Method for in-line treatment of thread and system therefore comprising treatment unit and thread speed sensor

Abstract

To provide a system and a method for in-line treatment of a thread for use with a thread consuming device.SOLUTION: This system comprises at least one treatment unit (100) being configured to dispense one or more coating substances onto at least one thread when activated and a thread speed sensor (50) being driven by the motion of at least one thread (20). There is also provided a method for in-line treatment of the at least one thread (20) for use with a thread consuming device.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to the technical field of thread-consuming devices. In particular, the present invention relates to a system comprising a processing unit used in connection with such thread-consuming devices.

Background Art

[0002] It has been proposed to provide an in-line device designed to provide specific processing to the thread in a thread-consuming device such as an embroidery machine. Such an in-line device is used, for example, to color the thread, so that when creating a multi-color pattern using an embroidery machine, a plurality of color nozzles can replace the current use of a plurality of pre-colored threads. In prior art systems where threads of different colors are used, one thread having a first specified color is used for some stitches, and another thread having a second specified color is used for other stitches.

[0003] To eliminate the obvious drawbacks of the requirements for a plurality of threads of different colors, the applicant has filed several patent applications regarding the technology of in-line coloring of threads, such as Patent Document 1 and Patent Document 2. The proposed solutions provide improvements in terms of color quality and also reduce the complexity of the thread-consuming device.

[0004] However, in order to further improve the quality and efficiency of in-line coloring of threads, it would be advantageous to modify the general principle of in-line coloring of threads to increase the accuracy in distributing the correct amount of coating substance at the intended position of the thread being processed.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0006] Therefore, an object of the present invention is to provide a solution that overcomes the disadvantages of the prior art. More specifically, the present invention provides a solution in which the length and speed of the thread are taken into account during the distribution of the coating material.

Means for Solving the Problems

[0007] In the present invention, the speed of the thread is measured by a thread speed sensor. In this way, the speed can be measured in an accurate manner without being affected by the elasticity of the thread and / or the heat generated by the system. Using a thread speed sensor has several advantages compared to other possible solutions, such as measuring the speed using a motor that drives the thread. Measuring the speed with a motor that drives the thread has several disadvantages. For example, the measurement is affected by the elasticity of the thread and the heat generated. Furthermore, the forces at the inlet and outlet of the system driven by the motor, and thus the speed generated by the motor, are affected by other components within the system, which causes uncertainty in the measurement.

[0008] In a first aspect, a system for in-line processing of a thread for use with a thread consuming device is provided. The system comprises a processing unit configured to distribute one or more coating materials to at least one thread during operation, and a thread speed sensor driven by the movement of at least one thread.

[0009] The thread speed sensor may be arranged upstream of the at least one processing unit.

[0010] The system may further comprise a control unit configured to control the operation of the processing unit.

[0011] The control unit may be configured to control the operation of the processing unit based on a predetermined operation scheme of the yarn consumption device.

[0012] The control unit may be configured to receive speed data from a yarn speed sensor and control the operation of the processing unit based on the received speed data.

[0013] The yarn speed sensor may include a rotation sensor driven by the movement of at least one yarn.

[0014] In one embodiment, the rotation sensor includes a pulley.

[0015] The yarn speed sensor may further include an encoder operably communicating with the pulley. The encoder may be a rotary encoder.

[0016] In one embodiment, the system further includes a light detection system for illuminating at least one yarn and receiving light reflected from the at least one yarn when the at least one yarn is illuminated. The light detection system is disposed downstream of at least one processing unit along the traveling direction of the at least one yarn.

[0017] The light detection system may include at least one light source and an optical sensor.

[0018] In one embodiment, the coating substance is a coloring substance, and the system further includes a control unit configured to receive data from the light detection system and determine the color of the coloring substance distributed to a designated section of at least one yarn based on the received data.

[0019] The control unit may be further configured to compare the determined color with a predetermined color scheme and generate an alarm signal and / or adjust the operation of the processing unit if the determined color and the predetermined color scheme do not match within an acceptable tolerance.

[0020] In one embodiment, the processing unit comprises a plurality of nozzles arranged at different positions with respect to at least one thread, the at least one thread moves during use, and each nozzle is configured to dispense one or more coating materials to the at least one thread when actuated.

[0021] In one embodiment, the nozzle is an inkjet nozzle.

[0022] In one embodiment, the system further comprises a thread consuming device. The thread consuming device can be an embroidery machine, a sewing machine, a knitting machine, a weaving machine, a tufting machine, a thread winding machine, or any combination thereof.

[0023] In a second aspect, a method for in-line processing of at least one thread for use with a thread consuming device is provided. The method includes providing a processing unit configured to dispense one or more coating materials to at least one thread when actuated, and providing a thread speed sensor driven by the movement of the at least one thread.

[0024] The method further includes controlling the operation of the at least one processing unit based on a predetermined operating scheme of the thread consuming device.

[0025] The method further includes receiving speed data from the thread speed sensor and controlling the operation of the processing unit based on the received speed data.

[0026] (Definition) In this context, a "thread consuming device" is any device that consumes thread during use. For example, it may be an embroidery machine, a sewing machine, a knitting machine, a weaving machine, a tufting machine, a thread winding machine, or any other thread consuming device, which can benefit from other processes involving exposing the thread to substances such as surface treatment or coating, or dyeing.

[0027] In this context, a "process" is any process designed to change the properties of a thread. Such processes include, but are not limited to, coloring, wetting, lubricating, cleaning, fixing, heating, curing, dyeing, etc.

[0028] In this context, a "thread" is a flexible, elongated member or substrate that is thin in the width and height directions and has a longitudinal extension that is extremely long compared to the longitudinal extension of any part of the system described herein and also compared to its width and height dimensions. Typically, a "thread" can be composed of a plurality of plies twisted together. Thus, the term "thread" includes yarns, wires, strands, filaments, etc. made from a variety of different materials such as glass fibers, wool, cotton, synthetic materials such as polymers, metals, polyester, viscose, or, for example, mixtures of wool, cotton, polymers or metals, or any combination thereof.

[0029] All references herein to "upstream side" and / or "downstream side" should be interpreted as relative positions when the device is operating to process an elongated substrate such as a thread that moves continuously in the normal operating direction within the device during the normal operation of the thread-consuming device. Thus, the upstream components are arranged such that a particular portion of the thread passes through the upstream components before passing through the downstream components.

[0030] Embodiments of the present invention will be described with reference to the accompanying drawings, which illustrate non-limiting examples of how the concepts of the present invention can be implemented in the following description of the present invention.

Brief Description of the Drawings

[0031]

Fig. 1a

Fig. 1b

Fig. 2

Fig. 3

Fig. 4a

Fig. 4b

Fig. 5a

Fig. 5b

Fig. 5c

Fig. 6a

Fig. 6b

Fig. 6c

Fig. 6d

Fig. 7

Fig. 8a

Fig. 8b

BEST MODE FOR CARRYING OUT THE INVENTION

[0032] The idea of the present invention is to provide a system and method for distributing a coating substance to a thread in a controlled manner for use in connection with a thread-consuming device. Starting with FIG. 1a, a schematic view of a system 10 for in-line processing of a thread is shown. The system 10 comprises a processing unit 100 for distributing one or more coating substances to at least one thread. The system 10 further comprises at least one thread-consuming device 15, which can be in the form of, for example, one or more embroidery machines, weaving machines, sewing machines, knitting machines, tufting machines, thread winding machines, etc. Thereby, the system forms a thread-consuming unit comprising at least one thread-consuming device 15 and the processing unit 100. Note that multiple threads can be used in the thread-consuming device.

[0033] Note that some aspects of the system are described herein and they do not require including the thread-consuming device 15. As will be further understood from below, in all embodiments, a system for in-line processing of a thread requires a processing unit 100 used in conjunction with a thread-consuming device and a thread speed sensor 50 (see, for example, FIG. 5) for measuring the thread speed of the thread.

[0034] Turning now to FIG. 1b, the thread-consuming device 15 is illustrated as an embroidery machine, and here is shown as a single-head embroidery machine equipped with a processing unit 100. The embroidery machine 15 comprises a movable stage 2b for carrying the fabric to be embroidered. During operation, the movable stage 2b is controlled to rapidly change its position in the X and Y directions (i.e., in this case, a horizontal plane, but could also be a vertical plane).

[0035] The processing unit 100 enables the embroidery machine 15 to operate without uniquely providing pre-colored threads as required by conventional embroidery machines. Instead, the processing unit 100 provides in-line coloring of the thread 20 according to a predetermined coloring pattern so that colored embroidery can be manufactured. Thus, the processing unit replaces individual thread reels as exists in prior art systems.

[0036] As shown in FIG. 1b, the only connection between the processing unit 100 and the embroidery machine 15 is the thread 20 and also an electrical connection (not shown). Thus, the processing unit 100 is provided as a stand-alone unit that does not have a mechanical connection to the movable stage 2b. In an optional embodiment, the stand-alone processing unit 100 is attached to the thread-consuming device 15 via a suspension device for reducing the transmission of vibrations to the processing unit 100.

[0037] Various components of the processing unit 100 are shown in FIG. 2. As can be seen in FIG. 2, most of the components are arranged inside the housing 105. Immediately downstream of the thread reel 120, a thread feeder 130 configured to pull the thread forward through the processing unit 100 can be arranged. The thread feeder 130, which will not be further described herein, for a more general understanding, receives and advances the thread 20. For this purpose, the thread feeder 130 is controlled by a control unit 190, which will be further described below. The thread feeder 130 is also preferably configured to control the thread tension, for example, by means of driven rollers, encoder wheels, and one or more thread guides. After passing through the thread feeder 130, the thread 20 engages with a thread guiding device 140.

[0038] The thread guiding device 140 can be in the form of, for example, one or more guiding rollers 142 or other suitable means, ensuring that the thread 20 is aligned with one or more processing nozzles that form part of the discharging device 150.

[0039] The discharge device 150 is configured to discharge a processing substance, such as a coloring substance, onto the thread 20 as the substance passes through the discharge device 150. For this reason, the nozzle is preferably arranged in the longitudinal direction of the thread 20, as will be further explained in connection with FIGS. 3a - c.

[0040] The discharge device 150 can be movable by a drive unit (not shown). By having a drive unit, it is possible to place the discharge device 150 in different operating states, for example, to perform different tasks such as a first state of distributing a coating substance onto the thread and a second state of performing a cleaning session or other maintenance or idling. For this purpose, the drive unit can be connected to the discharge device 150. The drive unit can be configured to move the discharge device 150 between an idle or maintenance position and an operating position by a transmission having different transmission ratios during the movement from the idle position to the operating position.

[0041] Downstream of the discharge device 150, another thread guiding device 160 is provided. The second thread guiding device 160 cooperates with the first thread guiding device 140 to ensure that the position of the thread 20 is correct while moving along the discharge device 150. The second thread guiding device 160 can be in the form of, for example, one or more guiding rollers 162, 164, but it can also be designed to induce rotation of the thread 20 along its longitudinal axis. This additional function can provide advantages for coloring, as will be explained below.

[0042] The system 10 may further include a thread speed sensor 50 configured to measure the speed of the thread 20 passing through the system 10. In FIG. 2, the thread speed sensor 50 is arranged immediately before the discharge device 150. In some embodiments, the thread speed sensor 50 can replace the thread guiding device 140.

[0043] In another embodiment, the yarn speed sensor 50 is disposed immediately downstream of the discharge device 150. The yarn speed sensor 50 can, in some embodiments, replace the second yarn guiding device 160. In yet another embodiment, two yarn speed sensors are provided, with the first disposed upstream of the discharge device 150 and the second disposed downstream of the discharge device 150. The yarn speed sensor 50 will be described in more detail with reference to FIG. 5.

[0044] Next, the yarn 20 is fed forward to pass through one or more fixing units 170 provided for fixing the treatment substance to the yarn 20. The fixing unit 170 preferably comprises heating means such as a hot air supply element or a heating element, or a UV light source for curing the treatment substance, for example a coloring substance, or fixing it to the yarn 20. As shown in FIG. 2, the fixing unit 170 can be arranged at any of horizontal, vertical, or at an angle between horizontal and vertical.

[0045] Before exiting the housing 105, the yarn 20 can pass through a cleaning unit 180 such as an ultrasonic bath, where unwanted particles are removed from the yarn 20. Once the treatment substance is fixed to the yarn 20, the cleaning unit 180 leaves the treatment substance unaffected.

[0046] The processing unit 100 may further comprise a lubricating unit 185 disposed inside the housing 105. Additional yarn buffers and yarn feeders (not shown) may also be included in the processing unit 100 disposed at various positions along the yarn path.

[0047] The yarn 20 preferably exits the processing unit 100 through an opening or the like, whereby the yarn 20 is sent to a related yarn-consuming device such as an embroidery machine 15, as shown in FIGS. 1a and 1b.

[0048] During operation, the yarn feeder 130 and other components that engage with the yarn 20 are preferably configured such that the force required to pull the yarn 20 from the processing unit 100, i.e., the pulling force applied by the downstream embroidery machine 15, is approximately the same as if the processing unit 100 had been replaced with a prior art yarn reel.

[0049] A control unit 190 is also provided, which includes associated electronic devices such as power electronics, a communication module, and a memory. The control unit 190 is connected to the yarn feeder 130, the discharge device 150, and the fixing unit 170, enabling control of the operation of these components. Further, the control unit 190 is configured to control the operation of the entire processing unit 100, including the cleaning unit 180, the lubrication unit 185, the splitting of the yarn 20, the yarn speed at various positions along the processing unit 100, and the yarn buffer. The control unit 190 may also be configured to receive control signals from one or more components of the processing unit 100, for example, control signals for triggering specific controls, or other information related to yarn consumption by the embroidery machine 15.

[0050] The control unit 190 can be implemented by any commercially available CPU ("Central Processing Unit"), DSP ("Digital Signal Processor") or any other electronic programmable logic device, or a combination of such a processor or other electronic programmable logic devices. The control unit 190 can be implemented by using computer program instructions executable in a general-purpose or dedicated processor that can be stored, for example, in a computer-readable storage medium (such as a disk, memory, etc.) executed by such a processor, using instructions that enable hardware functions.

[0051] In one embodiment, a user interface is also provided via a display 195 preferably disposed at the front end of the housing 105. The display 195 enables a user to interact with the control unit 190, and thus, the control parameters of the thread feeder 130, the discharge device 150, the fixing unit 170, etc., which are connected thereto, can be set according to the process specifications. The display 195 can also be preferably used to warn the user of critical situations, whereby the display 195 can be used for the control unit 190 to issue alarms and the like.

[0052] It should be noted that the above components are not necessarily included in the stand-alone processing unit 100. Instead, the components of the processing unit 100 can be separated into several units where at least one unit is a stand-alone unit. Preferably, the stand-alone unit includes at least one discharge device 150.

[0053] FIG. 3 shows a discharge device 150 that forms part of the processing unit 100 as described above. The moving direction of the thread 20 during use is indicated by the solid arrow in FIG. 3. As will be described in detail shortly, the discharge device 150 includes a plurality of nozzles 152a - f disposed at different longitudinal positions (e.g., separated by a distance d1) along the thread 20 passing through the processing unit 100 during use.

[0054] Each of the nozzles 152a - f is arranged to distribute a coating substance, such as ink, to the thread 20 when the nozzle is activated. The coating substance is absorbed by the thread 20, for example, at different circumferential positions of the thread 20 when the thread 20 is twisted around its longitudinal axis. The relative positions of two droplets to which the coating substance is adjacently distributed can be selected such that the droplets overlap.

[0055] The processing unit 100 includes one or more discharge devices 150. Each discharge device 150 is preferably formed as a series of inkjet print heads 151a - d, and each print head 151a - d has one or more nozzle arrays. Each nozzle array typically includes hundreds or thousands of nozzles. For the sake of illustration, only six nozzles 152a - f are shown for one of the print heads 151a - d. However, it should be understood that each nozzle array may include thousands of nozzles 152 each. As an example, each print head 151a - d can be associated with a single color. In the example shown, the discharge device 150 has four print heads 151a - d, and each print head 151a - d is associated with a specific color according to the CMYK standard. However, other color models can also be used.

[0056] The exact configuration of the processing unit 100 can vary. For example, the processing unit 100 includes a single discharge device 150 having a plurality of print heads 151a - d. Each print head 151a - d then includes a plurality of nozzles 152a - f.

[0057] In another embodiment, the processing unit 100 includes several discharge devices 150 arranged either in series or in parallel. Each discharge device 150 then includes a plurality of print heads 151a - d. When arranged in series, the upstream discharge device 150 can have print heads 151a - d associated with one or more colors of a specific color standard, while the downstream discharge device 150 has print heads 151a - d associated with other colors of the same color standard. When arranged in parallel, each discharge device 150 is associated with all colors of a specific color standard but can have print heads 151a - d associated with different threads 20. In such an embodiment, two separate threads 20 can be handled simultaneously and in parallel. Of course, combinations of parallel / series configurations are also possible.

[0058] In yet another embodiment, the discharge device 150 has only a single print head 151a - d. In that case, the dynamic coloring of the yarn 20 would require several discharge devices 150 of the processing unit 100.

[0059] Each nozzle 152a - f can dispense a coating substance having a color according to the CMYK color model where the primary colors are cyan, magenta, yellow, and black. Thus, it may be possible to dispense a wide variety of colors onto the yarn by operating the nozzles 152a - f such that the total coloring substance for a specific length of the yarn 20 becomes a mixture of the coloring substances dispensed by the nozzles 152a - f. As previously explained, this is preferably achieved by arranging several print heads 151a - d in series, whereby the nozzles 152a - f of a specific print head 151a - d are dedicated to a single color.

[0060] In another embodiment, each nozzle 152a - f dispenses a coating substance having a color that includes a mixture of two or more primary colors of the CMYK color model.

[0061] The control unit 190 is configured to control the operation of the nozzles 152a - f such that the coating substance is discharged onto the yarn 20 when the coating substance passes through the processing unit 100, particularly when passing through the discharge device 150. With such a configuration, very accurate coloring of the yarn 20 is possible, and the coloring provided by the processing unit 100 can provide, for example, a highly sophisticated and visually refined embroidery pattern.

[0062] In the case of the coloring operation, the control unit 190 receives one or more input signals that specify the desired color and / or coloring effect. The color input preferably includes information regarding the exact color and the longitudinal start and stop positions of the yarn 20 of that specific color. When the yarn speed is determined, the longitudinal start and stop positions can be represented by specific time values.

[0063] Figures 4a - b show top views of respective print heads 151a. The print head 151a has a plane on which nozzles 152 are arranged. As described above, the total number of nozzles 152 of a single print head can be up to several thousand when provided on a print head 151a of centimeter - sized dimensions. In the example shown, a far fewer number of nozzles 152 are shown. The nozzles 152 can be distributed into one or more nozzle arrays 153. In Figure 4a, the nozzles 152 are distributed into two parallel arrays 153. The arrays 153 are aligned with each other such that the nozzles 152 of one array 153 are arranged adjacent to the nozzles 152 of the other array 153.

[0064] Figure 4b shows a similar example, but there is a vertical offset between the two arrays 153.

[0065] Figures 5a - c are schematic views of a yarn speed sensor. The yarn speed sensor 50 is driven by the movement of at least one yarn within the system 10. Next, the yarn is driven by a motor or other type of drive unit.

[0066] As seen in Figure 5a, the yarn speed sensor 50 can include a rotation sensor 52 driven by the movement of at least one yarn 20. The rotation sensor can comprise or consist of a wheel such as a pulley 52 or a guide roller.

[0067] The yarn speed sensor 50 can further include an encoder 54 operably communicating with the pulley 52. In one embodiment, the encoder 54 is a rotary encoder or a shaft encoder. The rotary encoder converts an angular position or movement into an output signal that can be processed by the control unit 190 of the system 10. Thus, the encoder provides information about the movement of the pulley, and thus the movement of the yarn. The control unit 190 is configured to use this data to determine the speed of the yarn.

[0068] In one embodiment, the encoder is an absolute encoder. In yet another embodiment, the encoder is an incremental encoder.

[0069] In a preferred embodiment, the yarn speed sensor 50 is arranged upstream of the at least one processing unit 100. The yarn speed sensor 50 is preferably arranged upstream of and close to the processing unit 100. FIGS. 5b and 5c show two possible arrangements of the yarn speed sensor 50. In FIG. 5b, the yarn speed sensor 50 is arranged immediately before the discharge device 150. In this embodiment, the yarn speed sensor 50 replaces the yarn guiding device 140. Accordingly, the yarn speed sensor 50 comprises one or more guide rollers or other suitable means for ensuring that the yarn 20 is aligned with one or more processing nozzles forming part of the discharge device 150.

[0070] In FIG. 5c, the yarn speed sensor 50 is arranged immediately after the discharge device 150. In this embodiment, the yarn speed sensor 50 replaces the yarn guiding device 160. Accordingly, the yarn speed sensor 50 comprises one or more guide rollers or other suitable means for ensuring that the position of the yarn 20 is correct while the position of the yarn 20 moves along the discharge device 150.

[0071] As already explained, the control unit 190 can be configured to control the startup of the system 10 based on a predetermined operating scheme. More specifically, the control unit 190 can be configured to control the startup of the processing unit 100 based on a predetermined operating mode of the yarn consuming device 15. The predetermined operating scheme can be related to the speed of the yarn as well as to other yarn consumption parameters.

[0072] The control unit 190 is configured to receive data from the yarn speed sensor. The data is preferably related to the speed of the yarn 20. Based on the received data, the control unit 190 is further configured to control different parts of the system 10. In one embodiment, the control unit 190 is configured to control the operation of the processing unit 100 and / or other parts of the system 10 based on the received speed data.

[0073] In one embodiment, the control unit 190 is configured to control the operation of at least one discharge device 150 based on the speed data. The control unit can control the operation of one or more discharge devices 150, the operation of the print heads 151a - d, and / or the operation of one or more nozzles 152a - f.

[0074] The control unit 190 can be configured to adjust, for example, the speed, movement, timing of a print head, nozzle array or nozzle, and also to determine the number of active nozzles. For example, the control unit 190 can be configured to control the number of active nozzles and / or nozzle arrays and / or print heads based on the yarn speed.

[0075] Since the yarn is elastic and can be affected by various processing steps of the system 10, it is also beneficial to receive feedback on the actual yarn consumption at a later stage of the process. This can be achieved by adding an optical detection system 60 as shown in FIGS. 6a - b. The optical detection system 60 is arranged to illuminate the yarn 20 as shown in FIG. 6b, this is in order to receive the light reflected from the yarn 20 when the yarn 20 is illuminated. The optical detection system 60 is arranged downstream of at least one processing unit 100 along the traveling direction of at least one yarn 20.

[0076] In one embodiment, the light detection system 60 includes at least one light source 62 and at least one optical sensor 64. In an alternative embodiment, the light detection system 60 includes an optical sensor 64 configured to also function as a light source. The optical sensor 60 can be, for example, a monochrome sensor, a color sensor, or a spectrophotometer.

[0077] The control unit 190 can be configured to process data received from the light detection system 60. The control unit 190 can be configured to determine, for example, the color of a coloring substance distributed on the yarn. In a preferred embodiment, the control unit 190 is configured to determine the color of a coloring substance distributed on a specific section of at least one yarn 20.

[0078] The control unit 190 can be further configured to compare the determined color with a predetermined color scheme to determine whether the correct color is applied to the correct section of the yarn. If the determined color and the predetermined color scheme do not match within an acceptable tolerance, the control unit 190 can be configured to generate an alarm signal. The alarm signal can be displayed, for example, on the display 195 and / or can be an audible alarm and / or a visual alarm by illuminating, for example, light.

[0079] Additionally or alternatively, if the determined color and the predetermined color scheme do not match within an acceptable tolerance, the control unit 190 can be configured to adjust the position of different components of the system 10 and / or to adjust the color queue of the processing unit 100. By adjusting the position, the system can take into account the possibility of changes in the length of the yarn (shrinkage or elongation).

[0080] The light detection system 60 can be further configured to generate data for a control unit 190 that can be used to determine the position of one or more components of the system 10. For example, at least one of the plurality of nozzles is movable relative to the thread between a first position and a second position. At the first position, at least one of the plurality of nozzles is aligned with at least one thread. When the system is in the first position, another coating material dispensed from at least one nozzle strikes at least one thread 20. This is schematically shown in FIGS. 6c - d. FIG. 6c shows the system 10 being arranged in the first position, and FIG. 6d shows the system 10 being arranged in the second position. At the second position, at least one of the plurality of nozzles is not aligned with at least one thread. When the system is in the second position, another coating material dispensed from at least one nozzle misses at least one thread 20.

[0081] Accordingly, the control unit 190 is configured to determine whether the system is in its first position or its second position based on data received from the light detection system. This data can be used to determine the nozzle position when the processing unit is dispensing one or more coating materials onto at least one thread 20 (or when, at the second position, one or more coating materials are no longer being dispensed) and to store said position data. This information can be useful, for example, for evaluating whether the discharge device 150 is functioning properly.

[0082] In one embodiment, the control unit 190 is configured to combine speed data received from the thread speed sensor 50 and data received from the light detection system to control different parts of the system 10, such as, for example, controlling the dispensing device 150.

[0083] FIG. 7 shows a method for inline processing of at least one thread 20 for use with the thread consumption device 15. This method includes step 210 of providing a processing unit configured to dispense one or more coating substances to at least one thread during operation, and step 220 of providing a thread speed sensor 50 driven by the movement of at least one thread 20.

[0084] This method further includes step 230 of receiving speed data from the thread speed sensor 50, and step 240 of controlling the operation of at least one processing unit 100 based on the received speed data.

[0085] The present invention has mainly been described with reference to a system including one processing unit 100 and one thread consumption device 15, but those skilled in the art should understand that the features of the present invention can also be applied to other systems. FIGS. 8a - b show two examples of such alternative systems.

[0086] In FIG. 8a, the system 10 includes first and second processing units 100a, 100b and first and second thread consumption devices 15a - b. Each processing unit 100a, 100b controls and executes operations on each thread consumption device 15a - b. Note that the first and second processing units 100a may share one or more components even if they are separated. In one embodiment, the control unit 190 is arranged as a unit separate from the first and second processing units 100a, 100b, and thus one control unit 190 is configured to control the operations of both processing units 100a, 100b and correspondingly the operations of both thread consumption devices 15a - b.

[0087] In FIG. 8b, the system 10 includes one processing unit 100a and first and second thread consumption devices 15a - b. In this embodiment, one processing unit 100a is configured to control and execute the operations of the two thread consumption devices 15a - b.

[0088] Only two processing units and two yarn consumption devices are shown in FIG. 8a, and only one processing unit and two yarn consumption devices are shown in FIG. 8b, but it should be noted that any reasonable number of processing units and / or yarn consumption devices may be present in system 10.

[0089] Although the present invention has been described above with reference to specific embodiments, it is not intended to be limited to the specific forms described herein. Rather, the present invention is limited only by the appended claims.

[0090] In the claims, the term "comprising" does not exclude the presence of other elements or steps. Further, although individual features may be included in different claims, these may perhaps be combined advantageously, and including them in different claims does not mean that the combination of features is not feasible and / or not advantageous. Further, a single reference does not exclude a plurality. Terms such as "a", "an", "first", "second", etc. do not exclude a plurality. The reference signs in the claims are provided merely as examples for clarity and should not be construed as limiting the claims in any way.

Claims

1. A system (10) for in-line processing of a yarn (20) for use with a yarn consuming device (15), comprising: a treatment unit (100) configured to dispense one or more coating substances onto at least one yarn upon operation; a yarn speed sensor (50) driven by the movement of at least one yarn (20); A system (10) comprising:

2. The system (10) according to claim 1, wherein the yarn speed sensor is arranged upstream of the at least one processing unit (100).

3. The system (10) of claim 1 or 2, further comprising a control unit (190) configured to control an operation of the processing unit (100).

4. The system (10) according to claim 3, wherein the control unit (190) is configured to control the operation of the processing unit (100) based on a predetermined operation scheme of the yarn consuming device (15).

5. The control unit (190) receiving speed data from said yarn speed sensor (50); controlling operation of the processing unit (100) based on the received speed data; The system (10) according to claim 3 or 4, comprising:

6. The system (10) according to any one of the preceding claims, wherein the yarn speed sensor (60) comprises a rotation sensor (52) driven by the movement of at least one yarn (20).

7. The system (10) of claim 6, wherein the rotation sensor comprises a pulley (52).

8. The system (10) of claim 7, wherein the yarn speed sensor further comprises an encoder (54) in operative communication with the pulley (52).

9. The system (10) of claim 8, wherein the encoder (54) is a rotary encoder.

10. a light detection system (60) for illuminating the at least one thread (20) and receiving light reflected from the at least one thread (20) when the at least one thread (20) is illuminated; said optical detection system (60) being arranged downstream of at least one said processing unit (100) along a direction of travel of said at least one yarn (20); A system (10) according to any one of the preceding claims.

11. The system (10) of claim 10, wherein the light detection system comprises at least one light source (62) and an optical sensor (64).

12. the coating material is a coloring material, and the system comprises: receiving data from the optical detection system (60); determining a color of a coloring substance to be distributed to a designated section of the at least one yarn (20) based on said received data; The system (10) of claim 10 or 11, further comprising a control unit (190) configured.

13. The control unit (190). Comparing the determined color to a predetermined color scheme; generating an alarm signal and / or adjusting the operation of said processing unit (100) if said determined color and said predefined color scheme do not match within acceptable limits; The system (10) of claim 12 further comprising:

14. 14. The system (10) of any one of claims 1 to 13, wherein the treatment unit (100) comprises a plurality of nozzles (152a-f) arranged at different positions relative to at least one yarn (20), the at least one yarn (20) moving during use, and each nozzle (152) configured to dispense one or more coating substances onto the at least one yarn upon actuation.

15. The system (10) of claim 14, wherein the nozzles (152a-f) are inkjet nozzles.

16. The system (10) according to any one of the preceding claims, further comprising a thread consuming device (15).

17. 17. The system (10) of claim 16, wherein the thread consuming device (15) is an embroidery machine, a sewing machine, a knitting machine, a weaving machine, a tufting machine, a thread winding machine, or any combination thereof.

18. A method for in-line processing of at least one yarn (20) for use with a yarn consuming device (15), comprising: providing (210) a treatment unit (100) configured to dispense one or more coating substances onto at least one yarn upon operation; Providing (220) a yarn speed sensor (50) driven by the movement of at least one yarn (20); A method comprising:

19. 20. The method according to claim 18, further comprising the step of controlling (230) an operation of the at least one processing unit (100) based on a predetermined operation scheme of the yarn consuming device (15).

20. receiving (240) speed data from the yarn speed sensor (50); controlling (250) the operation of the processing unit (100) based on the received speed data; 20. The method of claim 18 or 19, further comprising:

Images