Yarn Package Dyeing with Sequential Flow and Bath Recirculation
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Solution Overview
Problem
Traditional machines for dyeing reels of yarn face issues with high energy consumption, non-uniform dye distribution, and reduced pump capacity due to the need for high flow rates and differential pressures, especially when dealing with delicate materials, leading to poor dyeing uniformity and increased costs.
Innovation Solution
A machine that selectively and sequentially supplies dyeing fluid to groups of reels, combined with recirculation mechanisms to maintain dye and temperature uniformity, using a centrifugal pump for intermittent flow and an axial pump for agitation, reducing energy requirements and pump capacity while ensuring uniform dye distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high flow rate and high differential pressure are used to ensure uniform dye distribution, then dyeing uniformity is improved, but energy consumption increases
Solution Approach 1:
The patent implements periodic action by sequentially activating different groups of reel-holder rods in alternating cycles. Instead of continuously supplying dyeing fluid to all reels simultaneously, the system divides reels into multiple groups and supplies fluid to one group at a time in periodic intervals, reducing peak flow rate requirements while maintaining uniform dye distribution through repeated exposure cycles.
Solution Approach 2:
The patent applies segmentation by dividing the total population of reel-holder rods into multiple separate groups, each connected to the dyeing fluid supply through distinct pathways. This segmentation allows the circulation pump to serve smaller groups sequentially rather than all reels simultaneously, reducing the required flow rate and differential pressure while achieving uniform dyeing across all reels over time.
2Productivity
If high flow rate is used to pass through difficult materials like polyester or cotton, then dyeing effectiveness is improved, but pump power requirements increase
Solution Approach 1:
For difficult-to-dye materials, the system uses periodic action by repeatedly cycling the dyeing fluid through the reels in sequential groups. This allows sufficient time for dye penetration during each exposure phase while reducing peak power requirements compared to continuous high-flow operation, as the pump only needs to maintain adequate flow during active dyeing phases rather than continuously.
Solution Approach 2:
The patent applies preliminary action by ensuring that each group of reels receives adequate dyeing fluid exposure and saturation before moving to the next group. This preliminary saturation approach allows the use of lower pump power during each sequential phase, as the dye has sufficient time to penetrate the material thoroughly during the extended exposure period of each cycle.
3Power
If selective and sequential supply to small groups of reels is used, then pump capacity requirements are reduced, but dye bath circulation uniformity deteriorates
Solution Approach 1:
The patent merges two distinct functions: an internal recirculation mechanism that continuously circulates dyeing fluid within the dyeing chamber to maintain uniform temperature and concentration, and external sequential supply systems that deliver fluid to different groups of reels. This combination allows reduced pump capacity for reel supply while maintaining bath uniformity through the separate internal recirculation function.
Solution Approach 2:
The patent introduces an intermediary internal recirculation system that acts as a mediator between the dyeing fluid reservoir and the sequential reel supply groups. This intermediary mechanism continuously mixes and redistributes the dyeing fluid within the chamber, ensuring uniform concentration and temperature are maintained throughout the bath even as fluid is selectively supplied to different reel groups at different times.
4Manufacturing precision
If high number of dye bath refills per minute is executed to ensure temperature and colour uniformity, then dyeing uniformity is improved, but electricity consumption increases
Solution Approach 1:
The system uses periodic action with extended exposure cycles, where each group of reels receives prolonged dyeing fluid exposure during sequential activation. This reduces the frequency of complete bath refills needed, as each sequential group undergoes thorough dyeing during its active phase, thereby reducing electricity consumption associated with frequent pump operations while maintaining uniform dyeing results.
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 solution achieves superior dyeing uniformity, reduces energy consumption, and maintains dye bath characteristics, allowing for efficient dyeing of both delicate and robust materials with lower operational costs and reduced pump capacity.
Implementation Method 1
using a centrifugal pump for intermittent flow
Implementation Method 2
using a centrifugal pump for intermittent flow and an axial pump for agitation
Data Source
Figure 1
Figure 2
AI summary
This invention relates to a machine (1) for the dyeing of reels of yarn (8) and of textile fibres wound on packages. The machine (1) comprises: a structure (2) that delimits a chamber (3) at least partially or fully filled with at least a dyeing fluid (4); support means (6), in particular at least one support plate (6), immersed in the dyeing fluid (4); a plurality of reel- holder rods (7) that communicate via the fluid with the support means (6) to allow the dyeing fluid (4) to pass between the latter; recirculation means (9) for the dyeing fluid (4) associated with the structure (2) to initiate the transit of the dyeing fluid (4) in accordance with at least one set route. The recirculation means (9) comprise an initial recirculation mechanism (10) interposed between the chamber (3) and the support plate (6) to induce the dyeing fluid (4) to pass through the reel-holder rods (7). The first recirculation mechanism (10) comprises a pump (10a) and respective selection mechanisms (12) to channel the dyeing fluid through the support means (6), the reel-holder rods (7) and the respective reels (8), on an intermittent basis. The recirculation means (9) comprise a second recirculation mechanism (11), to induce the transit of the dyeing fluid (4) within the chamber (3) in accordance with at least one closed route.