Variable Flow Spin Pump Control for Yarn Color Variation
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Solution Overview
Problem
Existing methods for creating color variation in bundles of filaments are time-consuming and wasteful, and they struggle to achieve consistent and efficient color gradation along the length of the filament.
Innovation Solution
A system comprising N extruders and M spin stations, where each extruder produces a polymer with unique color, hue, luster, and dyability characteristics. The system uses a processor to adjust the volumetric flow rates of spin pumps to achieve specific ratios of polymers in the yarn, allowing for continuous filament formation and variable color variation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional methods of changing dye sourcing are used to create color variation in filaments, then color variation can be achieved, but the process becomes time-consuming and wasteful
Solution Approach 1:
The patent applies dynamics by making the spin pump speeds variable rather than fixed. The system dynamically adjusts the speed of individual spin pumps during operation to control the ratio of different colored polymers being spun into the yarn. This allows continuous variation of color composition without stopping production or changing dye sources, resolving the contradiction between achieving precise color variation and maintaining efficient production timing
Solution Approach 2:
The patent changes the operational parameter of spin pump speed to control polymer ratio and color variation. By varying the speed parameter of spin pumps, the system can precisely control the proportion of different colored polymers entering the spinnerets, achieving desired color effects without time-consuming reconfiguration of dye sourcing. This parameter-based control eliminates waste while maintaining production efficiency
2Adaptability or versatility
If multiple extruders with different polymer characteristics are used to achieve color variation, then color diversity improves, but system complexity increases
Solution Approach 1:
The patent applies universality by designing a control system that can manage multiple extruders with different polymer characteristics through a single integrated processor. The processor universally controls all spin pumps regardless of which extruder they are connected to, coordinating their speeds to achieve desired color ratios. This multi-functional control approach allows the system to handle diverse polymer inputs without proportionally increasing operational complexity
Solution Approach 2:
The system implements feedback control where the processor monitors and adjusts spin pump speeds based on the desired polymer ratios. This feedback mechanism coordinates the operation of multiple extruders and spin pumps, ensuring that despite the diversity of polymer inputs, the system maintains controlled and consistent color variation in the output yarn, managing complexity through intelligent coordination
3Manufacturing precision
If variable volumetric flow rates are used to control polymer ratios, then color variation precision improves, but control complexity increases
Solution Approach 1:
The patent replaces complex mechanical flow control mechanisms with electronic control of spin pump speeds. Instead of using mechanical devices to directly regulate polymer flow rates, the system uses electronically controlled spin pumps where speed adjustment provides precise control over volumetric flow rates. This substitution simplifies the control system while maintaining or improving polymer ratio precision through easier speed regulation
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 system enables efficient and continuous production of yarns with consistent color variation along the length, reducing waste and improving production speed compared to traditional methods.
Implementation Method 1
The volumetric flow rates extruded by each of the spin pumps in a respective one of the M spin stations is greater than zero and is variable such that flow of the polymer streams through the spinnerets of the respective spin station is continuous and supports continuous filament formation
Data Source
AI summary
Systems for producing M bundles of filaments, wherein M>1, include N extruders. M spin stations, and a processor, wherein N>1. Each extruder includes a polymer having a color, hue, luster, and/or dyability characteristic, which are different from each other. Each spin station produces N bundles of filaments that form a yarn. Each spin station comprises N spinnerets through which filaments are spun from molten polymers streams received by the respective spin station and N′ spin pumps upstream of the N spinnerets for the respective spin station. Each spin pump is paired with one of the Nextruders. The processor is in electrical communication with the N*M spin pumps and is configured to adjust the volumetric flow rate of the polymers pumped from each spin pump to achieve a ratio of the polymers to be included in the yarn from each spin station.