U.S. patent application number 14/816075 was filed with the patent office on 2017-02-09 for dyeing process control method of conveyor drive rope-like fabric dyeing machine.
The applicant listed for this patent is Chi-Lung Chang. Invention is credited to Chi-Lung Chang.
Application Number | 20170037569 14/816075 |
Document ID | / |
Family ID | 58052877 |
Filed Date | 2017-02-09 |
United States Patent
Application |
20170037569 |
Kind Code |
A1 |
Chang; Chi-Lung |
February 9, 2017 |
Dyeing Process Control Method Of Conveyor Drive Rope-Like Fabric
Dyeing Machine
Abstract
Disclosed is a method for controlling a dyeing process of a
conveyor drive rope-like dyeing machine, which uses the number of
cycles of circulation of fabric in a dyeing bath as a control unit
for controlling the dyeing process. In other words, the entire
dyeing process, including the speed of adding chemicals, the speed
of heating/cooling, the time interval of holding temperature, and
the time interval of rinsing with water, and the likes of the
dyeing process, is controlled with the number of cycles of
circulation of fabric as the control unit for a computer or a
programmable logic controller to control the dyeing process.
Inventors: |
Chang; Chi-Lung; (Taoyuan
City, TW) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Chang; Chi-Lung |
Taoyuan City |
|
TW |
|
|
Family ID: |
58052877 |
Appl. No.: |
14/816075 |
Filed: |
August 3, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D06B 3/28 20130101; D06B
23/22 20130101 |
International
Class: |
D06P 5/00 20060101
D06P005/00; D06P 5/20 20060101 D06P005/20 |
Claims
1. A method for controlling a dyeing process of conveyor drive
rope-like fabric dyeing machine, in which time interval or speed of
treatments of chemical addition, heating, temperature holding,
cooling, and water rinsing of the dyeing process are controlled
with number of cycles of circulation of fabric in the dyeing
machine as a control unit in carrying out dyeing of the fabric.
Description
(a) TECHNICAL FIELD OF THE INVENTION
[0001] The present invention generally relates to a conveyor drive
fabric dyeing machine that is used to dye rope-like fabric, and
more particularly to a method for controlling a dyeing process.
(b) DESCRIPTION OF THE PRIOR ART
[0002] FIG. 1 is a schematic view illustrating a dyeing circulation
of fabric in a conventional dyeing machine. The operation principle
is that dye liquid F is pressurized by a pump D2 and passes through
a heat exchanger C (for increasing or decreasing temperature) into
a nozzle A4 to generate a jetting or overflowing liquid flow and
then returns to a fabric accumulation tank A1 of a dyeing machine
A. Fabric B is driven by a fabric roller A3 (or alternatively using
no fabric roller) into the nozzle A4 so that the fabric B is driven
by the force induced by the jetting or overflowing liquid flow from
the nozzle A4 to circulate. Dye liquid and chemical agents are
supplied from a service tank E and pressurized by a pump D1 to feed
into a dyeing circulation loop of the dyeing machine A. During the
circulation, the dye liquid F and the fabric B undergo a process of
heating, temperature holding, and cooling achieved with the heat
exchanger C to have the dye absorbed by the fabric thereby
achieving a dyeing effect of scouring, coloring, color fixing, and
water rinsing. Uniformity of dyeing (levelness) is determined by
the number of cycles of circulation of the fabric during the dyeing
process, namely the number of interactions between the fabric B and
the dye liquid in the nozzle A4 and the dyeing tube A2. A great
number of cycles of circulation indicates a great number of
interactions and thus better uniformity of dyeing, as well as the
extent of water rinsing and dyeing fastness.
[0003] Referring to FIG. 2, which shows a typical dyeing process
employed in a conventional dyeing machine, theoretically or
empirically, the conventional dyeing machine uses "time" as a
control unit (denominator) to carry out treatments of fabrics
dyeing, including, in sequence, chemicals adding, heating,
temperature holding, heating, temperature holding, cooling, water
rinsing, chemicals adding, heating, temperature holding, cooling,
and hot water rinsing. Control is generally achieved with a
computer or a programmable logic controller (PLC).
[0004] Since the conventional dyeing machine uses "time" as a
control unit, it generally takes the same amount of time to
complete a dyeing process regardless the actual length or weight of
the fabrics being dyed. However, in an actual dyeing process, since
different pieces of fabric that are dyed may have different weights
or the thicknesses of the fabrics may be different, the lengths of
fabrics in each batch and each tube may be different. Although the
fabrics may be of the same type, adopting a dyeing process of the
same amount of dyeing time is generally a waste of time. Further,
during the entire dyeing process of the fabrics, due to the actual
amount (length) of fabric to be dyed in each batch or each tube of
the dyeing machine being different, the number of cycles of
circulation is different. Consequently, even though the dyeing time
is identical, the extent of dyeing so obtained is different,
leading to issues regarding tube deviation or batch deviation,
inconsistent dyeing fastness, and poor reproductivity. As such,
re-dyeing may be necessary and the quality and efficiency of
productions are poor. A great amount of energy and human labor are
wasted and additional environmental pollution may result. Such a
reproductivity issue is a long existing problem of the dyeing
workshops and has not yet been overcome.
SUMMARY OF THE INVENTION
[0005] An object of the present invention is to overcome the
problems occurring in a dyeing process of a conventional dyeing
machine that uses "time" as a control unit so that the same amount
of time is taken in carrying out the dyeing process for the same
type of fabrics regardless the actual lengths of the fabrics that
are dyed so that even though the dyeing time is identical, the
results of the dyeing operations are different thereby leading to
the problems of batch deviation or tube deviation, inconsistent
fastness, poor reproductivity, and waste of time.
[0006] To overcome such problems, the present invention is made to
change the way of control of the conventional dyeing machine by
using the number of cycles of circulation of fabric as a control
unit (denominator). In other words, the horizontal axis of the plot
shown in FIG. 2 is changed from "time" to "number of cycles of
circulation of fabric". As such, regardless the actual length of
fabric introduced, the dyeing process is controlled on the basis of
the number of cycles of circulation of fabric. For a rope of fabric
having a great length, the time required for the entire dyeing
process is long; and for a rope of fabric having a small length,
the time required for the entire dyeing process is short. Thus,
since, for fabrics of the same type, the number of cycles of
circulation adopted for each dyeing tube or each batch of the
dyeing operations of the fabrics is all the same, the degree of
dyeing and the extent of water rinsing are all identical. This
ensures zero tube deviation or zero batch deviation, consistent
fastness, and one hundred percent of reproductivity and greatly
improves the quality and efficiency of production and also greatly
reduces the dyeing cost and achieves environmental protection
through saving energy and reducing carbon.
[0007] The technical solution of the present invention is to
arrange a fabric seam and circulation time and circulation cycle
counter at a proper location in a machine body of a conveyor chive
rope-like fabric dyeing machine. Since movement of fabric from a
rear end toward a front end is driven by a conveyor, a circulation
speed of the fabric is synchronous with the conveyor. Thus,
although circulation time of the fabric of each cycle of
circulation is adjustable, a fixed speed and a fixed time period
are adopted once selected and set. The present invention makes use
of such a characteristic of speed being fixed and, through
employment of a computer of a programmable logic controller (PLC),
uses the number of cycles of circulation of fabric as a control
unit for the dyeing process. This ensures, as mentioned above,
shortening of dyeing time, no color deviation, no batch deviation,
consistent fastness, and one hundred percent of reproductivity, and
also improve product quality, improves production efficiency,
lowers down manufacturing cost, saves energy and reduce carbon, and
enhances environmental protection.
[0008] The advantages of the present invention includes: [0009] (1)
The time of an entire dyeing process can be shortened according to
the length of a rope of fabric that is dyed. [0010] (2) Regardless
the actual lengths of the fabrics dyed, the number of cycles of
circulation is made identical so that the interaction degree of
dyeing is identical and the reproductivity of dyeing is one hundred
percent and there is no tube deviation and no batch deviation, and
no concern about fastness difference. [0011] (3) Regardless the
actual lengths of the fabrics dyed, the number of cycles of
circulation is the same and the number of contacts between a fabric
and the dyeing machine (friction and stretching) is the same, so
that the quality of the fabric is consistent.
[0012] The foregoing objectives and summary provide only a brief
introduction to the present invention. To fully appreciate these
and other objects of the present invention as well as the invention
itself, all of which will become apparent to those skilled in the
art, the following detailed description of the invention and the
claims should be read in conjunction with the accompanying
drawings. Throughout the specification and drawings identical
reference numerals refer to identical or similar parts.
[0013] Many other advantages and features of the present invention
will become manifest to those versed in the art upon making
reference to the detailed description and the accompanying sheets
of drawings in which a preferred structural embodiment
incorporating the principles of the present invention is shown by
way of illustrative example.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a schematic view illustrating a cycle of
circulation of dyeing fabric in a conventional dyeing machine.
[0015] FIG. 2 is a plot showing a typical dyeing process of the
conventional dyeing machine.
[0016] FIG. 3 is a plot showing a dyeing process of a conveyor
drive rope-like fabric dyeing machine according to the present
invention.
[0017] FIG. 4 is a schematic view showing the conveyor drive
rope-like fabric dyeing machine according to the present
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] The following descriptions are exemplary embodiments only,
and are not intended to limit the scope, applicability or
configuration of the invention in any way. Rather, the following
description provides a convenient illustration for implementing
exemplary embodiments of the invention. Various changes to the
described embodiments may be made in the function and arrangement
of the elements described without departing from the scope of the
invention as set forth in the appended claims.
[0019] As shown in FIG. 4, the present invention provides a
conveyor drive rope-like fabric dyeing machine, which comprises a
fabric seam and circulation time and circulation cycle counter
arranged at a proper location in a machine body of the conveyor
drive rope-like fabric dyeing machine. Since movement of fabric
from a rear end toward a front end is driven by a conveyor, a
circulation speed of the fabric is synchronous with the conveyor.
Thus, although circulation time of the fabric of each cycle of
circulation is adjustable, a fixed speed and a fixed time period
are adopted once selected and set. The present invention makes use
of such a characteristic of speed being fixed and, through
employment of a computer of a programmable logic controller (PLC),
uses the number of cycles of circulation of fabric as a control
unit for the dyeing process. This ensures, as mentioned above,
shortening of dyeing time, no color deviation, no batch deviation,
consistent fastness, and one hundred percent of reproductivity, and
also improve product quality, improves production efficiency,
lowers down manufacturing cost, saves energy and reduce carbon, and
enhances environmental protection.
[0020] FIG. 3 is a plot showing a dyeing process of a conveyor
drive rope-like fabric dyeing machine according to the present
invention, in which "number of cycles of circulation" is used to
substitute "time" that is used as the horizontal axis of the dyeing
curve shown in FIG. 2 of a conventional rope-like fabric dyeing
machine and a computer or a programmable logic controller is used
to control the dyeing process. In other words, treatments of the
dyeing process, including, in sequence, chemicals adding, heating,
temperature holding, heating, temperature holding, cooling, water
rinsing, chemicals adding, heating, temperature holding, cooling,
and hot water rinsing are carried out with the "number of cycles of
circulation" being taken as a control unit. This means the amount
of chemical added each time, the temperature variation achieved in
each heating or cooling operation, the temperature interval of
temperature holding or water rinsing, and the likes are all
controlled with the "number of cycles of circulation" as the
control unit. In this way, the total time for a dying process may
differ for different lengths of a piece of fabric subjected to the
dyeing process. For example, for the same type of fabric, a 500 kg
capacity dyeing machine that, in actual operations, would spend
about half the time used for handling fabric of 500 kg in handling
fabric of 250 kg, but provide exactly the same degree of dyeing and
the same result of dyeing thereby achieving consistent
reproductivity. This is a revolutionary innovation.
[0021] It can be appreciated from the above description that the
actual dyeing effect obtained with the conveyor drive rope-like
fabric dyeing machine is primarily and directly determined by the
number of cycles of circulation of the fabric, not the length of
time (namely an absolute relationship being had with respect to the
number of cycles of circulation, while a relative relationship is
had with respect to time). Thus, when the fabric speed in each tube
or each batch of the dyeing machine is the same, if the time used
is the same, then the number of cycles of circulation is less for
fabric having a greater length and the number of cycles of
circulation is greater for fabric having a shorter length. Thus,
even though time is the same, the degree of dyeing is different and
the result of dyeing is also different, leading to issues of tube
deviation, batch deviation, inconsistent fastness, and inconsistent
reproductivity. Thus, to have consistent result of dyeing for
fabrics of the same type, the number of cycles of circulation must
be identical regardless the actual length of fabric dyed. In other
words, for fabric that is short, the time can be shortened
correspondingly. This can shorten the time for the entire dyeing
operation and since the number of cycles of circulation is the same
regardless the length of the fabric, the degree of dyeing is the
same and one hundred percent of reproductivity of dyeing can be
achieved. Thus, there will be no need for re-dyeing due to tube
deviation or batch deviation and inconsistency of fastness.
[0022] It will be understood that each of the elements described
above, or two or more together may also find a useful application
in other types of methods differing from the type described
above.
[0023] While certain novel features of this invention have been
shown and described and are pointed out in the annexed claim, it is
not intended to be limited to the details above, since it will be
understood that various omissions, modifications, substitutions and
changes in the forms and details of the device illustrated and in
its operation can be made by those skilled in the art without
departing in any way from the spirit of the present invention.
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