BACKGROUND OF THE INVENTION Silk yarns are produced from silk cocoons. During the production silk cocoons are boiled, filled with water, a cocoon thread end is recognized and caught, the silk thread is unreeled and combined with other threads to form a silk yarn.

Prior art devices usually handled only some of the above mentioned stages, and were tailored to work with cocoons of a predetermined quality. The prior art devices have large external dimensions, and a production line of silk yarns which is size, power and labor consuming.

Prior art machines could exploit only up to 70% of a cocoon thread was exploited to produce a yarn. Prior art silk yarn production devices did not control the thickness of each yarn.

There is a need for a highly efficient device and a method for producing silk yarns from silk cocoons, a device and method that enables to exploit almost all the cocoon thread, a device and a method that are adapted to produce silk out of cocoons of different quality and breed, to provide a concise device for producing silk yarn, to reduce the labor involved in the production of silk yarns, to control the thickness of each silk yarn that is produced by the device and to produce high quality silk yarns.

SHORT DESCRIPTION OF THE DRAWINGS While the invention is pointed out with particularity in the appended claims, other features of the invention are disclosed by the following detailed description taken in conjunction with the accompanying drawings in which:

FIG. lis a side view of a device for producing silk yarns, according to a preferred embodiment of the invention; FIG. 2 is a top view of a device for producing silk yarns, according to a preferred embodiment of the invention; FIG. 3 is a cross sectional view of a device for producing silk yarns, according to a preferred embodiment of the invention; FIG. 4 is a top view of a water bath, according to a preferred embodiment of the invention; FIG. 5 is a cross sectional view of a boiling unit, according to a preferred embodiment of the invention; FIG. 6 is a top view of a portion of a cocoon selection unit, according to a preferred embodiment of the invention; FIG. 7 is a cross sectional view of a carousel type thread catching station, according to a preferred embodiment of the invention; FIG. 8 is a top view of a carousel type thread catching station, according to a preferred embodiment of the invention; FIG. 9 is a cross sectional view of a portion of a thread catching device arm, according to a preferred embodiment of the invention; FIG. 10 is a top view of a bristle base, according to a preferred embodiment of the invention; FIG. 11 is a top view of mechanism for forcing a thread catching device arm to perform a return rotary motion, according to a preferred embodiment of the invention; FIG. 12 is a top view of a linear conveyor station, according to a preferred embodiment of the invention; FIG. 13 is a cross sectional view of a linear toothed conveyor and a sloped bar, according to a preferred embodiment of the invention; FIG. 14 is a side view of a linear conveyor station, according to a preferred embodiment of the invention; FIG. 15 is a top view of a cocoon oscillating bar, according to a preferred embodiment of the invention; FIG. 16 is a cross sectional view of a thread guiding shaft, according to a preferred embodiment of the invention;

FIG. 17 is a top view of a jagged carousel and carousel catchers, according to a preferred embodiment of the invention; FIG. 18 is a top view of an intermediate catcher base, according to a preferred embodiment of the invention; FIG. 19 is a cross section view of a carousel catcher, according to a preferred embodiment of the invention; FIG. 20 is a top view of an intermediate thread catcher, according to a preferred embodiment of the invention; FIG. 21 is a side view showing an intermediate thread catcher and a pneumatic driven rod, according to a preferred embodiment of the invention; FIG. 22 is a side view of a yarn defect detector, according to a preferred embodiment of the invention; FIG. 23 is a top view of a yarn defect detector, according to a preferred embodiment of the invention; FIG. 24 is a side view of a yarn thickness monitor, according to a preferred embodiment of the invention; FIG. 25 is a top view of a yarn thickness monitor, according to a preferred embodiment of the invention; FIG. 26 is a side view of a yarn twisting and guiding unit, according to a preferred embodiment of the invention; FIG. 27 is a side view of a winding yarn guide, according to a preferred embodiment of the invention; FIG. 28 is a partial sectional view of a winding station, according to a preferred embodiment of the invention; FIG. 29 is a cross sectional view of a grooved drive roller, according to a preferred embodiment of the invention; and FIG. 30 is a cross sectional view of a yarn drying unit, according to a preferred embodiment of the invention.

DETAILED DESCRIPTION OF THE DRAWINGS It should be noted that the particular terms and expressions employed and the particular structural and operational details disclosed in the detailed description and

accompanying drawings are for illustrative purposes only and are not intended to in any way limit the scope of the invention as described in the appended claims.

The invention provides a device and a method for producing silk yarns, the device is configured to receive silk cocoons, to boil the cocoons, fill the cocoons with water, recognize a thread end and catch it, and unreel the cocoon, while controlling the quality of a silk yarn made of a plurality of silk threads.

The invention provides a highly efficient device and method for producing silk threads, in which almost all of the cocoon thread is extracted. The device has a thread catching station that does not damage a cocoon during a step of finding a cocoon thread end and catching it. Furthermore, cocoons that do not give an end of a thread or that have their thread broke during the production are directed to a thread catching station for repeat treatment.

The invention provides a device that has a waste removing and transporting mechanism, for receiving cocoon threads from the thread catching station, for removing dirt and untangle tangled cocoon threads and for transporting the cocoon threads to a plurality of thread processing units. Especially, the waist removing and transporting mechanism comprising a linear conveyor station and a carousel type conveyor.

The invention provides a compact device for producing silk thread that can be used in a considerably more limited amount of space than prior art devices for producing silk yarns.

The invention provides a device for producing a plurality of high quality silk yarns, wherein the device controls the quality of each silk yarn being produced by it. Especially, a yarn thickness is monitored in a manner such that when the silk yarn is too thick (i. e.- is above a second predetermined threshold), the yarn is not being winded around a bobbin.

When one or more threads break the velocity of the yarn winding is diminished, until new threads are joined to the yarn. When the yarn is too thin (i. e.- is below a first predetermined threshold) the winding speed of that yarn is decreased and if the yarn remains too thin for predetermined period it is further decreased. The winding process can stop if the yarn remains too thin for another predetermined period. Controlling the quality of each silk yarn allows the device to produce a silk yarn of cocoon threads of different quality and breeding.

The invention provides a device that has an almost tension free winding station, allowing silk yarns to be wound at more than 250 meters per minute.

The invention provides a device for producing silk yarn in which the various steps of silk yarn production are synchronized in a manner that optimizes the device performances.

Especially, provision rate of cocoons to the a boiling unit within the device, the temperature of water within the boiling unit, the duration of the cocoons within the boiling unit, the rotational speed of a plurality of brushes that are configured to recognize a cocoon thread end and catch it, are synchronized to the rate in which cocoons threads are being winded.

FIGS. 1-3 are a side, top and cross sectional views of device 31 for producing silk yarns, according to a preferred embodiment of the invention. The various pats of device 31 are shown in further details in FIG. 4-30. FIGS. 1-3 illustrate some portions of device 31 such as base 32, boiling unit 60, cocoon selection unit 70, first selection unit axis 74, second selection unit axis 75,76, cocoon sprayer 77, waist unit 80, thread catching station 90, wadding collector 100, linear conveyor station 109, cocoon oscillating bar 110, thread guiding shaft 120, jagged carousel 130, intermediate thread catcher 140, carousel catcher 150, rod 160, yarn defect detector 170, yarn thickness monitorl80, yarn twisting and guiding station 190, winding unit 200, winding station motor 207, yarn drying unit 210, central pole 230, two supporting members 231 and 232 that are connected to central pole support various portions of a plurality of thread processing stations, bath 250, bath bottom 251, soaking unit 260, control panel 270, cocoon chamber 616, two ends of flipping lever 952 and 955 Water bath 250 is adapted to be partially filled with water, in which cocoons are transferred during the yarn production. Bath 250 is mounted on base 32. Base 32 supports a plurality of motors, such as boiling unit motor 66, selection unit motor 76, catching device axis motor 9123, and also supports control unit 280 (not shown). Control unit 280 preferably comprising of at least one processor.

Referring to FIG. 4, water bath 250 comprises of several sections, such as annular channel 99 in which cocoons are transferred while thread catching unit 90 (shown in greater detail in FIG. 7-8) detects and finds a thread end; a conveyance section 258 in which cocoons are conveyed by linear toothed conveyer 102 and have dirt, tangled threads and external cover being removed so that a single continuously unreeled cocoon is provided to a plurality of thread catchers cooperable with a plurality of yarn processing stations; and circular duct 256 in which cocoons are unreeled.

Water bath 250 comprising horizontal bath bottom 251, bath external vertical wall 252, first to third bath internal vertical walls 253,254 and 255, bath inlet 256 and bath outlet 257. Horizontal bath bottom 251 supports bath external vertical side wall and first to third bath internal vertical walls 253,254 and 255. First bath internal vertical wall 253 is circular and surrounds catching device sleeve 93. A first portion 2521 of external vertical wall 252 is

curved in a manner that it, bottom 251 and first bath internal wall 253 form annular channel 99.

Annular channel 99 is partly filled with water in which cocoons from cocoon selection unit 70 are transferred while a plurality of brushes detect and catch cocoon thread ends.

Second internal vertical wall 254 is rectangular shaped, and surrounds rectangular base 101, being a part of linear conveyor station 109. Conveyance section 258 is formed between a facet of internal vertical wall 254 and a portion of bath external vertical wall 252.

Third bath internal vertical wall 255 is circular and surrounds central vertical pole 230. A second portion 2522 of external vertical wall 252, opposed to first portion 2521 of external vertical wall 252 is curved in a manner that it, bottom 251 and third bath internal wall 254 form a circular duct 256.

A water pump (not shown) forces water to go through bath water inlet 256 and to flow within circular duct 256, in a manner that cocoons that do not give an end of a thread or that have their thread broke during the unreeling process are directed to thread catching station 90 for repeat treatment. Conveniently, water flows from bath outlet 257 through a water filtering unit (not shown) and return to bath 250 through bath inlet 256.

A perforated pipe (not shown) is placed below the water level within bath 250 and surrounds third internal vertical wall 255. Air flows from an air pump (not shown) that is connected to an input of the perforated pipe and through a plurality of holes within the pipe, thus preventing cocoons to stick to third vertical wall 255.

Boiling unit 60 is adapted to receive cocoons from soaking unit 260, to boil the cocoons and fill them with water. Referring to FIG. 5, boiling unit 60 comprises of boiling unit housing 61, boiling unit heating element 62, boiling unit conveyor 63, boiling unit water inlet 65 and boiling unit motor 66. Housing 61 has a boiling unit cocoon inlet 610 and a boiling unit cocoon outlet 611. Boiling unit cocoon inlet 610 is fixed to a cocoon chamber 616 that is adapted to receive cocoons from soaking unit cocoon outlet 261. Cocoon chamber 616 has a rectangular cross section and is oriented at about 60 degrees to the horizon. Boiling unit heating element 62 is located within boiling unit housing 61, near a lower portion of boiling unit housing 61. Boiling unit heating element 62 is configured to heat water (i. e.- heated water) within boiling unit housing 62 and to remove sericin from the cocoon. The water is heated to 85-95 degrees centigrade.

Boiling unit conveyor 63 comprising of boiling unit conveyor belt 631 and a pair of boiling unit conveyor axis 632. Boiling unit conveyor belt 631 is driven by pair of boiling unit conveyor axis 632 that are driven by boiling unit motor 66. The revolution speed of boiling unit motor is controlled by BUMSPEED signals sent from control unit 90. A plurality of fins 634 are integrally fixed to boiling unit conveyor belt 631, to form a plurality of cocoon boiling unit holders. Cocoons that are provided from soaking unit 260 fall by gravity to the cocoon boiling unit holders, and are conveyed along a elliptical path through the heated water to cocoon boiling unit outlet 611, to be provided to cocoon selection unit 70.

Boiling unit conveyor belt 631 also plays a role of a cover intended for forced sinking cocoons into the heated water.

A waist unit 80 and a cocoon selection unit 70 are located near boiling unit cocoon outlet 611 in a manner such that cocoons that exit boiling unit 60 are provided to cocoon selection unit 70, to be selected by the latter. Selected cocoons are provided to thread catching station 90 and the remaining cocoons are provided to waist unit 80.

Referring to FIG. 6, cocoon selecting unit 70 comprising a plurality of parallel selecting unit bars 71 displaced at a fixed distance CSU1 from each other (each selecting unit bar having two ends) a first and second selection unit drive chains 72 and 73, first and second selection unit axis 74 and 75, selection unit motor 76 and a cocoon sprayer 77. A first end of each bar of selecting unit bars 71 is fixed to first selection unit drive chain 72 and an opposite end of each bar of selecting unit bars 71 is fixed to second selection unit drive chain 73.

Cocoon selecting unit 70 selects cocoon that are wider than predetermined threshold CS U 1. Cocoons that are narrower than CSU1 fall between parallel selecting unit bars, to be provided to waist unit 80.

Each of selection unit axis 74 and 75 has two chain wheels, a first chain wheel is fixed to one end of a selection unit axis and a second chain wheel is fixed to an opposite end of the selection unit axis. First chain wheel of both selection unit axis 74 and 75 is configured to receive first selection unit drive chain 72 and to drive it, when first and second selection unit axis 74 and 75 are driven by selection unit motor 76. Second chain wheel of first and second selection unit axis 74 and 75 are configured to receive second selection unit drive chain 73 and to drive it, when first and second selection unit axis 74 and 75 are driven by selection unit motor 76.

First selection unit axis 74 is placed beneath the surface of water within water bath 250, second selection unit axis 75 is placed above this surface, and near thread catching station 90.

Cocoons that are provided by boiling unit 60 fall by gravity to a location near an emerging point EP in which selecting unit bars 71 emerge from under the water within water bath 250. These cocoons are conveyed by selecting unit bars 71 from emerging point EP along a sloped linear path to pass over second selection unit axis 75 and to be fed to thread catching unit 90. Cocoon selection unit 70 also receives and accordingly selects cocoons from circular duct 256.

The cocoons are heated while they pass through boiling unit 60, thus softening the sericin within the cocoons. The heated sericin can cause cocoons to stick to each other. In order to separate the cocoons from each other and in order to strengthen the cocoons before passing through thread catching station 90, there is a need to cool the cocoons. While cocoons are being conveyed by selecting unit bars they are washed by relatively cold water (about 10-25 degrees centigrade) from cocoon sprayer 77. Cocoon sprayer 77 is located above second selection unit axis 75 and faces selection unit bars 71.

Thread catching station 90 is occupied by carousel-type catching device 9 i and annular channel 99. Thread catching station 90 is configured for finding ends of cocoon threads without damaging the cocoon, and providing the found ends to linear conveyor station 109. Catching device 91 is comprising a plurality of brushes (collectively denoted 901) that perform reciprocal motion around their axis and also a progressive displacement along annular channel 99.

Brushes 901 are configured to contact an upper portion of the cocoons that are within annular channel 99, to find a cocoon thread end and to catch it without damaging the cocoon.

The return rotary motion of brushes 901 cause cocoons that contact the brushes to stay within annular channel 99 for a relative long period, thus increasing the probability that a thread end is found and caught. The return rotary movement drives a cocoon to move from a brush to a consecutive brush and vice verse. Usually, the cocoon is sunken in water, its upper end is located near the surface of the water and brushes 901 enter the water and make contact with the upper end of the cocoon.

Annular channel 99 is closed by cover 991 along its length, cover 991 is provided with a split in which the catching device arms are able to move. Brushes are fastened on the

edges of the split and reduce losses of heat in the surroundings and reduce the energy consumption for the water heating.

Referring to FIG. 7-11, catching device circular upper part 911 is connected for rotary movement to vertical catching device axis 912, being surrounded by vertical catching device sleeve 93. Catching device sleeve 93 is fixed to bottom 2501 of water bath 250 and is perpendicular to the latter. An upper end of vertical catching device axis 912 is fixed to circular upper part 911 and a lower end of vertical catching device axis 912 is fixed to a vertical catching device axis disc 9121, adapted to receive a catching device axis belt 9122.

Vertical catching device 912 is driven by friction by catching device axis belt 9122, driven by catching device axis motor 9123.

A plurality of radially extending catching device arms having a forked shaped end, are pivotally mounted to catching device upper part 911 by means of a plurality of catching device shafts.

Catching device shaft 921 passes through a forked shaped end of a first element 922 of catching device arm 92, and through radially extending element 91 l 1 fixed to catching device circular upper part 911. An opposite end of first element 922 of catching device arm 92 is fixed to catching device arm sleeve 924, in which catching device arm axis 925 revolves. Catching device arm sleeve 924 and catching device arm axis 925 are perpendicular to first element 922 of catching device arm 92. Catching device arm disc 926 is fixed to catching device arm axis 925, and is used, in accordance with horizontal guide groove 941 to control the revolution of catching device arm axis 925.

An end of catching device arm axis 925 is fixed to brush 9271, brush 9271 comprising concave bristle base 927 and a plurality of elastic bristles 929. A plurality of elastic bristles 929 are fixed to bristle base 927. Bristles 929 are fabricated of polymer mono-fibers with high ability of catching threads. Conveniently, a plurality of cavities 928 are formed within bristle base 927, whereas each cavity is adapted to hold several bristles. Cavities 9281-9289 and accordingly bristles that are held by them are oriented at about 35 degrees to catching device arm axis 925. Cavities 9271-9273 and accordingly bristles that are held by them are parallel to catching device arm axis 925. Cavities 9281-9286, cavities 9287-9299 and cavities 9291-9293 are angularly positioned at a first distance R1, second distance R2 and third distance R3 respectively from catching device arm axis 925. R1<R2<R3.

Catching device member 95 is connected for rotary movement to vertical catching device sleeve 93. An upper part of catching device member 95 is shaped as ring, whereas

catching device member groove 951 is formed at a circumference of the ring. Catching device member groove 951 is adapted to contact catching arm disc 926 in a manner such that a rotation of catching device member 95 forces catching device arm disc 926 to revolve.

A radially extending catching device member lever 951 has one end fixed to a lower part of catching device member 95 and another end pivotally mounted to one end of flipping lever 952. An opposite end of flipping lever 952 is engaged to a flipping pin 953. Flipping pin 953 is fixed to flipping disc 954 in a manner that it is subjected to angular movement by flipping disc 954. Flipping disc 954 is driven angularly by flipping motor 955.

The angular movement of flipping disc 954 forces catching device member 95 to perform an alternating angular movement. When flipping pin 953 moves away from catching device member 95, catching device member 95 rotates counterclockwise. When flipping pin moves towards catching device member 95, catching device member 95 rotates clockwise.

The rotation of catching device circular upper part 911 cause catching device arms such as catching device arm 92, bristle base 927, catching device arm axis 924, and bristles 959 to move in a circular path. When catching device arm disc 926 contacts horizontal guide groove 941 brushes such as brush 9271 comprising bristle base 927 and bristles 929 further perform an alternating circular movement around catching device arm axis 924.

A curved track 94 is fixed to a horizontal disc 98, connected to catching device sleeve 93. Curved track 94, contacted by hollow catching device sleeve 924, is adapted to lift each catching device arm after the brush connected to the catching device arm exits annular channel 99 and to lower it before entering curved chamber 99. Catching device arm 93 is being lifted and lowered after exiting annular chamber 99 to enable a thread that is caught by brush 9271 to be placed upon wadding collector 100, installed on the way of the lowered catching device arm 93 in a manner that brush 9271 will roll one third of the perimeter of the face plane of wadding collector 100. By this means reliable catch of the cocoons thread and their winding on wadding collector 100 are executed.

Catching device arm 92 is forced to descend relatively fast so that the found ends of the cocoon threads remain caught by catching device arm 92 until being transferred to wadding collector 100. Conveniently, a forked shaped cleaning device (not shown) is placed in the way of the lowered catching device arm in a manner such that a portion of dirt and tangled cocoon threads are caught by it before a cocoon thread is provided to wadding collector 100.

Referring to FIGS. 12-14, linear conveyor station 109 of cleaning and transporting mechanism 333 is occupied by base 101, linear toothed conveyor 102, sloped bar 103, hexahedral-shaped wadding collector 100, thread cutting device 104 and cocoon oscillating bar 110. Linear conveyor station 109 is configured to receive a thread from thread finding station 90 and to remove dirt, untangle and remove tangled threads and a cover of a cocoon, and to provide a single continuous cocoon thread to thread guiding shaft 120.

A lower toothed conveyor disc 1021 is connected for rotary movement to a sloped lower toothed conveyor axis 1202, passing through sloped lower toothed conveyor cylinder 1203 and base 101. An upper toothed conveyor disc 1029 is connected for rotary movement to a sloped upper toothed conveyor axis 1208, passing through sloped upper toothed conveyor cylinder 1207 and base 101. Sloped upper toothed conveyor axis 1208 is parallel to sloped lower toothed conveyor axis 1202, both are oriented at about one hundred degrees to base 101. Lower toothed conveyor disc 1021 faces thread catching station 109, while upper toothed conveyor disc 1029 faces thread guiding shaft 120 and center pole 230.

A circumference of upper toothed conveyor disc 1029 is bigger than a circumference of lower toothed conveyor disc 1021. A groove is formed in each of these circumferences and is configured to receive an inner portion of toothed conveyor belt 1205. Upper toothed conveyor disc 1029 is higher than lower toothed conveyor disc 1021.

Smooth sloped bar 103 is configured to prevent a thread that is being conveyed by a portion of toothed conveyor belt 1205 in the direction of thread guiding shaft 120 from making contact with another portion of toothed conveyor belt 1205 that advances to the opposite direction. Smooth sloped bar 103 has a sloped portion 1031 fixed to base 101 by two vertical bar portions 1031 and 1033. Smoothed sloped bar 103 is surrounded by toothed conveyor belt 1025. Vertical bar portion 1031 faces sloped lower toothed conveyor cylinder 1203 and vertical bar portion 1033 faces sloped upper toothed conveyor cylinder 1207.

Sloped portion 1031 is located above both upper and lower toothed conveyor discs 1029 and 1201.

Wadding collector 100 comprising a horizontal wadding collector axis 1001, that is connected for rotary movement to a pair of horizontal wadding station supporters 1002, that are positioned at a right angle to wadding collector axis 1001 and are fixed to base 101. A wadding connector sleeve 1003 surrounds wadding collector axis 1001 and is fixed to wadding collector axis 1001 and to a plurality of radially extending fins 1004. Radially extending fins 1004 are fixed to wadding collector axis 1001 to form a hexahedral. Wadding

collector 100 can be shaped in other forms such as a cylinder. A wadding station groove 1005 is formed at one end of wadding collector axis 1001 and is configured to receive a wadding axis belt 1006. Wadding collector axis 1001 is driven by friction by wadding axis belt 1006, driven by wadding collector motor 1007. A plurality of radially extending pins 1008 are fixed to a circumference of the radially extending fins.

Wadding collector axis 1001 is parallel to base 101 and is parallel to a horizontal projection of smooth sloped bar 103. A first end 10001 of wadding collector 100 faces catching device member 90 and a second opposite end 10002 of wadding collector 100 faces central pole 230. Three radially extending pins are located near first end 10001 and a fourth pin is located near second end 10002.

The plurality of radially extending fins 1004 undergo a circular path. The highest point in the path is referred to as top of wadding collector path. Wadding collector 100 and smoothed sloped bar 103 are configured so that most of smoothed sloped bar 103 is lower than the top of the wadding collector path. The height of sloped portion 1031 of smoothed sloped bar 103 equals the height of the top of wadding collector 100 near second end 10002 of wadding collector 100. Thread cutting device 104 is located near second end 10002, and is configured to make contact with a thread that is being conveyed by linear toothed conveyor 102, to cut it near its end and to allow the cocoon thread to be handled to thread guiding shaft 120. The remaining portion of the thread is wrapped around wadding station 100. Thread cutting device 104 comprising vertical thread cutting device supporter 1041 and a horizontal heating element 1042.

Cocoon oscillating bar 110 oscillates in a manner such that prevent cocoon having their threads being wound around wadding collector 100 from being drawn to wadding collector 100 and from sticking to cocoon oscillating bar 110. Cocoon oscillating bar 110 expose cocoons to impact actions that help to remove dirt, untangle and remove tangled cocoons and a cover of a cocoon from the cocoon.

Referring to FIG. 15, cocoon oscillating bar 110 is pivotally mounted to base 101 by means of oscillating bar axis 114 passing through two clops 113 fixed to base 101. Cocoon oscillating bar 110 is forced to move upwards and downwards by oscillating arm 115. One end of oscillating arm 115 is fixed to clip 113 and an opposite end of oscillating arm 115 is engaged to a oscillating pin 116. Oscillating pin 116 is fixed to oscillating disc 117 in a manner that it is subjected to angular movement by oscillating disc 117. Oscillating disc 117 is driven angularly by oscillating motor 118. The angular movement of oscillating disc 117

forces cocoon oscillating bar 11 to perform an alternating angular movement. When oscillating pin 118 moves downwards, cocoon oscillating bar moves downwards, and vice verse.

Cocoon oscillating bar 110 and a horizontal shield 112 form a slot in which threads that are being conveyed by linear toothed conveyer 102 can move. Cocoon oscillating bar 110 prevents a cocoon from being drawn to wadding collector 100 Carousel type conveyor 334 of cleaning and transporting mechanism comprising of thread guiding shaft 120 and jagged carousel 130. Carousel type conveyor 334 is adapted to receive a cocoon thread end from linear conveyor station 109 and to provide it to one of the thread processing stations.

Conical shaped thread guiding shaft 120 is configured to receive a single continuously unreeled cocoon thread from linear toothed conveyor 109, after the cocoon thread end is cut by thread cutting device 104 and to provide the cocoon thread to jagged carousel 130 and to a carousel catcher 150. Thread guiding shaft 120 places an upper end of the cocoon thread above jagged carousel 130 so that the cocoon thread is placed in the way of jagged carousel 130 circumference passage and in the way of carousel catcher 150 passage.

Referring to FIG. 16 thread guiding shaft 120 has one narrow end 121 facing wadding collector 100 and a larger opposite end 122 facing central pole 230. A thread guiding shaft groove 124 is formed near opposite end 123 of thread guiding shaft 120 and is configured to receive a thread guiding shaft belt 125. Thread guiding shaft 120 is driven by friction by thread guiding shaft belt 125 driven by thread guiding shaft motor 126.

Referring to FIG. 17 and 19, jagged carousel 130 is mounted for rotary movement to central pole 230. Jagged carousel 130 rotates clockwise and is adapted to receive a plurality of threads from thread guiding shaft 120 and to provide the threads to a plurality of carousel thread catchers such as carousel catcher 150 angularly positioned above jagged carousel 130.

Jagged carousel 130 is toothed at its circumference and the number of teeth is over the number of thread processing station at least twice.

Each of carousel thread catchers is connected for rotary movement to jagged carousel 130 and is placed near the circumference of jagged carousel 130 in a manner such that a thread that is received by jagged carousel 130 is caught by one of the carousel thread catchers.

Carousel catcher 150 comprising vertical carousel catcher cylinder 151 that surround a vertical carousel catcher axis 152, a lower end of vertical carousel catcher axis 152 passes

through jagged carousel 130, a pair of horizontal radially extending carousel catcher arms 154 fixed to vertical carousel catcher cylinder 151, and a horizontal oriented carousel catcher groove 155, adapted to receive a carousel catcher belt 156 that forces the plurality of carousel catchers to rotate around their axis.

Carousel catcher arms 154 are configured to catch a cocoon thread, being held by thread guiding shaft 120 and a tooth out of a group of the tooth that is formed at the circumference of jagged carousel 130, the group being located near carousel catcher 150. The rotation of carousel catcher arms 154 force this cocoon thread to be wrapped on carousel catcher cylinder 151.

The circular path that is undergone by a pair of carousel catcher arms of a carousel catcher partly overlaps a circular path that is undergone by a pair of carousel catcher arms of a consecutive carousel catcher. In order to prevent these two pair of arms from colliding, one pair of carousel catcher arms is positioned at a higher location than the other pair of carousel catcher arms.

A plurality of thread processing stations are located around center pole 230. Each thread processing station is configured to receive a plurality of cocoon thread fi-om jagged carousel 130 and to generate a silk yarn having a predetermined thickness. Each thread processing station comprises of a processing station thread catcher (conveniently, each processing station thread catcher comprises of a rod and a intermediate thread catcher), a yarn defect detector, a yarn thickness monitor, a yarn twisting and guiding unit, a winding unit and a drying unit.

For convenience of explanation thread processing station 300 is referred to. Thread processing station 300 comprising processing thread catcher 301 (conveniently comprising of rod 160 and intermediate thread catcher 140), yarn defect detector 170, yarn thickness monitor 180, yarn twisting and guiding unit 190, winding unit 200 and drying unit 210.

A horizontal, disc shaped rod base 161 is fixed to central pole 230. Rod base 161 is positioned below jagged carousel 130 and is configured to support a plurality of rods, angulary positioned near the circumference of rod base 161. Radially extending horizontal oriented rod 160 undergoes a linear path after receiving a PUSH-1 control signal. Referring to FIG. 21, the linear path starts above the circumference of rod base 161, crosses over the circumference of jagged carousel 130 and ends near intermediate thread catcher 140, positioned in front of rodl60. Rod 160 is preferably driven by a pneumatically driven.

When rod 160 receives a PUSH-1 control signal from control unit 280 it undergoes a linear path that ends near intermediate thread catcher 142 positioned in front of rodl60. If a thread that is held by one of the plurality of carousel catchers passes through the linear path undergone by rod 160, the thread is fed to intermediate thread catcher 140.

Referring to FIG. 18,20 and 21, intermediate thread catcher 140 comprising of a propellor shaped lower part (i. e.- propeller) 141, that is fixed to an intermediate thread catcher disc 143, both connected for rotary movement to a split ring shaped intermediate thread catcher base 142. Intermediate catcher base 142 internal side faces the circumference of jagged disk 130. An intermediate thread catcher groove 144 is formed at the circumference of intermediate thread catcher disc 143 and is adapted to receive a intermediate thread catcher belt 146, that is used to drive the plurality of intermediate thread catchers.

A vertical oriented intermediate thread catcher groove 147 passes through a center of propeller 141, through intermediate thread catcher disc 143 and through intermediate thread catcher base 142.

Intermediate thread catcher 140 is configured to receive a cocoon thread from rodl60, to join the cocoon thread to other threads being driven through intermediate thread catcher groove 146, to spin these threads and provide them to yarn defect detector 170.

Yarn defect detector 170 is adapted to sense when a yarn is too thick and accordingly to send a THICK-1 signal to control unit 280 that accordingly stops the winding of the yam by winding unit 200. Referring to FIG. 22-23, yarn defect detector 170 comprising defect detector arm 171, vertically oriented defect detector supporter 172, defect detector axis 173 and defect detector arm location detector 174. Defect detector arm 171 is pivotally mounted to defect detector supporter 172 by means of defect detector axis 173. A slot is formed at one end of defect detector arm 171 and is configured to allow a yarn to pass through it as long as the yarn is not too thick. As long as the yarn is not to thick defect detector arm 171 is in a first position. When the yarn is too thick it gets stuck in the slot and causes defect detector arm 171 to rotate upwards and to be in a second position. Defect detector arm location detector 174 detects that defect detector arm 171 is positioned at the second position and sends a THICK-1 signal to control unit 280.

Yarn thickness monitor 180 is adapted to sense when a yarn is too thin and accordingly to send a THIN_1 signal to control unit 280 that accordingly sends a series of PUSH_1 signals to rodl60, in order to catch further cocoon threads and to join them to the yarn.

Referring to FIG. 24-25, yarn thickness monitor 180 comprising thickness monitor arm 181, vertically oriented thickness monitor supporter 182, thickness monitor axis 183, thickness monitor arm location detector 184 and thickness detector weight 185. Thickness monitor arm 181 is pivotally mounted to thickness monitor supporter 182 by means of thickness monitor axis 183. Thickness monitor weight 185 forces thickness monitor arm 181 to fall by gravity to a first position. A trapezoid shaped slot 185 is formed at an opposite end of thickness monitor arm 181 and is configured to allow a yarn within a predetermined range of thickness to force thickness monitor arm 181 to be held in a second position by friction. As long as the yarn is thick enough it forces thickness monitor arm 181 to be positioned in the first position. When the yarn is too thin, there is not enough friction to overcome the effect of thickness detector weight 185 and thickness monitor arm 181 pivots out from the second position. Thickness monitor arm location detector 185 detects that thickness monitor arm 181 in not located at the second position and sends a THIN-1 signal to control unit 280.

Thickness monitor weight 185 comprises of a bolt and a nut, and is configured to be calibrated by the screwing or unscrewing the nut.

Referring to FIG. 26, yarn twisting and guiding unit 190 comprises of three guiding wheels 191-193 and eccentric guiding wheel 194. First guiding wheel 191 is connected for rotary movement to defect detector supporter 172, and is located above defect detector axis 173. Second and third guiding wheels 192 and 194 eccentric guiding wheels are each connected for rotary movement to thickness monitor supporter 182. Second guiding wheel 192 is positioned above first guiding wheel 191 and below thickness monitor arm location detector 184. Eccentric guiding wheel 194 is located below trapezoid shaped slot 185, third guiding wheel is located above the trapezoid shaped slot 185. Eccentric guiding wheel 194 and third guiding wheel 193 are configured to receive a yarn, guide it through the trapezoid shaped slot 185 and provide the yarn to a winding yarn guide 202.

Eccentric guiding wheel 194 is configured to receive a yarn and force it to swivel back and fourth, so that some of the water absorbed in the yarn is forced to leave the yarn.

Eccentric guiding wheel 194 has a disc shaped exterior in which an eccentric shaped groove is formed, the eccentric shaped groove is adapted to receive the yarn.

Yarn from intermediate thread catcher 140 is guided to second guiding wheel 192 than to first guiding wheel 191, is twisted around the yarn that is guided from intermediate thread catcher 140 to second guiding wheel 191, then is guided to eccentric guiding wheel 194, through trapezoid shaped slot 185, third guiding wheel 193 and to winding unit 200.

Referring to FIGS. 27-29, winding unit 200 is occupied by grooved drive roller 203, bobbin 205, winding yarn guide 202, winding station belt 206 and winding station motor 207.

Winding unit 200 is cooperative with yarn drying unit 210. Winding unit 200 is configured to receive a yarn from third guiding wheel 193 and wind the yarn around bobbin 205. The rotation speed of winding station motor 207 is controlled by WSMSPEED1 signals from control unit 290. Preferably, control unit 280 receives a WSM_SPEED_1* signal from a winding station motor detector that monitors the speed of winding station motor 207.

Grooved drive roller 203 is connected for rotary movement to a horizontal grooved drive axis 2031, passing through vertical winding station supporters 2012. Grooved drive roller 203 further comprising helically arranged guiding groove 2032 and belt groove 2032.

Conveniently, guiding groove is oriented at about 30 degrees to horizontal grooved drive axis 2031. Belt groove 2032 is adapted to receive belt 206.

Winding yarn guide 202 is pivotally connected to horizontal winding station base . 2011 by means of winding yarn guide axis 204. One end of winding yarn guide axis 204 passes through slot 2025 formed within first horizontal portion 2024 of winding yarn guide 202 and is fixed to the latter. An opposite end of winding yam guide axis 204 passes through horizontal winding station base 2011. One end of first horizontal portion ? 024 i : turned upwardly and is fixed to a contact element, such as a winging yarn guide roller 2026.

Winding yarn guide roller 2026 is adapted to move within guiding groove 2032, in a manner such that a rotation of grooved drive roller 203 forces winding yarn guide roller 2026 and accordingly winding yarn guide 202 to perform a horizontal reciprocal movement. An opposite end of first horizontal portion 2024 of winding yarn guide 202 is fixed to an end of a sloped and upwardly extending yarn guide element 2023, having an opposite end fixed to a second vertical portion 2021 of winding yarn guide 202.

A yarn guiding slot 2022 is formed within an opposite end of second vertical portion.

Yarn guiding slot 2022 is adapted to receive a yarn and to guide the yarn to bobbin 205.

Bobbin further comprising a bobbin belt groove 2053 that is adapted to receive belt 206.

Bobbin 205 is connected for rotary movement to horizontal bobbin axis 2051, passing through vertical winding station supporters 2012. Horizontal bobbin axis 2051 is parallel to horizontal grooved drive axis 2031. Winding yarn guide 202 is disposed upstream of bobbin 205 in the running direction of the yarn. Bobbin 205 can be of many shapes, such as a cylinder. Bobbin 205 can also comprise of a plurality of radially extending fins fixed to horizontal bobbin axis 2051.

Bobbin 205 and grooved drive roller are driven by friction by belt 206, driven by bobbin motor 207. A rotational speed of bobbin motor 207 is controlled by control unit.

Preferably, belt 206 contacts an inner portion of bobbin belt groove 2053, facing central pole 230. Horizontal bobbin axis 2051 passes through a pair of open ended winding station supporter grooves 2013 formed within a circumference of vertical winding station supporters 2012. Thus, bobbin 205 can be drawn out of winding station and be put into the winding station in a swift manner, without interrupting the rotation of belt 206, and groove drive roller 203.

Referring to FIG. 30, yarn drying unit 210 is comprised of a yarn drying heating element 211, that faces bobbin 205 and a drying motor 212 for forcing air to flow from yarn drying element 211 to bobbin 205. Drying heating element 211 is activated by DRY-1 signals from control unit 280 when a yarn is winded around bobbin 205.

Control unit 280 controls the production of silk yarn, it receives information about the current parameters of the silk yarn production process and it adjusts them on the optimal level. Especially, control unit controls the thickness of the silk yarn and synchronizes the various elements of the device. Control unit 280 comprises a central processing unit and a plurality of input/output interfaces adapted to receive and transmit. control signals, such as a plurality of THINj signals, 0<j<=N I from a plurality (N I) of thread thickness monitors, a plurality of THICKi signals from a plurality (N 1) of yarn defect detectors, a plurality of WSMSPEEDJ and WSM_SPEEDj* signals from a plurality (N1) of winding station motors and a plurality (N1) of winding station motor monitors, and various signal that control the speed of the various motors of the device.

Control unit 280 receives data regarding the radial velocity of the plurality of winding stations and accordingly regulates the feeding of cocoons from soaking unit 260, the duration of cocoons within boiling unit 60 and temperature of the heated water within boiling unit 60, the return-rotary movement and progressive displacement of brushes 901 of thread catching station 90, the rotation of wadding collector 100 and linear conveyor belt 120, the rotation of thread guiding shaft 120, the rotation of jagged carousel 130 and carousel catchers 150.

Control unit 280 activates the rods, when there is a need to add a cocoon thread to a silk yarn, and according to the thickness of the yarn accelerates or decelerates the winding process.

For example, when control unit 280 receives a THICK1 signal from defect detector arm location detector 174 is stops the winding of yarn at winding station 200 by sending to

winding station motor 207 control signal WSMSPEED1 indicating that winding station motor has to stop.

When the yarn becomes too thin (for example, when one or more threads break or expires) thickness monitor arm location detector 185 sends a THIN_1 signal to control unit 280. The THIN_1 signals are sent until recovery of the thickness of the yarn. When control unit receives THIN_1 signal it sends a WSMSPEED1 signal to winding station motor 207 in order to reduce the velocity of the yarn winding, with the aim to reduce the length of the section where the yarn becomes thin in large measure. Control unit 280 also sends PUSH-1 signals to rod 160 in order to catch new threads to be integrated in the yarn. If threads are not caught within a predetermined period of time, control unit 208 sends WSMSPEED1 signals in order to further reduce the velocity of the yarn winding. In a case of sharp thickening of the yarn control unit 280 stops winding station motor 207 completely. After recovery of the required thickness of yarn THIN_1 signals are not generated and the velocity of the yarn winding is restored to an optimal level.

A control panel 270 is connected to an upper part of winding station base 2011.

Control panel 270 has a screen and a concise keyboard, and allows to determine the process parameters such as the first and second thresholds of each thread processing unit. Control panel 270 allows to enter a plurality of instructions to control unit 280, such as an instruction to determine the maximum winding speed of a winding station, to tix the winding speed or to allow control unit 280 to regulate the winding speed.

The proposed device is functioning in the following manner: Soaking unit 260 feeds boiling unit 60 with cocoons that fall by gravity from soaking unit outlet 261, via cocoon chamber 616 and boiling unit cocoon inlet 610 to cocoon boiling unit holders formed on boiling unit conveyor belt 631. These cocoons are conveyed along an elliptical path through the heated water within boiling unit 80 to cocoon outlet 611, to be provided to cocoon selection unit 70. During their passage through boiling unit 80 the cocoons are heated and filled with water so that a portion of the sericin of the cocoons leaves the cocoons.

Cocoons exit boiling unit 60 and fall by gravity to a location near an emerging point EP in which selecting unit bars 71 emerge from under the water within water bath 250. The cocoons are conveyed by selecting unit bars 71 from emerging point EP along a sloped linear path to pass over second selection unit axis 75 and to be fed to thread catching unit 90. While the cocoons are being conveyed they are washed by relatively cold water from cocoon

sprayer 77. Cocoons that are thinner than CSU1 fall between parallel bars of selection unit 70 to be provided to waist unit 80.

Cocoons that are fed to thread catching unit 90 are usually sunken in water, their upper end are located near the surface of the water. Brushes 901 contact an upper portion of the cocoons, force them to move within annular channel 99 and to stick to a brush that contacts a cocoon. Brushes 901 are configured not to damage the cocoons while they contact the cocoons.

Sericin that still remains in the cocoon helps cocoon threads to stick to the brushes of the thread finding station 90. The return rotary motion of the brushes causes cocoons that contact the brushes to stay within annular channel 99 for a relative long period, this movement drives cocoons from one brush to another and increases the probability that a thread end is found and caught.

Cocoons that exit thread finding station 90 without having their thread being caught by one of the brushes are forced to move through conveyance section 258 and circular duct 256 and to arrive to cocoon selection unit 70.

Cocoons that have their threads caught by a brush of thread catching station 90 remain in the water within conveyance section 258, while their thread end is provided to wadding station 100, hy a catching. device arm that is lifted and lowered by curved track 94 in a manner such that the a reliable catch of a cocoon end is achieved by wadding collector 100.

Sericin that still remains in the cocoons help wadding collector 100 to perform a reliable catch of the cocoon thread end. Cocoon oscillating bar prevent cocoons having their thread winded around wadding collector 100 from sticking to cocoon oscillating bar 110 and from being drawn to wadding collector 100.

Cocoons threads and accordingly cocoons are conveyed along linear conveyor station 109, while dirt is removed and tangled threads are untangled or removed, so that when cocoons reach the end of linear conveyor station 109 a single continuous silk thread is provided. Before reaching that end the thread ends are cut by thread cutting device 104.

Smooth sloped bar 103 prevents a thread that is being conveyed toward thread guiding shaft to be forced to move to an opposite direction.

Thread guiding shaft 120 receives the single cocoon thread and places the thread in way of jagged carousel 130 and carousel catcher 130 so that the thread is caught by a carousel catcher arm and wrapped around a carousel catcher cylinder. Jagged carousel 130 and the carousel catcher rotate clockwise, forcing the cocoon thread and accordingly the

cocoon to rotate clockwise, until the thread is provided to one of the thread processing stations positioned around central pole 230.

A thread is provided to a thread processing station by means of a rod that contacts the thread and provides it to an intermediate thread catcher positioned in front of the pneumatically driven rod. For convenience of explanation it is assumed that the thread is provided to thread processing station 300.

Conveniently, thread processing station 300 is initialized by directing at least one thread through intermediate thread catcher 140, yarn defect detector 170, yarn thickness monitor 180, yarn twisting and guiding unit 190, and winding unit 200. After the initialization each thread that is provided to intermediate thread catcher unit 140 sticks to other threads that were previously fed to intermediate thread catcher unit 140 and passes with these threads through the various elements of thread processing station 300.

A thread end passes through intermediate catcher groove 144 and passes through yarn defect detector 170, that sends THICK 1 signals that indicate if a silk yarn is too thick, and if so stops the winding process.

As long as the silk yarn is not too thick, the threads that form the yarn pass through twisting and guiding unit 190 where they are twisted and tbrced to swivel back and fourth so that a portion of the water absorbed in the threads exits the threads.

The silk yarn passes through yarn thickness monitor 180 that detects when the yam is too thin. If a yarn is too thin a THIN_1 signal is sent to control unit 280, that activates pneumatic driven rod 160 in order to catch new threads and to join them to the thin yarn. The winding speed of the yarn is decreased until the yarn is thick enough, and the winding speed is restored to an optimum level. The winding speed can be decreased if the yarn does not thicken during a predetermined period.

From the yarn thickness monitor the yarn is provided to a winding station 200, and passes through yarn guiding slot 2022 to bobbin 205. The rotation speed of bobbin 205 is controlled by control unit 280. During the winding process yarn drying unit 210 dries the silk yarn being wound around bobbin 205.

Thus, there has been described herein an embodiment including at least one preferred embodiment of an improved device for producing silk yarns. It will be apparent to those skilled in the art that the disclosed subject matter may be modified in numerous ways and may assume many embodiments other than the preferred form specifically set out and described above. Accordingly, the above disclosed subject matter is to be considered

illustrative and not restrictive, and to the maximum extent allowed by law, it is intended by the appended claims to cover all such modifications and other embodiments which fall within the true spirit and scope of the present invention. The scope of the invention is to be determined by the broadest permissible interpretation of the following claims and their equivalents rather than the foregoing detailed description.