Thread Dyeing Length Adjustment for Embroidery Color Position Accuracy
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Solution Overview
Problem
Existing dyeing embroidery technologies face challenges in maintaining consistent thread elongation and color application due to variations in the winding curl strength caused by changes in the outer diameter of the thread remaining on the bobbin.
Innovation Solution
A liquid application unit comprising a supply member with a cylindrical winding core, a liquid application device, and an application controller that adjusts the liquid application length based on the winding thickness of the remaining thread, ensuring consistent dyeing and elongation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the thread is wound on the bobbin with varying outer diameter, then the winding curl strength varies, but the thread elongation becomes inconsistent
Solution Approach 1:
The system performs preliminary detection of the outer diameter of the remaining thread on the bobbin before the dyeing process, and pre-adjusts the dyeing length based on the detected winding thickness. This allows the thread elongation to be compensated in advance, ensuring consistent embroidery results despite variations in bobbin outer diameter.
Solution Approach 2:
The system implements a feedback mechanism where the outer diameter of the remaining thread is continuously detected, and the dyeing length is automatically adjusted based on this detection information. The control unit modifies the dyeing length in real-time according to the winding thickness, creating a closed-loop control system that maintains thread elongation consistency.
2Manufacturing precision
If the winding curl strength of the thread is different, then the amount of elongation of the thread changes, but the color position deviates
Solution Approach 1:
The system detects the winding thickness and adjusts the dyeing length before the actual dyeing process begins. By pre-calculating the required compensation based on the detected outer diameter, the system ensures that the color is applied at the correct position even when thread elongation varies due to different winding curl strengths.
Solution Approach 2:
The system changes the dyeing length parameter based on the detected winding thickness. When the outer diameter of the remaining thread is small (indicating stronger winding curl), the system increases the dyeing length to compensate for the greater elongation that will occur during the embroidery process, thereby maintaining color position accuracy.
3Manufacturing precision
If the outer diameter of the remaining thread on the bobbin changes, then the winding curl varies, but the dyeing length becomes inaccurate
Solution Approach 1:
The system uses a detection unit to continuously monitor the outer diameter of the remaining thread on the bobbin and feeds this information back to the control unit. The control unit then automatically adjusts the dyeing length based on this feedback, ensuring accurate dyeing positioning despite changes in bobbin outer diameter during the embroidery process.
Solution Approach 2:
The system performs detection and adjustment of the dyeing length in advance before the embroidery process begins. By detecting the initial outer diameter of the thread on the bobbin and pre-adjusting the dyeing length accordingly, the system eliminates positioning errors that would otherwise occur due to varying winding curl strengths.
Data Source
AI summary
A liquid application unit includes a supply member, a liquid application device, and an application controller. The supply member includes a cylindrical or columnar winding core around which a linear medium is wound. The liquid application device applies liquid to the linear medium unwound and fed from the supply member. The application controller adjusts a liquid application length of the liquid applied by the liquid application unit to the linear medium in a feed direction of the linear medium. The application controller adjusts the liquid application length in the feed direction of the linear medium in accordance with a winding thickness of a remaining amount of the linear medium from an outer peripheral surface of the winding core.