US-20260125236-A1 - PACKING SYSTEM FOR HEAT SET

US20260125236A1US 20260125236 A1US20260125236 A1US 20260125236A1US-20260125236-A1

Abstract

A system has at least one winder configured to wind yarn to form a yarn package. At least one sampling and tying machine is configured to remove a portion of the yarn of the yarn package and tie off a free end of the yarn around the yarn package to inhibit the yarn package from unwinding. A dunnage supply area has therein at least one support structure for receiving a plurality of yarn packages thereon. A robotic arm is configured to: move the yarn package from the at least one winder to the at least one sampling and tying machine; move the yarn package from the at least one sampling and tying machine to at least one case assembly area; and stack the yarn package on a support structure in the at least one case assembly area.

Inventors

Wesley Moore

Assignees

SHAW INDUSTRIES GROUP, INC.

Dates

Publication Date: 20260507
Application Date: 20251231

Claims (18)

1 . A system comprising: at least one winder configured to wind yarn to form a yarn package; at least one sampling and tying machine that is configured to remove a portion of the yarn of the yarn package and tie off a free end of the yarn around the yarn package to inhibit the yarn package from unwinding; a dunnage supply area having therein at least one support structure for receiving a plurality of yarn packages thereon; at least one case assembly area; and a robotic arm configured to: move the yarn package from the at least one winder to the at least one sampling and tying machine; move the yarn package from the at least one sampling and tying machine to the at least one case assembly area; and stack the yarn package on a support structure in the at least one case assembly area.
2 . The system of claim 1 , wherein each of the at least one winder, the at least one sampling and tying machine, the dunnage supply area, the at least one case assembly area, and the robotic arm is within a locked-out area.
3 . The system of claim 2 , further comprising a barrier that surrounds the locked-out area.
4 . The system of claim 1 , wherein the at least one support structure of the dunnage supply area comprises at least one pallet, at least one spacer, or a combination thereof.
5 . The system of claim 1 , wherein the robotic arm is further configured to move a support structure of the at least one support structure in the dunnage supply area to the at least one case assembly area.
6 . The system of claim 1 , wherein the at least one winder is a winder of a heat set apparatus.
7 . The system of claim 1 , further comprising at least one automated guided vehicle (AGV) that is configured to deliver the at least one support structure to the dunnage supply area.
8 . The system of claim 7 , wherein the at least one AGV is further configured to carry a case from the least one case assembly area, wherein the case comprises at least one support structure and a plurality of yarn packages thereon.
9 . The system of claim 1 , wherein the robotic arm is configured to form a case comprising at least one pallet, a plurality of packages stacked on the pallet, at least one spacer stacked on the plurality of packages stacked on the pallet, and a plurality of packages stacked on the spacer.
10 . The system of claim 9 , wherein the case comprises four layers of yarn packages and three spacers, wherein each of the three spacers is positioned between respective layers of yarn packages.
11 . The system of claim 1 , further comprising a staging rack that is configured to store at least one support structure from the dunnage supply area.
12 . The system of claim 1 , wherein the at least one winder comprises two winders.
13 . The system of claim 1 , wherein the at least one sampling and tying machine comprises two sampling and tying machines.
14 . The system of claim 1 , further comprising a first conveyor that is configured to carry a case from the at least one case assembly area.
15 . The system of claim 14 , further comprising a second conveyor that is configured to receive the case from the first conveyor.
16 . The system of claim 1 , further comprising a vertical wrapper that is configure to move a roll of wrapping material about a periphery of a case comprising at least one support structure and a plurality of yarn packages thereon.
17 . The system of claim 1 , further comprising a horizontal wrapper that is configured to rotate the case to apply wrapping material to a periphery of a case comprising at least one support structure and a plurality of yarn packages thereon.
18 . A method comprising: using a system comprising: at least one winder configured to wind yarn to form a yarn package; at least one sampling and tying machine that is configured to remove a portion of the yarn of the yarn package and tie off a free end of the yarn around the yarn package to inhibit the yarn package from unwinding; a dunnage supply area having therein at least one support structure for receiving a plurality of yarn packages thereon; at least one case assembly area; and a robotic arm configured to: move the yarn package from the at least one winder to the at least one sampling and tying machine; move the yarn package from the at least one sampling and tying machine to the at least one case assembly area; and stack the yarn package on a support structure in the at least one case assembly area, wherein using the system comprises winding, by the winder, yarn to form a yarn package; moving, by the robotic arm, the yarn package from the winder to the at least one sampling and tying machine; moving, by the robotic arm, the yarn package from the at least one sampling and tying machine to a first case assembly area of the at least one case assembly area; and stacking, by the robotic arm, the yarn package on a support structure in the first case assembly area.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application is a Continuation of U.S. application Ser. No. 19/213,691, filed May 20, 2025, which is a Continuation of U.S. application Ser. No. 18/724,116, filed Jun. 25, 2024, which claims priority to and the benefit of the filing dates of U.S. Provisional Patent Application No. 63/381,838 , filed Nov. 1, 2022, and U.S. Provisional Patent Application No. 63/478,780 , filed Jan. 6, 2023, the entirety of each of which is hereby incorporated by reference herein. FIELD This disclosure relates to systems and methods for handling yarn packages. BACKGROUND Conventionally, yarn packages formed on a winder of a heat set are handled by an operator. The operator cuts a yarn sample, ties a loose end of the yarn package, and stacks the yarn package on a pallet. This requires a substantial number of operators and exposes the operators to typical occupational hazards. Accordingly, a way to reduce direct operator interaction is desirable. Further, conventionally, an operator cuts a yarn sample from a yarn package to dye and test the sample for quality assurance purposes. An operator subsequently ties the loose end of the yarn package to secure the package. This operation exposes operators to typical occupational hazards. Accordingly, a way to reduce direct operator interaction is desirable. SUMMARY Described herein, in various aspects, is a system having at least one winder configured to wind yarn to form a yarn package. At least one sampling and tying machine is configured to remove a portion of the yarn of the yarn package and tie off a free end of the yarn around the yarn package to inhibit the yarn package from unwinding. A dunnage supply area has therein at least one support structure for receiving a plurality of yarn packages thereon. The system further includes at least one case assembly area and a robotic arm. The robotic arm is configured to move the yarn package from the at least one winder to the at least one sampling and tying machine; move the yarn package from the at least one sampling and tying machine to the at least one case assembly area; and stack the yarn package on a support structure in the at least one case assembly area. In another aspect, a method includes winding, by a winder, yarn to form a yarn package. A robotic arm moves the yarn package from the winder to at least one sampling and tying machine. The robotic arm moves the yarn package from the at least one sampling and tying machine to a case assembly area. The robotic arm stacks the yarn package on a support structure in the at least one case assembly area. Also described herein, in various aspects, is a system for sampling and tying yarn of a package having a free end. The system includes a spindle and a first actuator. The first actuator is configured to rotate the spindle in a first direction and opposed second direction. A yarn sampling assembly is configured to receive a portion of the yarn comprising the free end. A yarn tying assembly is configured to tie a knot in the yarn of the package to prevent unwinding of the yarn from the package. In another aspect, a method includes receiving a package comprising yarn on a spindle. The yarn has a free end. A first actuator coupled to the spindle rotates the package to deliver the free end to a sampling assembly. The sampling assembly removes a portion of the yarn comprising the free end to provide a yarn sample and to form a new free end of the yarn remaining on the spindle. DESCRIPTION OF THE DRAWINGS FIG. 1 is a top plan view of a system as disclosed herein. FIG. 2 is a perspective view of the system of FIG. 1 FIG. 3 is perspective view of a global system of a plurality of systems as shown in FIG. 1. FIG. 4 is a block diagram of an operating environment comprising a computing device as disclosed herein for controlling the system of FIG. 1. FIG. 5 illustrates an exemplary case as disclosed herein. FIG. 6 illustrates the exemplary case of FIG. 5 being transported on a first conveyor to a second conveyor. FIG. 7 illustrates an exemplary first wrapper as disclosed herein. FIG. 8 illustrates an exemplary second wrapper as disclosed herein. FIG. 9 illustrates an exemplary yarn package as disclosed herein. FIG. 10 is a perspective view of an exemplary sampling and tying machine as disclosed herein. FIG. 11 is a perspective view of the exemplary sampling and tying machine of FIG. 10 showing an exemplary yarn package being loaded. FIG. 12 is a perspective view of the exemplary sampling and tying machine of FIG. 10 showing an exemplary yarn sampling assembly. FIG. 13 is a perspective view of the exemplary sampling and tying machine of FIG. 10 showing an exemplary location of a sensor. FIG. 14 is a perspective view of the exemplary sampling and tying machine of FIG. 10 showing exemplary components of the yarn sampling assembly of FIG. 12 in an open position. FIG. 15 is a perspective view of the exemplary components of the yarn sampling assembly of FIG. 14 i