Liquid Discharge Nozzle Micro Vibration for Thread Dyeing Stability
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Solution Overview
Problem
Existing liquid discharge systems in embroidery machines face challenges in maintaining stable discharge due to varying thread speeds and nozzle clogging, leading to potential discharge defects and reduced productivity.
Innovation Solution
A liquid discharge apparatus with a head featuring a row of nozzles and circuitry that generates a discharge timing synchronized with thread movement, applies a drive waveform, and includes a micro vibrating pulse to the nozzle meniscus after each discharge pulse to prevent liquid thickening and maintain nozzle stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If liquid is discharged continuously through nozzles during thread processing, then productivity is improved, but nozzle clogging occurs due to liquid thickening and discharge stability deteriorates
Solution Approach 1:
The patent applies a micro-vibrating pulse to the pressure generating element (piezoelectric element) after liquid discharge to mechanically vibrate the nozzle internal passage and meniscus. This vibration prevents liquid thickening and maintains discharge stability, resolving the contradiction between continuous discharge and nozzle clogging. The vibration frequency is specifically controlled to resonate with the nozzle passage, effectively clearing accumulated liquid without causing unwanted discharge.
Solution Approach 2:
The patent implements periodic micro-vibrating pulses at predetermined intervals after each discharge cycle. This periodic action maintains the nozzle passage clear of thickened liquid, ensuring reliable continuous operation. The timing is precisely controlled to occur after discharge completion but before the next discharge cycle begins, preventing clogging while maintaining productivity.
2Adaptability or versatility
If thread speed varies during processing, then adaptability is improved, but discharge timing accuracy deteriorates leading to discharge defects
Solution Approach 1:
The patent employs feedback control by detecting actual thread speed variations and adjusting the discharge timing accordingly. The control unit receives speed information and modifies the discharge timing to maintain synchronization between liquid discharge and thread position, ensuring precise application even when thread speed varies. This feedback mechanism resolves the contradiction between speed adaptability and timing accuracy.
Solution Approach 2:
The patent dynamically adjusts discharge timing based on real-time thread speed conditions. Rather than using fixed timing, the system continuously adapts the discharge timing to match varying thread speeds, maintaining precision across different operating conditions. This dynamic approach enables the system to handle speed variations while preserving discharge accuracy.
3Reliability
If micro vibrating pulse is applied to prevent nozzle clogging, then discharge stability is improved, but additional control complexity increases
Solution Approach 1:
The patent merges the micro-vibrating pulse function with the existing discharge control circuitry. The same pressure generating element (piezoelectric element) used for liquid discharge is also used to generate the micro-vibrating pulses by applying different voltage waveforms. This integration avoids adding separate vibration mechanisms and reduces overall control complexity while maintaining discharge stability.
Solution Approach 2:
The piezoelectric element serves multiple functions: it generates pressure for liquid discharge during normal operation and generates micro-vibrating pulses for preventing nozzle clogging. This multi-functionality eliminates the need for separate components and simplifies the control system, resolving the contradiction between reliability improvement and complexity increase.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution ensures stable liquid discharge even with variable thread speeds, reduces nozzle clogging, and enhances productivity by preventing discharge defects through controlled micro vibration of the nozzle meniscus.
Implementation Method 1
applying a micro vibrating pulse to the head after application of a discharge pulse for discharging the liquid and before a subsequent discharge timing. The micro vibrating pulse is for vibrating a meniscus of the nozzle.
Data Source
AI summary
A liquid discharge apparatus includes a head including a row of a plurality of nozzles configured to discharge a liquid. The liquid discharge apparatus further includes circuitry configured to generate a discharge timing in accordance with movement of a linear object to which the head applies the liquid, apply a drive waveform to the head based on the discharge timing, and apply a micro vibrating pulse to the head after application of a discharge pulse for discharging the liquid and before a subsequent discharge timing. The micro vibrating pulse is for vibrating a meniscus of the nozzle.