Continuous Rope Fabric Treatment with Venturi Transfer Control
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Solution Overview
Problem
Existing fabric treatment machines in rope form face issues with high production and maintenance costs, frequent stops for loading/unloading, energy consumption, and difficulty in controlling treatment consistency and efficiency, especially when processing large or complex fabric dimensions.
Innovation Solution
A continuous treatment machine with multiple treatment sections arranged in series, featuring bidirectional transfer systems and separate conveying means to manage fabric flow independently, allowing for repeated treatments and efficient transfer using a pneumatic Venturi tube system, along with control units and suction systems to optimize fabric movement and treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If discontinuous cycle machines are used to treat fabric in rope form, then treatment can be performed in a bath with mechanical and chemical action, but frequent stops for loading and unloading are required resulting in loss of production and high labor costs
Solution Approach 1:
The patent implements a continuous cycle machine where fabric in rope form moves continuously through multiple treatment tanks without stopping. The fabric enters at one end and exits at the other end, eliminating the need to stop for loading and unloading operations that plague discontinuous machines, thereby maintaining high productivity while providing comprehensive treatment capabilities.
Solution Approach 2:
The machine is divided into multiple independent treatment tanks arranged in sequence along the fabric path. Each tank can perform different treatment functions (washing, enzyme treatment, chemical treatment, etc.), allowing the fabric to receive comprehensive treatment continuously as it moves through each stage without interruption.
2Reliability
If discontinuous cycle machines operate at pressure and/or temperature, then treatment effectiveness is improved, but the need to depressurize and cool the machine results in considerable energy consumption
Solution Approach 1:
The continuous cycle operation allows the machine to maintain pressure and temperature conditions continuously without repeated depressurization and cooling cycles. The fabric moves steadily through treatment tanks that can be maintained at optimal treatment conditions, eliminating the energy-wasting thermal cycles inherent in discontinuous operation.
Solution Approach 2:
The machine can be brought to the required pressure and temperature conditions once at the beginning of operation, and these conditions are maintained throughout continuous operation. This preliminary preparation eliminates the need for repeated heating and pressurization cycles that would otherwise be required with discontinuous operation.
3Productivity
If machines with two tanks in line are used to process fabric continuously, then production levels increase, but processing pieces of fabric of considerable dimensions requires considerable processing times as countless alternate cycles are required
Solution Approach 1:
Instead of using just two tanks that require alternate cycling, the machine employs multiple treatment tanks arranged in linear sequence along the fabric path. This segmentation allows the fabric to progress through all treatment stages in a single continuous pass, eliminating the need for countless alternate cycles required by two-tank systems, especially for large fabric pieces.
Solution Approach 2:
The patent transitions from a two-dimensional alternating tank system to a linear one-dimensional arrangement of multiple tanks along the fabric path. This dimensional change allows continuous processing of long fabric pieces without requiring the fabric to be repeatedly fed back and forth between limited tanks.
4Ease of operation
If multi-tank machines are designed with tanks placed side by side longitudinally with a single reel for feeding fabric, then fabric transfer between tanks is facilitated, but it is difficult to control the supply of fabric that accumulates in each tank and treatment is bland with limited speed
Solution Approach 1:
The machine divides the fabric handling system into separate functional sections: independent reels for fabric entry and exit, and individual transfer mechanisms for moving fabric between specific tanks. This segmentation allows precise control of fabric supply to each tank while maintaining efficient transfer, overcoming the limitations of a single reel system.
Solution Approach 2:
The machine employs dynamic control of fabric transfer between tanks, with adjustable transfer speeds and independent control of fabric accumulation in each tank. This allows optimization of treatment speed while maintaining proper fabric supply control, eliminating the bland and limited-speed operation of fixed single-reel systems.
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 machine achieves high production levels with reduced costs, improved treatment control, and increased efficiency, enabling continuous processing without downtime for loading/unloading, while maintaining compact dimensions and efficient energy use.
Implementation Method 1
efficient transfer using a pneumatic Venturi tube system
Data Source
Figure 1~2B
Figure 3
Figure 4
AI summary
The machine has a path for passage of fabric in rope form (T) with a transfer system (7), such as a pneumatic system. Along the path said fabric (T) passes through a plurality of accumulation areas (3A, 3B; 3C, 3D; 3E, 3F) with alternate motion.