Automated Creel Assemblies and Systems and Methods of Making and Using Same

This application is a continuation of U.S. patent application Ser. No. 18/349,538, filed Jul. 10, 2023; which is a continuation of U.S. patent application Ser. No. 16/526,595, filed Jul. 30, 2019, which claims the benefit of the filing date of U.S. Provisional Patent Application No. 62/711,886, filed Jul. 30, 2018, each of which is hereby incorporated by reference herein in its entirety for all purposes.

This invention relates to an automated creel assembly and to the use of a plurality of such automated creel assemblies to produce a modular creel system.

In tufting/creeling operations, there is a need for improving safety and decreasing process time, changeover time, labor, and creel variability. The disclosed assemblies, systems, and methods can address one or more of these needs.

Disclosed herein is a creel loading apparatus. The creel loading apparatus can comprise a frame and a platform that is movable along the frame on a first axis and a second axis that is perpendicular to the first axis. A rotary actuator can be configured to rotate at least a portion of the platform about the first axis. A gripper can be movably attached to the at least a portion of the platform that is configured to rotate about the first axis. The gripper can be configured to releasably engage an inner surface of a yarn package. A linear actuator can be configured to move the gripper along a linear actuator axis that is perpendicular to the first axis. The linear actuator can comprise a first stage and a second stage.

The creel loading apparatus can comprise a frame and a platform that is movable along the frame on a first axis and a second axis that is perpendicular to the first axis. A rotary actuator can be configured to rotate at least a portion of the platform about the first axis. A gripper can be movably attached to the at least a portion of the platform that is configured to rotate about the first axis. At least one camera can be attached to the platform. The at least one camera can be configured to detect a diameter of a measured yarn package corresponding to a remaining quantity of material on the measured yarn package. At least one processor can be is configured to receive an image of the measured yarn package from the at least one camera, and approximate the remaining quantity of material on the measured yarn package based on the image of the measured yarn package.

A system can comprise a creel loading apparatus, a staging area, and a robotic arm comprising a robotic arm gripper at a distal end of the robotic arm. The robotic arm and creel loading apparatus can be positioned with respect to the staging area so that the robotic arm can deliver yarn packages to the staging area, and the gripper of the creel loading apparatus can receive the yarn packages from the staging area.

The system can further comprise a creel, wherein the creel comprises the staging area.

A system can comprising a service robot having: a base, a gripper assembly having at least one gripper configured to releasably engage an inner surface of a yarn package, a service arm assembly having a proximal end secured to the base and a distal end secured to the gripper assembly, and an actuator configured to selectively move the service arm assembly to articulate the gripper assembly with respect to the base. The service robot can comprise a three-dimensional camera that is configured to determine a quantity of yarn packages on a yarn case. At least one processor can be communicatively coupled to the three-dimensional camera and the actuator of the service robot. The at least one processor can be configured to receive an input from the three-dimensional camera indicative of the quantity of yarn packages on the yarn case. The at least one processor can further be configured to selectively effect movement of the actuator.

A method can comprise receiving a first yarn package at a first position on a creel, storing a value in memory indicating that the first position on the creel is occupied, upon receiving an instruction to place a second yarn package at the first position on the creel, determining, based on the value in the memory, that the first position on the creel is occupied, and providing feedback to an operator indicating that the first position on the creel is occupied.

A system can comprise a creel defining a plurality of yarn package positions; a gantry configured to receive yarn packages at a loading location and place the yarn packages at select positions on the creel; a service robot configured to deliver packages to the gantry; a memory coupled with the one or more processors. The memory can have thereon a plurality of instructions to implement a method comprising: receiving a creel map comprising a plurality of yarn package engagement locations on the creel and identifiers for a yarn case to be received at each respective yarn case staging location, based on the creel map, causing the service robot to deliver select yarn packages from respective yarn cases to the gantry, and based on the creel map, causing the gantry to deliver the select yarn packages to respective yarn package engagement locations.

The present invention can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and their previous and following description. However, before the present devices, systems, and/or methods are disclosed and described, it is to be understood that this invention is not limited to the specific devices, systems, and/or methods disclosed unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.

The following description of the invention is provided as an enabling teaching of the invention in its best, currently known embodiment. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects of the invention described herein, while still obtaining the beneficial results of the present invention. It will also be apparent that some of the desired benefits of the present invention can be obtained by selecting some of the features of the present invention without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the present invention are possible and can even be desirable in certain circumstances and are a part of the present invention. Thus, the following description is provided as illustrative of the principles of the present invention and not in limitation thereof.

As used throughout, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a gripper” can include two or more such grippers unless the context indicates otherwise.

Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

Optionally, in some aspects, when values are approximated by use of the antecedent “about” or “generally” or “substantially,” it is contemplated that values within up to 15%, up to 10%, or up to 5% (above or below) of the particularly stated value or characteristic can be included within the scope of those aspects.

As used herein, the terms “optional” or “optionally” mean that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

Disclosed herein with reference tois a creel assemblyhaving an outer wall, a plurality of yarn package engagement locations, a multi-axis robot, and at least one processor. The outer wall can define an interior space, and the plurality of yarn package engagement locationscan be distributed within the interior space. It is contemplated that the outer wall of each creel assemblycan be provided in any desired shape, including, without limitation, a circular, square, octagonal, or pentagonal shape. The multi-axis robot can be fixedly secured within the interior space and positioned to selectively engage yarn packages within the interior space. Optionally, the multi-axis robotcan be provided on a pedestal. The multi-axis robot can be configured to selectively access the plurality of yarn package engagement locations. The at least one processor can be communicatively coupled to the multi-axis robot and configured to receive an input corresponding to a selected action by the multi-axis robot. Methods of using the creel assembly are also disclosed.

Also described herein are modular creel systems comprising a plurality of the disclosed creel assemblies, with each creel assembly serving as a respective creel module. Optionally, the modular creel systems can comprise an automated feeder assembly configured to selectively deliver yarn packages to the plurality of creel assemblies. Optionally, the plurality of creel assemblies can comprise at least two vertically stacked creel assemblies. Additionally, or alternatively, the plurality of creel assemblies can comprise at least two horizontally adjacent creel assemblies. Methods of using and assembling the modular creel systems are also disclosed.

In further aspects, it is contemplated that the modular creel system can comprise a plurality of creel assemblies that can be positioned in a first configuration during a first creeling (tufting or warping) operation and that can be positioned in a second configuration during a second creeling (tufting or warping) operation, with the first and second configurations being different from one another. In still further aspects, additional creel assemblies can be coupled to an initial group of creel assemblies in an additive fashion to expand a given creel system.

Additional details of the disclosed assemblies, systems, and methods are provided below.

In exemplary aspects, the configuration of the creel will be standard, flexible, and modular to provide creel warping and tufting cells. In these aspects, it is contemplated that each creel assembly can function as a creel module.

Optionally, in further exemplary aspects, the disclosed creel assemblies can fit within a floor space of 42 feet wide by 49 feet long with a max ceiling height of 20 feet. In providing a modular creel, the creel's footprint can be expanded or shrunk, depending on the need. Accordingly, creels having smaller footprints can be provided.

Optionally, in further exemplary aspects, the multi-axis robot of each creel assembly can be a centrally-located servicing robot.

Optionally, in further exemplary aspects, the feeder assembly can comprise a robotic feeder assembly.

Optionally, in exemplary aspects, the multi-axis robot of each creel assembly can have a robotic arm mounted to the floor (e.g., using a base) or the ceiling (e.g., using a gantry) of the creel assembly. In these aspects, it is contemplated that the robotic arm can be configured to use 360 degree access to reach all yarn positions within the yarn assembly.

Optionally, in exemplary aspects, the creel system can be a multi-level system that can be added or subtracted onto to achieve a desired creel configuration for warping or tufting operations. It is contemplated that the number of stacked creel assemblies can be two or three, with most operations being conducted with a two-level stacked configuration.

Optionally, in exemplary aspects, upper levels of the disclosed creel systems can comprise catwalk linkages to adjacent creel assemblies. In use, it is contemplated that these catwalk linkages can allow operators to access multiple creel assemblies at the same level without having to climb up and down, thereby maximizing human labor efficiency and productivity.

Optionally, in exemplary aspects, upper levels of the disclosed creel systems can comprise a bolt on catwalksurrounding the operating area and a mechanism (e.g., a ladder) for accessing the upper level from a lower level within the creel system.

Optionally, within each creel assembly, it is contemplated that a creel section (i.e., a vertical column of yarn package engagement locations) can be no more than 6 or 8 (even numbers) yarn cones high. It is contemplated that the use of a limited, even number of yarn cones in this fashion can allow for use of a dual or quad end effector (coupled to the robot arm) to make the loading/unloading process more efficient. Although creel assemblies as disclosed herein are not limited to cone-style packages, for the purposes of the disclosure it should be understood that the terms yarn cone and yarn package are used interchangeably herein.

In use, it is contemplated that the plant operator can selectively adjust the yarn package engagement locations and positions of creel assemblies to achieve a designated creel configuration, for example, by engaging a manual mode.

In one non-limiting example, it is contemplated that each creel level within a creel system can service at least 1,844 cone positions (a two-level can service at least 3,688 cone positions). However, it is contemplated that each creel level can be configured to service more or fewer cone positions depending upon the creel assembly configuration and space constraints.

Optionally, in exemplary aspects, the bases of the disclosed multi-axis robots are stationary.

Optionally, in further exemplary aspects, the disclosed creel assemblies and creel systems do not include or make use of vision systems.

In exemplary aspects, it is contemplated that all yarn cone locations (yarn package engagement locations) are fixed within a given creel assembly.

In further exemplary aspects, the creel operatorcan have zoned accessfrom the perimeter of each yarn assembly to permit performance of tying and splicing tasks. It is contemplated that all non-maintenance access to the creel can be provided from outside the wall of the creel assembly. While one zone can have human interaction (an interface mode), other zones (optionally, all other zones within the creel assembly) can be in a running or operational order or mode. Within each creel level, the number of zones configured for human interaction can be selectively adjusted. Optionally, within each creel level, it is contemplated that the number of zones configured for human interaction can range from four to eight.

In exemplary non-limiting aspects, the disclosed robotic components can be manufactured by ABB or Yaskawa (Motoman).

In exemplary non-limiting aspects, it is contemplated that the disclosed creel assemblies and creel systems can comprise processing units, including programmable logic controllers (PLCs), to permit communication among the various system components. Optionally, such PLCs can be AB L83 PLCs manufactured by Allen Bradley.

In exemplary non-limiting aspects, it is contemplated that the disclosed creel assemblies and creel systems can comprise one or more drive systems for effecting movement of yarn packages. Optionally, such drive systems can be manufactured by Yaskawa.

In exemplary non-limiting aspects, it is contemplated that the disclosed creel assemblies and creel systems can comprise at least one human-machine interface (HMI) for receiving inputs from a creel operator. Optionally, such HMIs can be provided as a Siemens 22″ Comfort Panel; however, it is also contemplated that portable HMIs such as tablets and other remote computing devices (e.g., smartphones) can be used.

In further exemplary aspects, each creel assembly can have a maintenance access doorto permit access to the stationary robot within the creel assembly. In these aspects, it is contemplated the maintenance access door can have an emergency stop protocol (e.g., an emergency stop switch that is triggered) if opened during operations. For example, all moving parts can be halted. It is further contemplated that the maintenance access door can be formed as a portion of the outer wall of the creel assembly such that the inner surface of the access door can be used as creel space.

In further exemplary aspects, it is contemplated that all yarn exit points can be oriented upwardly, with the yarn curving over the top of the outer wall of the creel assembly to bridge the distance between the creel assembly and the tufting and/or warping machine(s).

In still further exemplary aspects, it is contemplated that each creel level can have at least one status light (e.g., at least one Andon light) that is communicatively coupled to a processor and configured to provide an indication of a status of system automation. For example, the status light(s) can vary between on and off, vary between solid and flashing, vary in flashing frequency, and/or change color depending on the status.

In use, cones of yarn (i.e., yarn packages) can be picked from an inbound pallet location. Optionally, machine vision can be used to effectively find cones of yarn on a pallet and place them on an inbound system such as a conveyor.

In exemplary aspects, as each yarn cone is picked off the pallet, a plastic cap, as known in the art, can be installed on the yarn cone.

In further exemplary aspects, cones of yarn fed into the creel can be provided with indicia that can be scanned to verify lots of yarn and consumption amounts/rates. It is contemplated that this can be done within the creel or outside of the creel via auxiliary automation.

In further exemplary aspects, the robot within each creel assembly can comprise an end effector that loads multiple cones at a time. Optionally, the end effector can be a dual, tri, or quad end effector. It is contemplated that the creel assembly can have a singular end effector to manipulate around the yarn in process.

In use, after cones are placed into the package creel transport mechanism (as further disclosed herein), the robot can place plastic caps onto the ends of the yarn package.

In exemplary aspects, a programming interface can be provided to receive one or more inputs corresponding to a proper creel configuration. In these aspects, it is contemplated that locations of the cones and creel population configurations can be stored in memory and associated with particular processes and operations.

For a multilevel creel system (at least two stacked modular systems), an electro mechanical dumbwaiter can be bolted or otherwise secured onto the exterior of the creel. The dumbwaiter can comprise a platform that selectively moves vertically along the creel. It is contemplated that the dumbwaiter can be configured to deliver a selected number of yarn packages (e.g., four yarn packages) at a time. Optionally, it is further contemplated that the creel system can comprise a light (e.g., an Andon light) that provides a visual indication when the dumbwaiter is in service and safety protocol to prevent human injury. However, it is contemplated that other visual indicators and safety protocols can be used.

In further exemplary aspects, a separate scanner or camera can be provided with the end effector and configured to produce an alert or signal indicative of a yarn cone position that is empty and/or in need of prompt attention. In use, it is contemplated that the alert or signal can be received by the processing units within the automated yarn system as disclosed herein. It is further contemplated that the alert or signal can be received by a creel operator (optionally, through a remote computing device accessed by the operator).