Modular Fabric Treatment Machine for Faster Uniform Dyeing
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Solution Overview
Problem
Current fabric treatment machines, such as jiggers, face limitations in processing time, uniformity, and maximum loading capacity due to the single-strip, single-cylinder design, leading to prolonged dyeing cycles, energy inefficiency, and potential non-uniform treatment.
Innovation Solution
The machine divides the fabric into multiple strips, each treated on a pair of main cylinders within the same unit, allowing for simultaneous processing and controlled rotation to reduce treatment time and enhance uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single strip of fabric is treated on a single pair of main cylinders, then the machine structure is simple, but the treatment time is excessively long (over 8 hours) and productivity is low
Solution Approach 1:
The machine is divided into multiple independent processing modules, each containing a pair of main cylinders that can process fabric strips simultaneously. This segmentation allows parallel processing of multiple fabric strips, dramatically reducing treatment time from over 8 hours to approximately 2 hours while maintaining manageable machine structure through modular design
2Device complexity
If a single strip of fabric is treated on a single pair of main cylinders, then the machine structure is simple, but the treatment uniformity is poor due to heat differential and composition variation
Solution Approach 1:
Multiple processing modules operate in parallel, reducing the length of fabric strip treated by each individual module. This shorter treatment path minimizes heat differential between the fabric and treatment bath, and maintains more constant composition in the treatment bath throughout the passage, thereby improving treatment uniformity
Solution Approach 2:
The machine maintains continuous movement of fabric through the treatment bath with controlled passage rates. The synchronous rotation of cylinders ensures continuous, uniform treatment without stopping, preventing localized overheating or composition variation that would occur with intermittent processing
3Quantity of substance
If the maximum loading capacity is increased by enlarging the cylinder diameter to 1400 mm, then more fabric can be loaded, but the treatment time becomes excessively long and treatment uniformity deteriorates
Solution Approach 1:
Instead of using one large cylinder with diameter 1400 mm that would require excessively long treatment time, the machine uses multiple smaller cylinders in parallel. Each cylinder processes a portion of the total fabric load simultaneously, maintaining reasonable treatment time while achieving high overall loading capacity through parallel processing
4Productivity
If the fabric passage rate is increased to reduce treatment time, then productivity improves, but the tension on the fabric varies significantly and mechanical stress increases
Solution Approach 1:
The machine employs dynamic control systems with oil-dynamic control centres, electric motors, inverters, encoders, and charge cell sensors to continuously adjust and maintain constant fabric passage rate and tension despite varying cylinder diameters during the winding and unwinding process. This dynamic adjustment allows high productivity while preventing excessive mechanical stress on the fabric
Data Source
Figure 1
Figure 2
AI summary
A machine for the treatment of fabric comprising a machine, unit (2), in which there is at least one tank (3) containing a treatment bath (4) for the fabric. Inside said machine unit, there are at least two processing modules of the fabric, wherein each of these comprises a pair of winding/unwinding rolls (51, 51'; 52, 52') of a strip of fabric (T, T'), which by rotating in one direction or the other allow the passage of the fabric from one roll to the other passing through said tank (3).