WO2001038612A2

WO2001038612A2 - A device and method for producing a silk yarns from cocoon threads

Info

Publication number: WO2001038612A2
Application number: PCT/IL1999/000627
Authority: WO
Inventors: Izhak Barnoah; Boris Rubinov
Original assignee: Silktech Ltd.
Priority date: 1999-11-21
Filing date: 1999-11-21
Publication date: 2001-05-31
Also published as: WO2001038612A3; AU1293200A

Abstract

A device (20) and method for producing silk yarns from silk cocoon threads. The device comprising a carousel type conveyor (334), for receiving a cocoon thread end and providing the cocoon thread end to one of a plurality of thread processing stations (300), each thread processing station comprising: a yarn thickness monitor (180) for monitoring a thickness of a silk yarn in respect to a first predetermined threshold; a winding station (200) for winding silk yarns, a winding speed of the winding station is controlled by the control unit; a processing station thread catcher (301) for catching a cocoon thread and providing the cocoon thread to a yarn twisting and guiding unit; and a yarn twisting and guiding unit (190), for twisting a plurality of silk threads and guiding the plurality of silk threads and the silk yarn from the processing station thread catcher, through the yarn thickness monitor and to the winding station.

Description

A DEVICE AND METHOD FOR PRODUCING A SILK YARNS FROM COCOON THREADS

FIELD OF THE INVENTION

The present invention relates to a device and a method for producing silk yams from cocoon threads, and especially a device and method for producing high quality silk yams from silk cocoon threads of varying quality and breed.

BACKGROUND OF THE INVENTION

Silk yams are produced from silk cocoon threads. Prior art devices for producing silk yams of silk cocoon threads were tailored to work with cocoons of a predetermined quality.

The prior art devices for producing silk yams from cocoon threads have large external dimensions, and a production line of silk yams from silk cocoon threads which is both size and labor consuming. Prior art silk yam 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 yams from silk cocoon threads, a device and a method for producing silk yams from cocoon threads that are adapted to produce silk out of cocoon threads of different quality, to provide a concise device for producing silk yam from silk thread, to control the thickness of each silk yam that is produced by the device and to produce high quality silk yams.

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. 1 is a cross sectional view of a thread guiding shaft, according to a preferred embodiment of the invention;

FIG. 2 is a top view of a jagged carousel and carousel catchers, according to a preferred embodiment of the invention; FIG. 3 is a top view of an intermediate catcher base, according to a preferred embodiment of the invention;

FIG. 4 is a cross section view of a carousel catcher, according to a preferred embodiment of the invention; FIG. 5 is a top view of an intermediate thread catcher, according to a preferred embodiment of the invention;

FIG. 6 is a side view showing an intermediate thread catcher and a pneumatic driven rod, according to a preferred embodiment of the invention;

FIG. 7 is a side view of a yam defect detector, according to a preferred embodiment of the invention;

FIG. 8 is a top view of a yam defect detector, according to a preferred embodiment of the invention;

FIG. 9 is a side view of a yam thickness monitor, according to a preferred embodiment of the invention; FIG. 10 is a top view of a yam thickness monitor, according to a preferred embodiment of the invention;

FIG. 1 1 is a side view of a yam twisting and guiding unit, according to a preferred embodiment of the invention;

FIG. 12 is a side view of a winding yam guide, according to a preferred embodiment of the invention:

FIG. 13 is a partial sectional view of a winding station, according to a preferred embodiment of the invention;

FIG. 14 is a cross sectional view of a grooved drive roller, according to a preferred embodiment of the invention; FIG. 15 is a cross sectional view of a yam drying unit, according to a preferred embodiment of the invention;

FIG.16 is a side view of a device for producing silk yams comprising a device for producing silk yams from silk cocoon threads;

FIG. 17 is a top view of a device for producing silk yams, comprising a device for producing silk yams from silk cocoon threads; and

FIG. 18 is a cross sectional view of a device for producing silk yams comprising a device for producing silk yarns from silk cocoon threads. 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 yams from silk cocoon threads, the device is configured to receive silk cocoon threads, to unreel the cocoon, while controlling the quality of a silk yam made of a plurality of silk cocoon threads. The invention provides a compact device for producing silk thread that can be used in a much more limited amount of space than prior art devices for producing silk yams.

The invention provides a device for producing a plurality of high quality silk yams from silk cocoon threads, wherein the device controls the quality of each silk yam being produced by it. Especially, a yam thickness is monitored in a manner such that when the silk yam is too thick (i.e - is above a second predetermined threshold), the yam is not being winded around a bobbin. When one or more threads break the velocity of the yam winding is diminished, until new threads are joined to the yam. When the yam is too thin (i.e.- is below a first predetermined threshold) the winding speed of that yam is decreased and if the yam remains too thin for predetermined period it is further decreased. The winding process can stop if the yam remains too thin for another predetermined period. Controlling the quality of each silk yam allows the device to produce a silk yam of cocoon threads of different quality.

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

Device 20 for producing silk yams form silk cocoon threads comprising: Carousel type conveyor 334, for receiving a cocoon thread end and providing the cocoon thread end to one of a plurality of thread processing stations. A plurality of thread processing station, each thread processing station comprising: a yam thickness monitor, for monitoring a thickness of a silk yam in respect to a first predetermined threshold; a winding station, for winding silk yams, a winding speed of the winding station is controlled by the control unit; a processing station thread catcher, for catching a cocoon thread and providing the cocoon thread to a yam twisting and guiding unit; and a yam twisting and guiding unit, for twisting a plurality of silk threads and guiding the plurality of silk threads and the silk ya from the processing station thread catcher, through the yam thickness monitor and to the winding station.

Carousel type conveyor 334 comprising of thread guiding shaft 120 and jagged carousel 130. Carousel type conveyor 334 is adapted to receive a cocoon thread end 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 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. 1, 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 FIGS. 2 and 4 jagged carousel 130 is mounted for rotary movement to central po<e 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 catcner 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 from jagged carousel 130 and to generate a silk yam 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 yam defect detector, a yam thickness monitor, a yam 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), ya defect detector 170. yam thickness monitor 180, yam 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. 5, 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 rod 160. 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 rod 160. 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 FIGS. 3, 5 and 6, 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 rod 160, to join the cocoon thread to other threads being driven through intermediate thread catcher groove 146, to spin these threads and provide them to yam defect detector 170.

Yam defect detector 170 is adapted to sense when a yam 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 FIGS. 7-8, 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 foπnεd at one end of defect detector arm 171 and is configured to allow a yam to pass through it as long as the yam is noi too thick. As long as the yam is not too thick defect detector arm 171 is in a first position. When the yam 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 ami location detector 174 detects that defect detector ami 171 is positioned at the second position and sends a THICK_1 signal to control unit 280.

Yam thickness monitor 180 is adapted to sense when a yam 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 rod 160, in order to catch further cocoon threads and to join them to the yam.

Referring to FIG. 9-10, yam 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 yam within a predetermined range of thickness to force thickness monitor arm 181 to enter a second position by friction. As long as the yam is thick enough it forces thickness monitor arm 181 to be positioned in the first position. When the yam 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 THLN 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. 11, ya 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 yam, guide it through the trapezoid shaped slot 185 and provide the ya to a winding yam guide 202.

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

Yam from intermediate thread catcher 140 is guided to second guiding wheel 192 than to first guiding wheel 191, is twisted around the yam 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. 12-14, winding unit 200 is occupied by grooved drive roller 203, bobbin 205, winding yam guide 202, winding station belt 206 and winding station motor 207. Winding unit 200 is cooperative with yam drying unit 210. Winding unit 200 is configured to receive a yam from third guiding wheel 193 and wind the yam around bobbin 205. The rotation speed of winding station motor 207 is controlled by WSM_SPEED_1 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 yam guide 202 is pivotally connected to horizontal winding station base 2011 by means of winding yam guide axis 204. One end of winding yam guide axis 204 passes through slot 2025 formed within first horizontal portion 2024 of winding yam 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 2024 is turned upwardly and is fixed to a contact element, such as a winging yam guide roller 2026. Winding yam 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 yam guide roller 2026 and accordingly winding yam guide 202 to perform a horizontal reciprocal movement. An opposite end of first horizontal portion 2024 of winding yam guide 202 is fixed to an end of a sloped and upwardly extending yam guide element 2023, having an opposite end fixed to a second vertical portion 2021 of winding yam guide 202.

A yam guiding slot 2022 is formed within an opposite end of second vertical portion. Varn guiding slot 2022 is adapted to receive a yam 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 yam guide 202 is disposed upstream of bobbin 205 in the running direction of the yam. 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. 15, yam drying unit 210 is comprised of a yam drying heating element 211, that faces bobbin 205 and a drying motor 212 for forcing air to flow from yam 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 yam, it receives information about the current parameters of the silk yam production process and it adjusts them on the optimal level. Especially, control unit controls the thickness of the silk yam 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 THIN J signals, 0<j<=Nl from a plurality (Nl) of thread thickness monitors, a plurality of THICKJ signals from a plurality (Nl) of yam defect detectors, a plurality of WSM_SPEEDJ and WSM SPEEDJ* signals from a plurality (Nl) of winding station motors and a plurality (Nl) of winding station motor monitors, and various signal that control the speed of the various motors of the device.

Control unit 280 receives date regarding the radial velocity of the plurality of winding stations and accordingly regulates the rotation of thread guiding shaft 120, the rotation of jagged carousel 130 and carousel catchers 150. Control unit 280 (not shown) activates the rods, when there is a need to add a cocoon thread to a silk yam, and according to the thickness of the yam accelerates or decelerates the winding process.

For example, when control unit 280 receives a THICK_1 signal from defect detector arm location detector 174 is stops the winding of yam at winding station 200 by sending to winding station motor 207 control signal WSM SPEED 1 indicating that winding station motor has to stop.

When the yam becomes too thin (for example, when one or more threads break) 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 yam. When control unit receives THIN l signal it sends a WSM_SPEED_1 signal to winding station motor 207 in order to reduce the velocity of the yam winding, with the aim to reduce the length of the section where the yam 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 yam. If threads are not caught within a predetermined period of time, control unit 208 sends WSM SPEED 1 signals in order to further reduce the velocity of the yam winding. In a case of sharp thickening of the yam control unit 280 stops winding station motor 207 completely. After recovery of the required thickness of yam THLN_1 signals are not generated and the velocity of the yam 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 fix the winding speed or to allow control unit 280 to regulate the winding speed.

FIG. 16-18 illustrate a device 300 for producing silk yams from cocoons, in which various parts of device 300 are shown, such as base 32, boiling unit 60, cocoon selection unit 70, first selection unit axis 74, second selection unit axis 75, 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, yam defect detector 170. yam thickness monitorl80_; ya twisting and guiding station 190, winding unit 200, winding station motor 207, yam drying unit 21G, central pole 230, 231, 232, bath 250, bath bottom 251, soaking unit 260. control panel 270, cocoon chamber 616, two ends of flipping lever 952 and 955.

Device 300 comprising : device 20 for producing silk yam from silt cocoon threads; boiling unit 80, for receiving cocoons, boiling the cocoons and for filling the cocoons with water; cocoon selection unit 70 for selecting cocoon that are wider than predetermined threshold CSU1, whereas cocoons that are thinner than CSU1 are provided to waits unit 80, cocoon selecting unit 70 comprising of a plurality of parallel bars driven by belts that is driven by first and second selection unit axis 74 and 75, cocoons are conveyed on the parallel bars and are washed by cocoon sprayer before entering thread catching station 90; thread catching station 90, for receiving cocoons from cocoon selecting unit 70, finding cocoon thread ends and catching the cocoon thread ends; linear conveyor station 109 for receiving cocoon threads from the thread catching station, for removing dirt and tangled cocoon threads and for transporting the cocoon threads to device 20; and wadding collector 100 for winding cocoon threads and for collecting dirt and tangled cocoon threads. Water bath 250 is adapted to be partially filled with water, in which cocoons are transferred during the yam production. Water bath 250 comprises of several sections, such as annular channel 99 in which cocoons are transferred while thread catching unit 90 detects and finds a thread end; a conveyance section 258 in which cocoons are conveyed by linear toothed conveyer belt 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 yam processing stations; and circular duct 256 in which cocoons are unreeled.

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 a vertical wall 255 surrounding central pole 230.

The proposed device is functioning in the following manner:

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, yam defect detector 170, yam thickness monitor 180, yam 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 yam defect detector 170, that sends THICK_1 signals that indicate if a silk yam is too thick, and if so stops the winding process.

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

The silk yam passes through yam thickness monitor 180 that detects when the yarn is too thin. If a yam 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 yam. The winding speed of the yam is decreased until the yam is thick enough, and the winding speed is restored to an optimum level. The winding speed can be decreased if the yam does not thicken during a predetermined period. From the yam thickness monitor the yam is provided to a winding station 200, and passes through yam guiding slot 2022 to bobbin 205. The rotation speed of bobbin 205 is controlled by control unit 280. During the winding process ya 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 and method for producing silk yams from silk cocoon threads. 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.

Claims

WE CLAIM :

1. A device for producing silk yarns form silk cocoon threads comprising: a carousel type conveyor, for receiving a cocoon thread end and providing the cocoon thread end to one of a plurality of thread processing stations; a plurality of thread processing station, each thread processing station comprising: a yam thickness monitor, for monitoring a thickness of a silk yam in respect to a first predetermined threshold; a winding station, for winding silk yams, a winding speed of the winding station is controlled by the control unit; a processing station thread catcher, for catching a cocoon thread and providing the cocoon thread to a yam twisting and guiding unit; and a yam twisting and guiding unit, for twisting a plurality of silk threads and guiding the plurality of silk threads and the silk yam from the processing station thread catcher, through the yam thickness monitor and to the winding station.

2. The device of claim 1 wherein the plurality of thread processing stations are arranged radially with respect to a central axis of the device.

3. The device of claim 1 wherein each thread processing unit further comprises of a yam defect detector, for receiving a silk ya and sensing when a silk yam is thicker than a second predetermined threshold.

4. The device of claim 11 wherein each thread processing device further comprising a drying unit, for drying silk yams while the silk yams are being winded by the winding station; and wherein the yam twisting and guiding unit comprises an eccentric wheel that is configured to force a silk yam to swivel back and fourth in a manner such that water are extracted from the silk yam.

5. The device of claim 1 wherein each processing station thread catcher comprising of an intermediate thread catcher and a rod, the intermediate thread catcher has a central axis and is configured to rotate above the axis and to join a plurality of cocoon threads to a cocoon yam; and wherein the rod is adapted to undergo a linear path and to provide a cocoon thread to intermediate thread catcher, when the cocoon thread contacts the rod.

6. The device of claim 5 wherein the rod is electrically coupled to the control unit, wherein the control unit forces the rod to undergo the linear path when a silk yam is thinner than the first predetermined threshold.

7. The device of claim 1 wherein the winding station comprising: a winding yam guide, for receiving a yam and guiding the yam to a bobbin; a grooved guide, for forcing the winding yam guide to perform horizontal reciprocal movements; and a winding unit motor, for driving the grooved guide and the bobbin.

8. The device of claim 7 wherein the grooved guide is connected for rotary movement to a horizontal grooved drive axis, and the grooved guide has a helically arranged guiding groove for transforming a rotation of the grooved guide to horizontal reciprocal movements.

9. The device of claim 1 wherein the yam thickness monitor comprising: a thickness monitor arm adapted to receive a silk yam and to be positioned according to the yam thickness; and a thickness monitor arm location detector, for detecting a position of the thickness monitor arm and for notifying the control unit of the position.

10. The device of claim 9 wherein the yam thickness monitor arm is pivotally mounted to a thickness monitor supporter by means of thickness monitor axis, wherein a thickness monitor weight forces the thickness monitor arm to fall by gravity to a first position; and wherein a trapezoid shaped slot is formed at an opposite end of the thickness monitor arm and is configured to allow a yam within a predetermined range of thickness to force the thickness monitor arm to enter a second position by friction.

11. The device of claim 10 wherein the yam twisting and guiding unit comprising an eccentric guiding wheel for receiving a yam and forcing the yam to swivel back and fourth, in a manner that forces a portion of a water within the yam to exit the yam.

12. The device of claim 3 wherein the yam defect detector comprising : a defect detector arm adapted to receive a silk yam and to be positioned according to the yam thickness; and a defect detector arm location detector, for detecting a position of the defect detector aπn and for notifying the control unit of the position.

13. The device of claim 1 wherein the carousel type conveyor comprising a jagged carousel, mounted for rotary movement around the central axis of the device, the jagged carousel is adapted to receive the continuously cocoon thread and place it in a path of one of a plurality of carousel thread catchers located near a circumference of the jagged carousel.

14. The device of claim 13 wherein each carousel thread catcher has a axis, the axis is connected to the jagged carousel, and each carousel thread catcher is configured to execute a rotary motion around its axis.

15. The device of claim 14 wherein each carousel thread catcher further comprising a pair of horizontal arms, connected to a carousel catcher cylinder that is connected to the axis, the arms are configured to catch a cocoon thread and causing the cocoon thread to be winded around the carousel catcher cylinder.

16. The device of claim 13 further comprising conical thread guiding shaft, for receiving a cocoon thread and providing the cocoon thread to the jagged carousel.

17. The device of claim 1 wherein the control unit slows a winding of a silk yam when the silk yam is thinner than a first predetermined threshold.

18. The device of claim 1 wherein the control unit speeds the winding when the silk yam thickness resumes to be above the first predetermined threshold.

19. The device of claim 17 wherein if during a first predetermined time period the silk yam remains thinner than the first predetermined threshold the control unit further slows the winding of the silk yam.

20. The device of claim 19 wherein the winding is slowed until being stopped.

21. The method for producing silk yam from silk cocoon threads comprising: combining a plurality of cocoon threads to form a silk yam; monitoring the thickness of the silk yam; and winding the silk yam on a bobbin, wherein the winding speed is associated to a thickness of the silk yam.