Machine and method for the discontinuous dyeing of spools of yarn
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Solution Overview
Problem
Conventional dyeing machines for spools of yarn face inefficiencies in heat exchange, uniformity of dye distribution, and chemical product distribution, leading to non-uniform dyeing results and high power consumption due to pump limitations.
Innovation Solution
A dyeing machine with two separate pumps to manage the treatment bath: one for changing the bath inside the spools and another for mixing the remaining bath in the tank, combined with an external heat exchanger to maintain uniform temperature and efficient heat exchange, reducing the hydraulic circuit dimensions and power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a single main centrifugal pump is used to circulate the treatment bath through the spools, then the pump must provide sufficient head to overcome flow resistance, but the flow rate is reduced below expected values compromising heat exchange efficiency and bath uniformity
Solution Approach 1:
The patent divides the single pump function into two separate pumps: a first pump dedicated to circulating bath through the spools and a second pump dedicated to mixing the free bath in the tank. This segmentation allows each pump to operate at optimal flow rates without compromise, resolving the contradiction between pump head capability and heat exchange efficiency.
2Reliability
If the pump flow rate is reduced to prevent exceeding maximum admissible differential pressure, then yarn damage is prevented, but the capacity to render the bath uniform and maintain temperature uniformity is reduced
Solution Approach 1:
By separating the circulation function (first pump) from the mixing function (second pump), the system can maintain low differential pressure through the spools while independently ensuring bath uniformity through dedicated mixing action, preventing yarn damage while maintaining manufacturing precision.
Solution Approach 2:
The second pump acts as an intermediary mechanism that ensures bath uniformity without directly affecting the flow through the spools. It mixes the free bath in the tank, creating uniform conditions that then passively distribute to the spools through the first pump's circulation system.
3Manufacturing precision
If the entire quantity of bath is made to circulate through the spools three times per minute, then bath uniformity and temperature uniformity are achieved, but the power consumption and hydraulic circuit dimensions increase
Solution Approach 1:
The patent segments the bath treatment into two independent circulation loops: one for spool penetration (first pump) and one for tank mixing (second pump). This allows achieving dye distribution uniformity through targeted spool circulation without requiring the entire bath volume to circulate at high rates, reducing power consumption while maintaining manufacturing precision.
4Productivity
If the flow rate is increased to improve heat exchange efficiency, then bath uniformity improves, but the differential pressure exceeds the maximum admissible value damaging the yarn
Solution Approach 1:
The patent separates the heat exchange function (first pump circulating through spools) from the mixing function (second pump in tank). This allows the first pump to operate at lower flow rates that prevent yarn damage while the second pump independently maintains bath uniformity and temperature distribution, achieving heat exchange efficiency without exceeding admissible differential pressure.
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
Achieves uniform dyeing results, reduces electricity consumption by 38.88%, and maintains consistent bath conditions independent of differential pressure, while minimizing hydraulic circuit size and power requirements.
Implementation Method 1
an external heat exchanger to heat and/or to cool the treatment bath on the basis of a predefined program
Implementation Method 2
a first pump which moves a first portion of the treatment bath contained in the spools of yarn along a first hydraulic circuit
Implementation Method 3
a second pump which moves a second portion of the treatment bath, i.e. the remaining quantity of free bath, along a second hydraulic circuit outside the spools of yarn
Data Source
Figure 1
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Figure 3
AI summary
A machine and a method for the discontinuous dyeing of spools of yarn, which entails, within a closed tank (1) which contains the spools (2) of yarn to be processed immersed in a treatment bath, changing the quantity of bath held inside the spools of yarn a certain number of times per minute and conveniently mixing the remaining quantity of free bath inside the closed tank (1). A first pump (8) is substantially used to change the bath inside the spools and a second pump (20) is used to mix the free bath in the closed tank (1). Furthermore, an external heat exchanger (22) is installed on the circuit of the second pump (20) and is adapted to heat and/or cool the bath.