depending tubes to move along a variety of paths. While typically the variety of paths (yarn coil layouts) will be circles of varying

radii, the instant invention is not limited to such movements. For example, squares of decreasing area may be produced, if needed. The variation in coil shapes for the yarn are only limited by the length of the various threaded jackshafts to be described herein and by the amount of swivel allowed by pivot 12 and pivot mount 15. Tubes 10 are not limited to a fixed path such as in the '253 patent. These general premises apply to each embodiment disclosed herein of two-dimensional moving mechanism 50. As shown in Figure 3B, first linear moving mechanism 50a is mounted above frame 80 (FIGS. IA & IB) to a fixed and rigid overhead surface by first horizontal support bracket 51. First support bracket 51, adapted to be affixed to the fixed and rigid overhead surface, is generally flat. Mounted to, and below, first support bracket 51 are two pairs of bearings 52, 52' for rotatable receipt of two threaded jackshafts 45, 45' therein. Each jackshaft 45, 45' has a pulley 48, 48' mounted thereon, the pulleys 48, 48' being connected by drive belt 49. Accordingly, jackshafts 45, 45' will rotate in the same direction and at the same speed. Motor 40 is connected to an end of one of jackshaft 45, 45' for rotating the same. Motor 40 is electronically connected to, and controlled by, controller C. Typically, all motors used in the yarn coiler according to the invention will be stepmotors because they are easy to synchronize and produce precise amounts of rotation. Furthermore, all motors described herein will also be mounted, either directly or by bracket, to the various supports so as to be fixed except for their respective drive shafts. Mounted on each threaded jackshaft 45, 45' are threaded bearings 46, attached to second linear moving mechanism 50b. It should be noted that as referred to herein, "bearing(s) " refer to ordinary bearings for rotatably supporting ends of a shaft, while "threaded bearing(s) " refer to those types of bearings which have threaded interiors such that when a threaded shaft inside the threaded bearing is turned, the threaded bearing will move in a linear direction along the shaft.

As shown in Figure 3A, second linear moving mechanism 50B is mounted on second support bracket 55. Second support bracket 55 is generally H-shaped, having horizontal portion 55', upper vertical portions 55'', and lower vertical portions 55''' . In this regard, "upper" and "lower" are measured with respect to horizontal portion 55' . Upper vertical portions 55'' of the H support threaded bearings 46 of first linear moving mechanism 50a (FIG. 3B) . Thus, as controller C causes motor 40 to rotate jackshafts 45, 45', first linear moving mechanism 50A moves in the first linear direction.

Lower vertical portions 55''' of the H support bearings 54, 54' for receipt of another threaded jackshaft 43. At the end of jackshaft 43 is another motor 40a, also controlled by controller C, for rotating jackshaft 43. Carriage 57 has wheels 59 and is mounted to move along horizontal portion 55' of first support bracket 55, in a linear direction parallel to jackshaft 43 and perpendicular to jackshafts 45, 45' . To achieve this, middle portion of carriage 57 comprises a threaded bearing 58 that receives threaded jackshaft 43. Thus, as motor 40a causes jackshaft 43 to rotate, carriage 57 will be made to move in a linear direction parallel to jackshaft 43 and perpendicular to jackshafts 45, 45' . The lower portion of carriage 57 has a pin 85 downwardly depending therefrom. It is easily seen that as first linear moving mechanism 50a causes second linear moving mechanism 50B to move in a first linear direction, and that as second linear moving mechanism 50a causes carriage 57 to move in a second linear direction, perpendicular to and coplanar with the first, pin 85 will be caused to move along an arcuate path. To move depending tubes 10 in an arcuate direction, they must be linked for movement to pin 85. Achieving this goal, frame 80 (FIGS. IA & IB) comprises two perpendicular beams 81, 86 (FIG. 2) that are attached together. One of beams 81, 86 has a mount for receiving pin 85. Thus, as pin 85 moves, so do beams 81 and 86. Each beam 81, 86 has first and second ends. Ends 81, 86 are connected to depending tubes 10 by connecting bars 90. In the preferred embodiment there are eight (8) such

connecting bars 90. Each depending tube 10 is connected to both beams 81 and 86 by two connecting bars 90 and one frame connector 93. Connecting bars 90 are made from adjustable length mechanical elements. With this structure, as pin 85 is moved in an arcuate path by first and second linear moving mechanisms 50a, 50b, beams 81, 86 move in that same arcuate path, causing connecting bars 90 to move depending tubes 10 along that same arcuate path.

It is highly probable that many factories currently use prior art yarn coilers such as that in the '253 patent. Accordingly, it will be advantageous to retro-fit these prior art coilers to take advantage of the teachings of the instant invention. In this regard, that is simple. As shown in Figures IA and IB, the prior art drive mechanism of the '253 patent has been removed from bracket B. Then, all one would need to do is mount the selected embodiment of the two- dimensional moving mechanism to the existing overhead support, connect controller C to the two motors, and enter the selected program in controller C. This retro-fitting is conceived to take a minimum amount of time.

Figures 4-6 show various views of a second embodiment of a two-dimensional moving mechanism 150 for use with the yarn coiler according to the invention. In this embodiment, both first and second linear moving mechanisms 150a, 150b have dual jackscrew structures. As shown in Figures 4-6, first linear moving mechanism 150A is mounted above frame 80 (FIGS. IA & IB) to a fixed and rigid overhead surface by inverted U-shaped bracket 160. Mounted to downwardly depending legs 161, 162 of U-shaped bracket 160 are two pairs of bearings 163, 163' for rotatable receipt of two threaded jackshafts 180, 180' therein. Each jackshaft 180, 180' has a pulley 170, 170' mounted thereon and the pulleys 170, 170' are connected by drive belt 175. Accordingly, jackshafts 180, 180' will rotate in the same direction and at the same speed. Motor 155 is connected to an end of one of jackshafts 180, 180' for turning the same in accordance with the program in controller C. Mounted on each threaded jackshaft 180, 180' are threaded bearings 205, 205'

attached to second linear moving mechanism 150b. Second linear moving mechanism 150b is mounted in a generally inverted box¬ like second support bracket 200. Second support bracket 200 has a horizontal portion, two downwardly depending sides 201, 201', and two downwardly depending ends 202, 202' . Mounted to downwardly depending ends 202, 202' are two pairs of threaded bearings 205, 205' through which jackshafts 180, 180' pass. Thus, as controller C causes motor 155 to rotate jackshafts 180, 180', second linear moving mechanism 150b moves in the first linear direction.

As shown in Figure 6, second support bracket 200 has two pairs of bearings 241, 241' mounted on its sides 201, 201' , for receipt of another pair of threaded jackshafts 244, 244' . Each jackshaft 244, 244' has a pulley 260, 260' mounted thereon, pulleys 260, 260' being connected by drive belt 265. Accordingly, jackshafts 244, 244' will rotate in the same direction and at the same speed. Motor 255 is attached to an end of one of threaded jackshafts 244, 244' for rotating the same. Carriage 230 is mounted to move in a linear direction parallel to the direction of jackshafts 244, 244' and perpendicular to jackshafts 180, 180' (FIG. 5) . To achieve this, carriage 230 has threaded bearings 245, 245' that receive threaded jackshafts 244, 244' . Thus, as motor 255 causes jackshafts 244, 244' to rotate, carriage 230 will be made to move in a linear direction parallel to jackshafts 244, 244' and perpendicular to jackshafts 180, 180' . A lower portion of carriage 230 has pin 85 downwardly depending therefrom. It is easily seen that as first linear moving mechanism 150A causes second linear moving mechanism 150B to move in a first linear direction, and as second linear moving mechanism 150B causes carriage 230 to move in a second linear direction, perpendicular to and coplanar with the first, pin 85 (FIG. 4) will be caused to moved along an arcuate path.

Figures 7-9 show yet a third embodiment, a two dimensional moving mechanism 300 which is very similar to the second embodiment inasmuch as the third embodiment uses: two pairs of threaded jackshafts 322, 322' and 360, 360'; two pairs of

threaded bearings 345, 345'and 385, 385'; two motors 330, 355; two pairs of pulleys 370, 370' and 340, 340'; two drive belts 325, 375, connecting the pulleys; and pin 85. In this embodiment, two dimensional moving mechanism 300 is attached to the fixed and rigid overhead support by first support bracket 310, in the form of a generally flat bracket. Second linear moving mechanism 300B is attached to first linear moving mechanism 300A by use of a second support 350, which is mounted to threaded bearings 345 of first linear moving mechanism 300A. This embodiment works in an identical fashion to that described with respect to the second embodiment and only differs in the construction of the various supports of the two linear moving mechanisms.

Figures 10-12 show yet a fourth embodiment of a two dimensional moving mechanism 400. The fourth embodiment uses: two threaded jackshafts 422, 460; two threaded bearings 445, 485; two motors 430, 455 linked by controller C; and pin 85. This embodiment lacks the pulleys found in some of the other embodiments of the invention since first and second linear moving mechanisms 400A, 400B each comprises only a single threaded jackshaft. In this embodiment, it is foreseen that first and second linear moving mechanisms 400A, 400B each comprise a conventional, off-the-shelf linear movement generating device, such as an NSK MONOCARRIER. Such conventional linear movement generating devices comprise the combination of a fairly rigid and inflexible beam, bearings, threaded jackshaft, and motor. While such linear movement generating devices have seen use in many environments, prior to the instant invention, use of two such devices as a replacement for the mechanical gear drive of a yarn coiler such as shown in Gaghan has not been envisioned. In this embodiment, two dimensional moving mechanism 400 is attached to the fixed and rigid overhead support, preferably bracket B from which the prior art gear drive was hung (Figures IA, IB) , by use of one or more angle-members 410. Each angle member 410 preferably has a plurality of holes 470 therein for mating with the holes in bracket B and the passing of fasteners (not-shown)

therethrough. Hanging from angle-members 410, by use of fasteners 415 or any other means such as welding or adhesive, is first support bracket 451. First support bracket 451 will typically take the form of a generally flat rectangular or square plate. First linear moving mechanism 400A is hung from first support bracket 451 by mounting its first rigid and inflexible beam 453, which supports bearings 452, which themselves support threaded jackshaft 422, to the ends or lower surface of first rigid and inflexible beam 453. Second linear moving mechanism 400B is attached to first linear moving mechanism 400A by having threaded bearing 445 of first linear moving mechanism 400A support second support plate 465 thereunder using any known connectors, including but not limited to threaded fasteners or welding. Second rigid and inflexible beam 463 of second linear moving mechanism 400B is hung from, or is unitary with second support bracket 465. Bearings 441, which support threaded jackshaft 460, are mounted to the ends or lower surface of second rigid and inflexible beam 463. Finally, threaded bearing 485 is positioned on threaded jackshaft 460 and pin 85 downwardly depends from threaded bearing 485. The conventional construction of second linear moving mechanism 400B as described above in combination with second support bracket 465 assures that the second linear moving mechanism 400B will not pivot about threaded bearing 485. Accordingly, threaded jackshaft 460 will not jam within threaded bearing 485.

The embodiment of Figures 10-12 operates as follows and can be retro-fitted to replace a prior art gear drive as generally described above. The user first removes the prior art gear drive used in the prior art yarn coiler. Two dimensional moving mechanism 400 is hung from now-empty bracket B using fasteners passed through holes 470 and the corresponding holes in bracket B (other hanging mechanisms may be used) . As controller C causes motor 430 of first linear moving mechanism 400A to rotate jackshaft 422, second linear moving mechanism 400B moves in the first linear direction indicated by the arrows in Figure 11. Similarly, as controller

C causes motor 455 of second linear moving mechanism 400B to rotate jackshaft 460, threaded bearing 485 will be made to move in the second linear direction, parallel to jackshaft 460 and perpendicular to jackshaft 422, as indicated by the arrows in Figure 12. The lower portion of threaded bearing 485 has a pin 85 downwardly depending therefrom. It is easily seen that as first linear moving mechanism 400A causes second linear moving mechanism 400B to move in a first linear direction, and that as second linear moving mechanism 40OB causes threaded bearing 485 to move in a second linear direction, perpendicular to and co¬ planar with the first, pin 85 will be caused to move along an arcuate path.

Described to this point has been a single yarn coiling station, or apparatus, 5, comprising four separate yarn coiling tubes 10. Typically, however, a factory will have a plurality of yarn coiling stations 5, producing many more than four cans of yarn at a time. With prior art yarn coilers such as the one shown in the '253 patent, it has been very difficult to synchronize these plurality of yarn coiling stations. Mechanical gear and crank movements make it very hard to interconnect multiple coiler stations. Furthermore, each coiler station will need its own gear and crank transmission, adding substantial cost to the factory. With the instant invention, the use of controller C and step motors eliminates this problem. A single controller C, programmed with the desired yarn layout, can control virtually any number of step motors. Thus, one controller C can be used to cause any number of yarn coiling stations to produce the desired yarn layout, as schematically seen in FIG. 13, where a controller C is connected to yarn coiling stations 105, 205, 305, and 405, each of these stations being identical to the yarn coiler 5 described previously herein. This allows the layout of all the yarn coiling stations to be changed by merely making a single change to controller C, rather than changing the gear and crank transmission of each individual yarn coiling station.

Finally, while the invention is discussed with the use of a programmable controller which independently controls first

and second linear moving mechanisms to produce the arcuate movement of depending tubes 10 to produce the yarn coils, the concept behind the invention is not limited to such a use. It is entirely possible to use other methods, including the use of complex mechanical movements, to provide a yarn coiler having the ability to produce a variety of yarn layouts. While not preferred, all such methods are within the scope of the invention.

The above description is given in reference to an improved yarn coiler. However, it is understood that many variations are apparent to one of ordinary skill in the art from a reading of the above specification and such variations are within the spirit and scope of the instant invention as defined by the following appended claims.