EP1561850A1

EP1561850A1 - Improvements in a completely automated yarn dyeing system

Info

Publication number: EP1561850A1
Application number: EP04425061A
Authority: EP
Inventors: Iginio Bortolato
Original assignee: Individual
Current assignee: Individual
Priority date: 2004-02-03
Filing date: 2004-02-03
Publication date: 2005-08-10

Abstract

The present invention is about improvements in a completely automated system for dyeing yarns, able to provide for a finished product through a completely smart process, comprising rectangular modules consisting of a basement (1) on which are disposed tanks (3) suitable for containing a yarn reel (4) for each of its working stages, conduits (2) suitable for conveying the required fluids for the different working stages of said yarn reel (4), means for housing each of said yarn reels (4) inside each of said tanks (3), conduits (12,8) for introducing and for ejecting said fluids from each of said tanks (3). Said improvements are characterised by comprising means which allow to obtain the complete uniformity of the dyebath, and consequently to obtain a superior quality for the yarns, which avoid the possibility of breaking said yarn in the manufacturing (spooling) operation, compromising its quality, and which allow to obtain a considerable volume reduction of the dyebath, that therefore means less use of colouring substances and auxiliary products, lower energetic consumption and consequently lower volume of refluent waste to be treated.

Description

The present invention is about improvements in a completely automated yarn dyeing system able to provide for a finished product through a completely smart process.
Italian Patent No. IT1284576 of the same inventor, published on May 21, 1998, discloses a completely automated process for dyeing yarn reels, where the mere supply of the various feedings like electricity, steam, air, and so on is required, without needing to implement a complex installation, since the installation is already provided by the system.
The system comprises a multifunctional operating station, whose operation is described in Figure 1 of the aforesaid Patent, having the function of managing the different manufacturing operations required to obtain the dyeing of yarn reels, which will be used in the different industrial processes.
To obtain this purpose, rectangular modules are used, whose shape is an essential element for the insertion of the same modules in the multifunctional operating station where the industrial process is executed. Said rectangular modules, as visible in Figure 3 of the aforesaid Patent, comprise a basement 1 on which several small tanks 3 are placed, joined together through conduits 2 disposed on the same tanks top.
In Figure 4 of the aforesaid Patent the single tank 3, in which the reel 4 is housed, is shown in detail. The automated unit provides for placing the reel on the disk 6 with the aid of the centering pin 5. The spring 7, together with the disk 6, provides for sealing the reel's 4 cop on the system disk 6, in order to allow a correct development of the different operations.
The material to be processed (yarn on reel) is loaded in the production line with standard pallets, where the reels are preformed to allow the first step of gleaning. The gleaning (Figure 2 of the aforesaid Patent) is an operation consisting in eliminating the sharp edges (6, 7, 8 and 9) of the reels, to obtain a uniform dyeing. The gleaning is performed, contrary to the common working processes with a single reel, in multiple way, so that it is possible to reduce the lead times and to avoid dispersive manipulations. The above mentioned process is performed by an automated unit which takes all the reels from a pallet and puts them in an appropriate die where, by the pressing operation 1, the flanging (2, 3, 4 and 5) of the reels is obtained.
Once the gleaning step is finished, the automated unit puts the gleaned reels in the subsequent module to perform the dyeing operation. The dyeing module provides for the reels to be dyed in separate tanks, in which a single reel is placed (Figure 3 of the aforesaid Patent), so to obtain a uniform dyeing.
Once the dyeing step is finished too, the automated unit is preset at the multifunctional operating station to enter the hydroestraction step, which is performed by centrifugation. The robot takes the reels from the dyeing module and puts them in the centrifugation unit; once the centrifugation treatment is finished, the reel will have a perfectly cylindrical shape, which is important to optimize the subsequent industrial working processes.
Once the centrifugation step is finished, the automated unit prepares the system for the subsequent drying step. The drying module, which is similar to the dyeing module illustrated in Figure 3 of the aforesaid Patent, is inserted in the multifunctional operating station. The drying process and its similarity to the dyeing process are better described with reference to Figure 8 of the aforesaid Patent, where warm air, having a path indicated by the arrows 6, is inserted in the tank.
The flow, passing through the cop 10 of the reel 4, will permeate the yarn on the same reel and it will exit from the conduit 8.
When the drying operation is over, the automated unit provides for placing the reels on a standard pallet.
Once the pallet loading operation is finished, the last packaging step is automatically performed.
However, the above described process for dyeing yarn reels has some disadvantages. The flows of water and chemical solutions used in the dyeing step follow a path, visible in Figure 4 of the aforesaid Patent, which allows the yarn to lie down on the disk or even to slide out from the same disk, making the formation of furrows on the reel's yarn possible, and consequently allowing the breaking of said yarn in the manufacturing (spooling) operation, compromising its quality. This is partially due also to the disk's dimensions, whose diameter is sensibly smaller than the average diameter of each reel. Moreover, since the reels never have exactly the same diameter and thus the same hardness, although having the same weight, the average strength of each reel is different, and consequently the speed of water and chemical solutions used in the dyeing step is different too, causing small differences from one reel to the other in the dyeing step.
Is thus an object of the present invention to provide for a completely automated system for dyeing yarns able to overcome the aforesaid problems, preventing the formation of breakings concerning the yarn and allowing to obtain the complete uniformity of the dyebath, and consequently to obtain a superior quality for the yarns.
Is a further object of the present invention to obtain a considerable volume reduction of the dyebath, which therefore means less use of dyeing substances and auxiliary products, lower energetic consumption and consequently lower volume of refluent waste to be treated.
These and other characteristics, and advantages of the present invention will be better highlighted in the following description of a preferred embodiment of the same invention, given just as an example, with reference to the annexed drawings wherein:
Figure 1 describes the operation of a multifunctional operating station which uses the completely automated system for dyeing yarns according to the invention;
Figure 2 shows one of the rectangular modules which allows the yarns dyeing process operation;
Figure 3 shows the circulation of the operative flow of water and chemical solutions inside the completely automated system for dyeing yarns according to the invention;
Figure 4 shows in detail the single tank in which the reel is placed for the dyeing process;
Figure 5 shows one of the baskets in which the reel is placed for the centrifugation process;
Figure 6 shows in detail one of the baskets of Figure 5;
Figure 7 shows two of the tanks of Figure 4 provided with closing means; and
Figure 8 shows the lances for closing the tanks of each rectangular module.
With reference to Figure 2 of the annexed drawings, the completely automated system for dyeing yarns according to the invention provides for employing rectangular modules, used in the different steps of the yarns dyeing process, comprising a basement (1) on which are disposed several little tanks (3) suitable for containing a yarn reel (4), joined together through conduits (2) disposed on the same tanks (3) top.
In Figure 4 a single tank (3) is shown in detail, in which the reel (4) is placed for the dyeing operation. The automated unit provides for placing the reel on a lower disk (6) with the aid of a centering pin (5). A spring (7), together with said lower disk (6), provides for sealing the reel's (4) cop on said lower disk (6) of the system. Said spring (7) is conveniently made for allowing to introduce in the same tank (3) reels (4) of different height. There is also an upper disk (13) having the same diameter of said lower disk (6), the dimensions of said lower disk (6) and upper disk (13) being suitable for covering almost entirely the area of said tank (3), in order to enable a correct development of the different operations and to radically avoid dyebath leaks, to reduce water and energy consumptions and to obtain a better quality product.
The operative flow of water and chemical solutions follows the path shown by the arrows (9); said flow, passing through the cop (10), will permeate the yarn of said reel (4). The running direction of said flow is guided by the upper disk (13) and the lower disk (6), said disks being conveniently formed to allow said flow to escape from the outlet conduit (8). This ascent of the flow prevents the yarn to lie down on said lower disk (6), in order to avoid the forming of furrows on said reel's (4) yarn in the dyeing process, which could cause said yarn to break during its spooling operation.
With combined reference to the Figures 3 and 4 of the annexed drawings, at the bottom of each single tank (3) there is a conduct (11) having the function of draining the operative flow of water and chemical solutions. Said conduct (11) is put in connection with the other tanks trough the conduit (15), visible in Figure 3, said conduit (15) allowing the conduct (11) to act as a communicating vessel (16), making the pressure of the liquid composed by water and chemical solutions uniform inside each tank. The liquid that flows in the conduit (12) changes its speed, since changes the strength of the reel (4) because the reels never have the same diameter and thus the same hardness, although having the same weight. The liquid discrepancy is compensated or equalized thanks to the presence of conducts like (11), and the liquid is then drained at the same pressure by the outlet conduit (8). This system allows to have the same quantity of dyebath for each reel (4) and thus to obtain the complete uniformity of the dyebath.
In Figures 7 and 8 the closing system of the tanks (3) is shown. The reel (4) is sealed in each of said tanks-(3) by a cap (17) which, with the aid of a gasket (18), hermetically closes each of said tanks (3). Some lances (19) are furthermore provided, allowing the locking of each cap (17), by the insertion in the milling (20) of each tank (3).
Once the dyeing step is finished, the reels (4) are placed in the centrifugation unit. With combined reference to the Figures 5 and 6, said centrifugation unit comprises a basket (21) in which the reel (4) is positioned around an arm (22) fixed to said basket (21) through a pin (26). In loading phase, the reels (4) placed in the baskets (21) have their axis (23) parallel to the centrifuge axis (27). When the loading operation is completed, the centrifuge will start its rotation and the basket (21) will be affected by the centrifugal forces (24) having their direction perpendicular with the rotation axis of the reel so, because of the pin (26), the arm (22) and a spring (25) which connects said pin (26) with said arm (22), said reel (4) will be positioned so that its axis (23) will be perpendicular to the centrifugation basket axis (27), leaning against the basket's (21) wall. The refluent fluid will exit from the perforated wall (28). Similarly to the spring (7) placed inside the tanks (3), also said spring (25) is conveniently made for allowing to introduce in the same basket (21) reels (4) of different height. Thanks to this centrifugation system, the reel (4) will maintain its original perfectly cylindrical shape until the end of the process, this shape having an optimal use in the industrial working processes.
When the centrifugation process is completed the reel (4), failing the centrifugal force (24) and with the aid of said spring (25) and said pin (26), will reach by gravity a perpendicular position, in order to be extracted from the centrifugation unit.
It should be clear that all the controls and the mechanic, hydraulic, electric and electronic devices applied to the completely automated system for dyeing yarns according to the invention in order to allow its correct operation are comprised in the prior-art and thus their realization, installation and maintenance are possible for any technician expert in the related field.
Is therefore evident that the completely automated system for dyeing yarns according to the invention fully achieves the intended objects, but it is possible to introduce elements alterations, additions and/or replacements to said system without falling outside the invention's scope of protection, as it is also defined in the appended claims.

Claims

A completely automated system for dyeing yarns, comprising one or more rectangular modules consisting of a basement (1) on which are disposed one or more tanks (3), or one or more baskets (21), suitable for containing respectively a yarn reel (4) for each of the working stages of said yarn reel (4), conduits (2) disposed on top of said tanks (3), suitable for conveying the required fluids for the different working stages of said yarn reel (4), means for housing each of said yarn reels (4) inside each of said tanks (3) or said baskets (21), one or more conduits (12) able to introduce said fluids inside each of said tanks (3), one or more conduits (8) able to eject said fluids from each of said tanks (3), wherein said means for housing each of said yarn reels (4) inside each of said tanks (3) comprise an upper disk (13) and a lower disk (6), having proper shape and dimensions to be able to guide the running direction of said fluids' flow through said one or more outlet conduits (8), in order to prevent the yarn to lie down on said lower disk (6) so that the forming of furrows on said reel's (4) yarn in the dyeing process, which could cause said yarn to break during its subsequent working phases, is avoided.
The completely automated system for dyeing yarns according to claim 1, wherein said tank (3) comprises at least a conduct (11) placed at the bottom of said tank (3) and connected with the other tank(s) (3) trough at least a conduit (15), said at least a conduct (11) having the function of communicating vessel (16) able to equalize the pressure inside each tank (3) of said required fluid for the different working stages of said yarn reel (4).
The completely automated system for dyeing yarns according to the preceding claims, wherein said means for housing each of said yarn reels (4) inside each of said baskets (21) comprise an arm (22), fixed to said basket (21) through a pin (26), and at least a spring (25) which connects said pin (26) with said arm (22), able to position said reel (4) so that its axis (23) will be perpendicular to the axis (27) of said basket (21), allowing said reel (4) to maintain its original perfectly cylindrical shape.
The completely automated system for dyeing yarns according to the preceding claims, wherein said basket (3) comprises at least a spring (7) which, together with said lower disk (6), provides for sealing said reel's (4) cop on said lower disk (6) of the system, in order to enable a correct development of the different operations and to radically avoid the leaks of said required fluid for the different working stages of said yarn reel (4).
The completely automated system for dyeing yarns according to the preceding claims, wherein said spring (7) is so conveniently made as to allow introduction in said tank (3) of reels (4) of different height.
The completely automated system for dyeing yarns according to the preceding claims, wherein said spring (25) is so conveniently made as to allow introduction in said basket (21) of reels (4) of different height.
The completely automated system for dyeing yarns according to the preceding claims, wherein said reel (4) is sealed in each of said tanks (3) by a cap (17), said cap (17) hermetically closing each of said tanks (3) with the aid of at least a gasket (18).
The completely automated system for dyeing yarns according to the preceding claims, comprising lances (19) which allow to lock each of said caps (17), by the insertion in a proper milling (20) made on each of said tanks (3).