Automated creel assemblies and systems and methods of making and using same

Patent metadata

Field	Value
Publication number	US-12384650-B2
Application number	US-202318349538-A
Country	US
Kind code	B2
Filing date	Jul 10, 2023
Priority date	Jul 30, 2018
Publication date	Aug 12, 2025
Grant date	Aug 12, 2025

Abstract

A creel assembly having an outer wall defines an interior space, a plurality of yarn package engagement locations distributed within the interior space, a gantry that is movable secured within the interior space, and at least one processor. The gantry is positioned to selectively engage yarn packages within the interior space. In use, the gantry can selectively access the plurality of yarn package engagement locations. The processor is communicatively coupled to the gantry and receives an input corresponding to a selected action by the gantry. Modular creel systems can be formed from a plurality of the disclosed creel assemblies. Methods of using and assembling the disclosed creel assemblies and modular creel systems are also disclosed.

First claim

What is claimed is:

1. A system 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;

a three-dimensional camera that is configured to determine a quantity of yarn packages on a yarn case; and
at least one processor communicatively coupled to the three-dimensional camera and the actuator of the service robot, wherein the at least one processor is configured to receive an input from the three-dimensional camera indicative of the quantity of yarn packages on the yarn case, and wherein the at least one processor is further configured to selectively effect movement of the actuator.

2. The system of claim 1 , wherein the service robot comprises at least one dunnage removal assembly that is configured to remove dunnage from within and around a yarn case.

3. The system of claim 2 , wherein the dunnage removal assembly comprises a vacuum source and at least one suction cup in fluid communication with the vacuum source.

4. The system of claim 1 , wherein the three-dimensional camera is a range camera.

5. The system of claim 1 , wherein the three-dimensional camera is configured to determine a number of stacked yarn packages.

6. The system of claim 1 , wherein the at least one gripper of the gripper assembly comprises three axially spaced grippers, wherein a central gripper is positioned between first and second outer grippers.

7. The system of claim 6 , wherein the first and second outer grippers are operatively coupled to respective linear actuators that are configured to selectively adjust the axial spacing of the first and second outer grippers relative to the central gripper.

8. The system of claim 1 , wherein the three-dimensional camera is coupled to the gripper assembly.

9. The system of claim 1 , further comprising a yarn case comprising at least one yarn package, wherein the yarn case is in a fixed position, and wherein the at least one yarn package is in a fixed position with respect to the yarn case so that the processor of the system can determine a position of the yarn package with respect to the service robot.

10. The system of claim 1 , further comprising:
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, wherein the service robot is configured to deliver packages to the gantry; and
a memory coupled with the one or more processors, the memory having 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.

11. The system of claim 10 , wherein the creel comprises a plurality of sub-creel modules, and wherein the system further comprises a plurality of gantries, each gantry being configured for movement within a respective sub-creel module.

12. The system of claim 10 , wherein the gantry comprises:
a frame;
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 that is configured to rotate at least a portion of the platform about the first axis;
a gripper that is movably attached to the at least a portion of the platform that is configured to rotate about the first axis, wherein the gripper is configured to releasably engage an inner surface of a yarn package; and
a linear actuator that is configured to move the gripper along a linear actuator axis that is perpendicular to the first axis, wherein the linear actuator comprises a first stage and a second stage.

13. The system of claim 12 , wherein the first stage comprises a servo motor that is configured to move the gripper along the linear actuator axis, and wherein the second stage comprises a pneumatic actuator that is configured to move the gripper along the linear actuator axis.

14. The system of claim 13 , wherein the linear actuator further comprises a sub-platform, wherein the servo motor is configured to move the sub-platform along a track, and wherein the pneumatic actuator is attached to the sub-platform so that the pneumatic actuator is in a fixed position along the linear axis with respect to the sub-platform.

15. The system of claim 14 , further comprising a second gripper and a second linear actuator, wherein the second gripper is movably attached to the platform and configured to releasably engage an inner surface of a yarn package, and wherein the second linear actuator is configured to move the second gripper along the linear axis.

16. The system of claim 15 , further comprising a third gripper and a third linear actuator, wherein the third gripper is movably attached to the platform and configured to releasably engage an inner surface of a yarn package, and wherein the third linear actuator is configured to move the third gripper along the linear axis.

17. The system of claim 12 , further comprising a camera that is attached to the platform, wherein the camera is configured to detect a diameter of a measured yarn package corresponding to a remaining quantity of material on the measured yarn package.

18. The system of claim 17 , wherein the one or more processors are configured to:
receive an image of the measured yarn package from the camera; and
approximate the remaining quantity of material on the measured yarn package based on the image of the measured yarn package.

19. The system of claim 12 , wherein the frame comprises a horizontal track and a vertical member that is movable along the horizontal track, and wherein the platform is movably attached to the vertical member.

20. The system of claim 19 , further comprising a staging platform that is attached to the vertical member so that the staging platform is configured to move with the vertical member along the first axis.

Assignees

• Columbia Insurance Co

Inventors

• Kurtz Kallin
• Tillman Rocky
• Moore Wes
• Hall Zachary

Classifications

• B65H67/086

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• B65H2701/31

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• B65H49/16 Primary

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• B65H67/067

  Removing full or empty bobbins from a container or a stack · CPC title

• B65H67/02

  Arrangements for removing spent cores or receptacles and replacing by supply packages at paying-out stations ({for cans D01H9/008; arrangement of the service carriage B65H54/26; } supports for packages B65H49/04, B65H49/20) · CPC title