EP3984757B1 - Liquid discharge apparatus and dyeing apparatus - Google Patents
Liquid discharge apparatus and dyeing apparatus Download PDFInfo
- Publication number
- EP3984757B1 EP3984757B1 EP21202550.6A EP21202550A EP3984757B1 EP 3984757 B1 EP3984757 B1 EP 3984757B1 EP 21202550 A EP21202550 A EP 21202550A EP 3984757 B1 EP3984757 B1 EP 3984757B1
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- EP
- European Patent Office
- Prior art keywords
- thread
- liquid
- winder
- head
- discharge apparatus
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 239000007788 liquid Substances 0.000 title claims description 141
- 238000004043 dyeing Methods 0.000 title claims description 18
- 238000011084 recovery Methods 0.000 description 17
- 238000009940 knitting Methods 0.000 description 11
- 238000004804 winding Methods 0.000 description 11
- 238000012423 maintenance Methods 0.000 description 8
- 238000000034 method Methods 0.000 description 8
- 230000000694 effects Effects 0.000 description 7
- 230000008569 process Effects 0.000 description 7
- 238000012545 processing Methods 0.000 description 6
- 239000000975 dye Substances 0.000 description 5
- 230000000052 comparative effect Effects 0.000 description 4
- 230000002159 abnormal effect Effects 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 229920000742 Cotton Polymers 0.000 description 2
- 238000003491 array Methods 0.000 description 2
- 230000001186 cumulative effect Effects 0.000 description 2
- 238000001514 detection method Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 239000004744 fabric Substances 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 238000012805 post-processing Methods 0.000 description 2
- 238000011144 upstream manufacturing Methods 0.000 description 2
- 210000002268 wool Anatomy 0.000 description 2
- 238000005452 bending Methods 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 238000012937 correction Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 230000004044 response Effects 0.000 description 1
- 238000009958 sewing Methods 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
- B41J3/00—Typewriters or selective printing or marking mechanisms characterised by the purpose for which they are constructed
- B41J3/407—Typewriters or selective printing or marking mechanisms characterised by the purpose for which they are constructed for marking on special material
- B41J3/4078—Printing on textile
-
- D—TEXTILES; PAPER
- D05—SEWING; EMBROIDERING; TUFTING
- D05B—SEWING
- D05B67/00—Devices incorporated in sewing machines for lubricating, waxing, or colouring the threads
-
- D—TEXTILES; PAPER
- D05—SEWING; EMBROIDERING; TUFTING
- D05C—EMBROIDERING; TUFTING
- D05C11/00—Devices for guiding, feeding, handling, or treating the threads in embroidering machines; Machine needles; Operating or control mechanisms therefor
- D05C11/24—Devices for guiding, feeding, handling, or treating the threads in embroidering machines; Machine needles; Operating or control mechanisms therefor incorporating devices for dyeing or impregnating the threads
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06B—TREATING TEXTILE MATERIALS USING LIQUIDS, GASES OR VAPOURS
- D06B11/00—Treatment of selected parts of textile materials, e.g. partial dyeing
- D06B11/002—Treatment of selected parts of textile materials, e.g. partial dyeing of moving yarns
- D06B11/0023—Treatment of selected parts of textile materials, e.g. partial dyeing of moving yarns by spraying or pouring
Definitions
- aspects of this disclosure relates to a liquid discharge apparatus and a dyeing apparatus.
- a colored pattern flat knitting machine includes a synthetic dyeing unit, a knitting unit, and a positive thread feeding unit.
- the synthetic dyeing unit dyes a knitting thread to a desired color.
- the knitting unit knits a colored pattern knitted fabric from a dyed knitting thread.
- the positive thread feeding unit feeds a knitting thread used for knitting.
- the positive thread feeding unit is positively and rotationally driven. Further, one or more turns of the knitting thread are wound around each of a front roller and a rear roller.
- the positive thread feeding unit supplies the knitting thread while applying a constant tension between the front roller and the rea roller.
- the front roller is disposed upstream in a feeding direction of the knitting thread and the rear roller disposed downstream of the front roller in the feeding direction.
- the colored pattern flat knitting machine includes the synthetic dyeing unit between the front roller and the rear roller.
- Document WO 2020/137383 A1 discloses a liquid discharge apparatus for dyeing a thread. It includes heads to discharge a liquid; caps to contact and move away from the plurality of heads, respectively; individual drain passages communicating with the plurality of caps, respectively; at least one common drain passage communicating with at least two of the individual drain passages; suction devices provided in the individual drain passages, respectively; and a controller.
- the present invention has been made in view of the above-described problem, and an object of the present invention is to easily check a state of a liquid applied on the linear member (liquid application state).
- a novel liquid discharge apparatus includes a head configured to discharge a liquid from nozzles onto a linear member conveyed in a conveyance direction, the head including a nozzle array including the nozzles arrayed along the conveyance direction, and a state check unit downstream of the head in the conveyance direction, the state check unit configured to guide the linear member to form a two-dimensional surface with the linear member.
- the state check unit includes a path former forming a path that guides the linear member to form the two-dimensional surface, wherein, in the two-dimensional surface, multiple portions of the linear member onto which the liquid has been discharged from an identical nozzle of the nozzles are linearly arranged in the conveyance direction According to the present embodiment, it is possible to easily check the liquid application state of the linear member.
- FIG. 1 is a schematic side view of the liquid discharge apparatus 100 according to the first embodiment of the present disclosure.
- FIG. 2 is a schematic side view of a liquid application unit 300 of the liquid discharge apparatus illustrated in FIG. 1 .
- FIG. 3 is a plan view of a head array of the liquid application unit 300 as viewed from below.
- the liquid discharge apparatus 100 is an in-line embroidery device.
- the liquid discharge apparatus 100 includes a supply unit 200, a liquid application unit 300, a fixing unit 400, a post-processing unit 500, and an embroidery unit 600.
- the supply unit 200 includes a supply reel 210 and rollers 220 and 230.
- a thread 10 as a linear member is wound around the supply reel 210.
- the rollers 220 and 230 guide the thread 10 to the liquid application unit 300.
- the roller 230 includes an encoder 231 including an encoder wheel 231b and an encoder sensor 231a in the roller 230.
- the liquid application unit 300 applies a liquid to the thread 10 to dye (color) the thread 10 in a desired color.
- the liquid application unit 300 includes multiple heads 310 (3 10a to 310d) that discharge liquid of a desired color and multiple maintenance units 320 (320a to 320d) that respectively perform maintenance of the multiple heads 310 (310a to 310d) as illustrated in FIG. 2 .
- the heads 310a to 310d discharge, for example, cyan (C), magenta (M), yellow (Y), and black (K) color liquids.
- each of the heads 310 (310a to 310d) includes a nozzle surface 312 in which a nozzle array 313 is formed.
- the nozzle array 313 includes multiple nozzles 311, from which a liquid is discharged, are arranged in one line in a conveyance direction as indicated by arrow in FIG. 3 .
- Each head 310 is disposed such that a direction of the nozzle array 313 (nozzle arrangement direction) is along the conveyance direction of the thread 10.
- FIG. 3 illustrates the head 310 in the first embodiment including one nozzle array 313 on the nozzle surface 312 as an example.
- the head 310 may include multiple row of nozzles arrays 313 disposed on the nozzle surface 312 of the head 310.
- the head 310 may be configured to move in a direction orthogonal to the conveyance direction of the thread 10.
- the nozzle surface 312 of the head 310 may be capped by a cap 325 (see FIG. 4 ) of the maintenance unit 320 or may discharge a liquid from the nozzles 311 in different nozzle arrays 313 to apply liquid on the thread 10.
- the liquid discharge apparatus 100 includes a state check unit 700 (state check region) having a path along which the threads 10 are arranged in a direction orthogonal to a radial direction.
- the liquid discharge apparatus 100 may include a state check unit 700 having a path along which the thread 10 is bent multiple times in a radial direction or tangential direction orthogonal to the conveyance direction.
- the bent thread 10 is arrayed in the conveyance direction.
- the state check unit 700 is disposed downstream of the liquid application unit 300 and upstream of a fixing unit 400 in the conveyance direction.
- the state check unit 700 is not particularly limited as long as the state check unit 700 is disposed downstream of the liquid application unit 300 in the conveyance direction.
- the fixing unit 400 performs a fixing process (drying process) on the thread 10 to which the liquid discharged from the heads 310 of the liquid application unit 300 is applied.
- the fixing unit 400 includes, for example, a heater such as an infrared irradiator and a hot air sprayer to heat and dry the thread 10.
- the post-processing unit 500 includes, for example, a cleaning device that cleans the thread 10, a tension adjustment device that adjusts a tension of the thread 10, a feed amount detector that detects an amount of movement of the thread 10, and a lubricant application device that lubricates a surface of the thread 10.
- the embroidery unit 600 includes a needle 610 (embroidery needle) and a needle driver 620 (needle drive mechanism).
- the embroidery unit 600 vertically movably supports the needle 610.
- the needle driver 620 vertically moves the needle 610.
- the embroidery unit 600 sews the dyed thread 10 as an upper thread on the medium 20 (embroidery medium) such as cloth according to an embroidery pattern to perform an embroidery process.
- the embroidery unit 600 includes a winding collector 630 that winds and collects the thread 10 serving as an upper thread to be sewn on the medium 20 after passing through a hole of the needle 610.
- liquid discharge apparatus 100 serves as an embroidery apparatus.
- the liquid discharge apparatus 100 according to the first embodiment is not limited to the embroidery apparatus.
- the liquid discharge apparatus 100 may be applicable to, e.g., an apparatus using a linear object such as a thread, for example, an apparatus such as a loom, a sewing machine, or a printer to print image on a general sheet material.
- an apparatus using a linear object such as a thread for example, an apparatus such as a loom, a sewing machine, or a printer to print image on a general sheet material.
- aspects of the present disclosure can be applied not only to apparatuses having a post-process, such as an embroidery machine, but also to dyeing apparatuses and the like that dye and the wind threads 10, etc. as described below.
- Examples of “thread” include glass fiber thread, wool thread, cotton thread, synthetic thread, metal thread, mixed thread of wool, cotton, polymer, or metal, thread, filament, and linear member (continuous base materials) to which liquid can be applied.
- Example of the “thread” further includes braids and flat cords (flat braids).
- FIG. 4 is a schematic perspective view of the part of the liquid application unit 300 relating to the movement of one head 310 according to the first embodiment.
- the head 310 is mounted on a carriage 351.
- the carriage 351 is reciprocally movable in an X-direction indicated by arrow "X" in FIG. 4 .
- the head 310 is movable between a home position at which the head 310 is capped with the cap 325 of an individual maintenance unit 320 and a discharge position (dyeing position) at which the head 310 discharges the liquid onto the thread 10.
- the carriage 351 is reciprocally movably held by a main guide rod 352 and a sub-guide member 353.
- the liquid application unit 300 includes a driver 360 to reciprocally move the carriage 351.
- the driver 360 includes a motor 361 and a crank 362.
- the crank 362 is a drive force transmission member moved by the motor 361.
- the motor 361 includes a motor shaft 361a coupled to an arm 363.
- a rear end of the crank 362 is rotatably attached to the arm 363 with a shaft 364.
- the arm 363 is coupled to the motor shaft 361a.
- a leading end of the crank 362 is rotatably coupled to the carriage 351 by a support shaft 365 on the carriage 351.
- a tension coil spring 370 which is an elastic member, is disposed between the carriage 351 and a fixed portion.
- the motor 361 reciprocally moves the carriage 351 along the main guide rod 352 and the sub-guide member 353 via the crank 362 as the driver 360 drives the motor 361.
- the carriage 351 repeatedly moves and stops between the home position and the discharge position to maintain and recover the head 310.
- the head 310 faces the cap 325 and the cap 325 caps the head 310 at the home position.
- the head 310 discharges a liquid onto the thread 10 to dye the thread 10 as an application target at the discharge position.
- the maintenance unit 320 includes the cap 325 and a wiper 326.
- the cap 325 caps the nozzle surface 312 of the head 310.
- the wiper 326 wipes the nozzle surface 312.
- the driver 360 moves the head 310 to the home position facing the cap 325.
- the maintenance unit 320 caps the nozzle surface 312 with the cap 325.
- the driver 360 moves the head 310 to wipe the nozzle surface 312 of the head 310 with the wiper 326 when the head 310 performs a dummy discharge operation (discharges a dummy liquid), for example.
- the maintenance unit 320 includes a dummy discharge receptacle 321 having an opening on a top of the discharge receptacle 321 as illustrated in FIG. 4 .
- the head 310 discharges the dummy liquid into the opening in the dummy discharge receptacle 321.
- the dummy liquid is a liquid not discharged onto the thread 10 and does not contribute to a dyeing process of the thread 10.
- a state check unit 700 according to the first embodiment of the present disclosure is described with reference to FIGS. 5 and 6 .
- FIG. 5 is a schematic perspective view of the state check unit 700.
- FIG. 6 is a schematic perspective view of a winder 710.
- the winder 710 around which the thread 10 is wound is disposed in the state check unit 700.
- the winder 710 is a device to form a path.
- the winder 710 forms a path in which the thread 10 is arranged such that the liquid droplets discharged from an identical nozzle 311 of the nozzle array 313 of the head 310 are linearly arranged in the conveyance direction orthogonal to a radial direction (width direction) of the thread 10.
- a liquid discharge apparatus 100 includes the head 310 including nozzles 311 from which a liquid is discharged onto the thread 10 (linear member) conveyed in a conveyance direction, and the state check unit 700 downstream of the head 310 in the conveyance direction.
- the thread 10 is bent multiple times in a direction different from the conveyance direction to form a two-dimensional surface 730 in the state check unit 700, wherein the nozzles 311 are arrayed along the conveyance direction in the head 310.
- the direction different from the conveyance direction includes the radial direction (width direction) of the thread 10 and a tangential direction (winding direction) of the thread 10.
- the winder 710 is a roller-shaped member around which the thread 10 is to be wound without overlap to form the two-dimensional surface 730.
- the thread 10 is wound around the winder 710 a plurality of times (here, four times) in the first embodiment in FIG. 5 .
- a part of a surface of the winder 710 around which the thread 10 has been wound forms the two-dimensional surface 730.
- the state check unit 700 is configured to guide the thread 10 (linear member) to form the two-dimensional surface 730 with the thread 10 (linear member).
- a circumferential length of one turn of the thread 10 in a state wound around the winder 710 is equal to a length of the nozzle array 313 of the head 310 in the winder 710.
- the circumferential length of one turn of the thread 10 does not have to be equal to the length of the nozzle array 313 in the winder 710.
- a region onto which the liquid is not applied may be interposed between regions to which the liquid is applied by all the nozzles 311 in the nozzle array 313.
- a part of the thread 10 (linear member) wound around a circumferential surface of the winder 710 one turn has a length equal to a length of the nozzle array 313.
- the winder 710 can arrange a region of the thread 10 onto which the liquid is applied while making the circumferential length of one turn of the thread 10 to be longer than the length of the nozzle array 313.
- the winder 710 is a path former in the state check unit 700.
- the winder 710 (path former) is configured to form a path that forms the two-dimensional surface 730 by the thread 10.
- the multiple portions of the thread 10 to which the liquid is discharged from an identical nozzle 311 of the nozzles 311 of the head 310 for multiple times are linearly arranged in the conveyance direction in the two-dimensional surface 730 of the state check unit 700.
- the winder 710 includes grooves 710a that guide the thread 10 in a coil shape around the winder 710.
- the state check unit 700 includes a reader 720 such as a CCD sensor to read the thread 10 wound around the winder 710.
- a reader 720 in the state check unit 700 reads the thread 10 in the two-dimensional surface 730.
- FIG. 7 is a schematic side view of an example of the liquid application unit 300 in a discharge state to illustrate the effect of the winder 710 according to the first embodiment.
- FIG. 8 is a schematic plan view of the liquid application unit 300 illustrating a portion of the thread 10, wound around the winder 710, to which the liquid is applied by the liquid application unit 300.
- the liquid discharge apparatus 100 When the liquid discharge apparatus 100 performs a nozzle check operation to detect a discharge state of the nozzles 311 of the head 310, for example, the liquid discharge apparatus 100 performs a liquid application operation to discharge liquid 315 from all the nozzles 311 of the nozzle array 313 of the head 310 to apply the liquid 315 to the thread 10 as illustrated in FIG. 7 .
- an undyed region 111b in the thread 10 to which a liquid is not applied is generated together with a dyed region 111a in the thread 10 to which a liquid is applied in a liquid application region 111 in the thread 10.
- a length of the liquid application region 111 in the thread 10 corresponds to a length of the nozzle array 313.
- the discharge failure means non-discharge, bent discharge, or the like.
- This nozzle check operation is performed the number of times of winding around the winder 710 (here, four times as illustrated in FIG. 8 ).
- a circumferential length of the winder 710 in a circumferential direction of the winder 710 is substantially the same as the length of the nozzle array 313. Therefore, the thread 10 is wound around the winder 710 side by side such that the droplets discharged from an identical (same) nozzle 311 are arranged linearly in the conveyance direction as illustrated in FIG. 8 .
- the undyed region 111b (white portion in FIG. 8 ) appears in the thread 101 wound around the winder 710 such that the undyed regions 111b linearly aligned in one line in an arrangement direction (conveyance direction) of the thread 10 whereas the thread 10 is wound around the winder 710 in a direction orthogonal to the conveyance direction if there is the undyed region 111b in the thread 10 when the thread 10 is wound around the winder 710 as illustrated in FIG. 8 .
- the liquid discharge apparatus 100 can increase an area of a check unit in the thread 10 to be checked when the liquid discharge apparatus 100 check a discharge failure of a nozzle 311, a dyeing failure, or the like by a visual checking or by detection by a reading device.
- the liquid discharge apparatus 100 can easily check an application state of liquid 315 on the thread 10.
- a liquid discharge apparatus according to a comparative example is described below with reference to FIG. 9 .
- FIG. 9 is a schematic plan view of the thread 10 illustrating a dyed state of the thread 10 when the liquid 315 is applied to the thread 10 in the same manner as in FIG. 7 .
- the liquid discharge apparatus in the comparative example does not include the state check unit 700 and the winder 710.
- the thread 10 is linearly conveyed as it is in the conveyance direction of the thread 10 without wound around the winder 710. Therefore, the undyed regions 111b appear at intervals (dispersed manner) of the nozzle array 313 in the thread 10 as illustrated in FIG. 9 when the undyed regions 111b are generated in the thread 10.
- the undyed regions 111b appear in a dispersed manner in the thread 10 in the comparative example, unlike the first embodiment of the present disclosure.
- the liquid discharge apparatus in the comparative example cannot easily check the dyed state (application state) of the liquid on the thread 10.
- the liquid discharge apparatus 100 according to a second embodiment of the present disclosure is described with reference to FIG. 10 .
- FIG. 10 is a block diagram illustrating a portion related to control of the state checking operation in the second embodiment.
- the liquid discharge apparatus 100 includes a main controller 801 to control the head 310 to discharge liquid 315 from all the nozzles 311 in the nozzle array 313 of the head 310 via a head drive controller 802 in the nozzle check operation.
- the main controller 801 controls the head 310 to perform a dummy discharge operation from the nozzles 311, the discharged liquid of which does not contribute to an image formation, in a recovery operation of the nozzle 311 having the discharge failure of the head 310.
- the main controller 801 drives a winding collector 630 to wind and collect the thread 10 via a winding-collector drive controller 803 to discharge the liquid from all nozzles 311 in the head 310 for a plurality of times.
- the main controller 801 drives a winding collector 630 to convey the thread 10 for each length of the nozzle array 313 to update a liquid application position at which the head 310 discharge the liquid from the nozzles 311 onto the thread 10.
- the main controller 801 may not include the winding collector 630, and the main controller 801 may drive the needle 610 to feed the thread 10 to update the liquid application position.
- the main controller 801 receives a start instruction to start the nozzle check operation from an operation part 820.
- the nozzle check operation is started not only in response to the start instruction from the user but also at a predetermined timing.
- the main controller 801 controls a reader 720 to read a state of the thread 10 on the winder 710. Further, the main controller 801 inputs read information that is obtained by image processing a read output of the reader 720 by an image processor 804.
- the main controller 801 determines whether a recovery operation (maintenance operation) of the head 310 has to be performed according to the read information input to the main controller 801. When the main controller 801 determines that the recovery operation has to be performed, the main controller 801 executes the recovery operation and displays information such as the occurrence of the discharge failure on the display 830 to notify the user of the occurrence of the discharge failure.
- the main controller 801 starts a process as illustrated in FIG. 11 when the main controller 801 receives the start instruction to start the nozzle check operation from the operation part 820.
- the main controller 801 may start a process as illustrated in FIG. 11 at a predetermined timing.
- the predetermined timing includes, for example, a cumulative number of discharge of the liquid from the nozzles 311 of the head 310 reaching to a predetermined amount, a cumulative discharge amount of the liquid from the nozzles 311 of the head 310 reaching to a predetermined amount, or elapsed time of a standby state reaching to a predetermined time.
- the main controller 801 When the main controller 801 starts the nozzle check operation, the main controller 801 applies liquid according to a nozzle check pattern to the thread 10 (step S1).
- the step S1 is also simply referred to as "S1".
- the nozzle check pattern is a pattern in which liquid is discharged from all the nozzles 311 of the nozzle array 313 of the head 310 and applied to the thread 10.
- the main controller 801 drives and controls, for example, the winding collector 630 to convey the thread 10 by a predetermined amount (S2).
- the predetermined amount corresponds to the length of the nozzle array 313.
- the main controller 801 determines whether the head 310 has discharged the liquid according to the nozzle check pattern for a predetermined number of times (S3). When the head 310 has not discharged the liquid according to the nozzle check pattern for a predetermined number of times (S3, NO), the main controller 801 returns the nozzle check operation to step S1.
- the main controller 801 conveys the thread 10 until a portion of the thread 10 applied with (corresponding to) the nozzle check pattern has been wound around the winder 710 (S4).
- the main controller 801 controls the reader 720 to read the state of the thread 10 wound around the winder 710. Then, the main controller 801 captures read information obtained by performing image processing on the read result by the image processor 804 (S5).
- the main controller 801 checks whether there is the nozzle 311 having a discharge failure based on captured read information and determines whether there is an abnormal discharge (S6).
- the main controller 801 performs a dummy discharge operation as a recovery operation.
- the dummy discharge operation performs a dummy discharge in which the main controller 801 controls the head 310 to discharge a liquid from nozzles 311 in which a discharge failure has occurred (S7).
- the main controller 801 returns the process to step S1 to apply the liquid according to the nozzle check pattern on the thread 10.
- the main controller 801 ends this state check operation (nozzle check operation).
- the recovery operation may be performed by, for example, the main controller 801 notifying the user of the discharge failure through the display 830. Then, the main controller 801 performs the recovery operation after an instruction of the recovery operation is input from the operation part 820.
- the above describes the liquid discharge apparatus according to the second embodiment that reads a state of the thread 10 in the state check unit 700 by the reader 720 to check the state of the nozzles 311 (discharge state) of the head 310, as an example.
- the state check operation (nozzle check operation) of the liquid discharge apparatus 100 according to the second embodiment is not limited to the embodiments as described above.
- the main controller 801 may detect a state of the thread 10 such as a dyeing density or a color (using a color sensor) of the thread 10 to which the liquid is applied by using the read result of the reader 720. Then, the main controller 801 may control adjustment of the discharge amount for each color, for example, and correction of a density and a color tone of the thread according to the detection result.
- a state of the thread 10 such as a dyeing density or a color (using a color sensor) of the thread 10 to which the liquid is applied by using the read result of the reader 720. Then, the main controller 801 may control adjustment of the discharge amount for each color, for example, and correction of a density and a color tone of the thread according to the detection result.
- FIG. 12 is a flowchart illustrating a control of the state check operation in the third embodiment.
- a portion related to a control of the state check operation in the third embodiment is the same as a portion related to a control of the state check operation as described in the second embodiment.
- the liquid discharge apparatus in the third embodiment does not use the reader 720 in the nozzle check operation.
- steps S11 to S14 the main controller 801 performs the same processing as in the steps S1 to S4 of the second embodiment (see FIG. 11 ).
- a portion of the thread 10 to which the nozzle check patterns for times are formed is wound around the winder 710.
- the user visually checks (confirms) whether there is a nozzle omission (discharge failure) as described above.
- the nozzle omission is occurred when the nozzle 311 is clogged by hardened ink or foreign material so that the ink may not be discharged from the clogged nozzle 311.
- the user instructs the main controller 801 to perform the recovery operation from the operation part 820.
- the main controller 801 determines whether there is an instruction input of a recovery operation from the operation part 820 (S15). At this time, if there is the instruction input of the recovery operation, the main controller 801 performs the dummy discharge operation as the recovery operation similarly to the step S6 (see FIG. 11 ) in the second embodiment (S16). Then, the main controller 801 returns the process to step S11 to apply the liquid according to the nozzle check pattern on the thread 10 after the step S16.
- the main controller 801 ends the state check operation (nozzle check operation).
- the main controller 801 can determine an absence of the instruction input of the recovery operation in any way so that a state of the absence of the instruction input may include a state when the instruction for recovery operation is input, when another instruction is input, or when the instruction for recovery operation is not input for a predetermined time.
- the liquid discharge apparatus 100 can improve visibility of the undyed region 11 1b in the thread 10 that is a region corresponding to the discharge failure also when the user visually checks the discharge failure since the undyed region 111b is linearly aligned in one line in the thread 10 wound around the winder 710.
- FIG. 13 is a schematic side view of the winder 710 illustrating the state check unit of the winder 710 in the fourth embodiment.
- the liquid discharge apparatus 100 in the fourth embodiment includes the winder 710 around which the thread 10 is spirally wound.
- the winder 710 in the fourth embodiment has a shape in which an outer diameter of the winder 710 is varied stepwise in the conveyance direction.
- the thread 10 is wound around the winder 710 side by side so that positions of the liquid discharged from the same (identical) nozzle 311 on the thread 10 are linearly arranged while being obliquely shifted in the winding direction orthogonal to the conveyance direction when the thread 10 is wound around the winder 710.
- the liquid discharge apparatus 100 according to the third embodiment can obtain the same effect of easily detecting the discharge failure as the effect of the liquid discharge apparatus 100 according to each of the above described embodiment.
- FIG. 14 is a schematic side view of the state check unit according to the fifth embodiment.
- the liquid discharge apparatus 100 includes multiple guides 740 to guide the thread 10.
- the multiple guides 740 guides the thread 10 while folding back the thread 10 for a plurality of times (two times in FIG. 14 ).
- the multiple guides 740 form a path along which the thread 10 is folded back side by side such that positions of the liquid discharged from the same (identical) nozzle 311 of the head 310 on the thread 10 are linearly arranged in one line in the conveyance direction.
- the multiple guides 740 as the path former guides the thread 10 while bending the thread 10 multiple times to form the two-dimensional surface 730.
- the liquid discharge apparatus 100 according to the fifth embodiment can obtain the same effect of easily detecting the discharge failure as the effect of the liquid discharge apparatus 100 according to each of the above described embodiment.
- FIG. 15 is a schematic side view of the dyeing apparatus 1000.
- This dyeing apparatus 1000 includes a winding unit 1200 to wind the thread 10 after the thread 10 is dyed instead of the embroidery unit 600 in the liquid discharge apparatus 100.
- the dyeing apparatus 1000 supplies the thread 10 from a supply reel 210 of the supply unit 200, discharges and applies a liquid of a desired color from the liquid application unit 300 onto the thread 10 to dye the thread 10 into a target color, and winds the dyed thread 10 with a winding reel 1220 of the winding unit 1200.
- the liquid discharge apparatus 100 according to the present embodiment is not limited to the embroidery unit 600 or the dyeing apparatus 1000.
- Processing circuitry includes a programmed processor, as a processor includes circuitry.
- a processing circuit also includes devices such as an application specific integrated circuit (ASIC), a digital signal processor (DSP), a field programmable gate array (FPGA), and conventional circuit components arranged to perform the recited functions.
- ASIC application specific integrated circuit
- DSP digital signal processor
- FPGA field programmable gate array
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- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Treatment Of Fiber Materials (AREA)
- Coloring (AREA)
- Ink Jet (AREA)
Description
- Aspect of this disclosure relates to a liquid discharge apparatus and a dyeing apparatus.
- There is an apparatus that colors a linear member such as a thread by using a head that discharges a liquid.
- As described in
Japanese Patent Application Laid Open Publication No. 2006-299462 - The positive thread feeding unit is positively and rotationally driven. Further, one or more turns of the knitting thread are wound around each of a front roller and a rear roller. The positive thread feeding unit supplies the knitting thread while applying a constant tension between the front roller and the rea roller. The front roller is disposed upstream in a feeding direction of the knitting thread and the rear roller disposed downstream of the front roller in the feeding direction. The colored pattern flat knitting machine includes the synthetic dyeing unit between the front roller and the rear roller.
- However, when a liquid of desired color is applied to the linear member using a head that discharge a liquid, whether the liquid of desired color has been applied to the linear member has to be checked.
- Document
WO 2020/137383 A1 discloses a liquid discharge apparatus for dyeing a thread. It includes heads to discharge a liquid; caps to contact and move away from the plurality of heads, respectively; individual drain passages communicating with the plurality of caps, respectively; at least one common drain passage communicating with at least two of the individual drain passages; suction devices provided in the individual drain passages, respectively; and a controller. - The present invention has been made in view of the above-described problem, and an object of the present invention is to easily check a state of a liquid applied on the linear member (liquid application state).
- In an aspect of this disclosure, a novel liquid discharge apparatus includes a head configured to discharge a liquid from nozzles onto a linear member conveyed in a conveyance direction, the head including a nozzle array including the nozzles arrayed along the conveyance direction, and a state check unit downstream of the head in the conveyance direction, the state check unit configured to guide the linear member to form a two-dimensional surface with the linear member. The state check unit includes a path former forming a path that guides the linear member to form the two-dimensional surface, wherein, in the two-dimensional surface, multiple portions of the linear member onto which the liquid has been discharged from an identical nozzle of the nozzles are linearly arranged in the conveyance direction
According to the present embodiment, it is possible to easily check the liquid application state of the linear member. - A more complete appreciation of the disclosure and many of the attendant advantages and features thereof can be readily obtained and understood from the following detailed description with reference to the accompanying drawings, wherein:
-
FIG. 1 is a schematic side view of a liquid discharge apparatus according to a first embodiment of the present disclosure; -
FIG. 2 is a schematic side view of a liquid application unit of the liquid discharge apparatus illustrated inFIG. 1 ; -
FIG. 3 is a plan view of a head array of the liquid application unit as viewed from below; -
FIG. 4 is a schematic perspective view of a part of the liquid application unit relating to a movement of a head of the liquid application unit according to the first embodiment; -
FIG. 5 is a schematic perspective view of a state check unit according to the first embodiment; -
FIG. 6 is a schematic perspective view of a winder of the state check unit; -
FIG. 7 is a schematic side view of an example of the liquid application unit in a discharge state to illustrate the effect of the winder according to the first embodiment; -
FIG. 8 is a schematic plan view of the liquid application unit illustrating a portion of the thread, wound around the winder, to which the liquid is applied by the liquid application unit; -
FIG. 9 is a schematic plan view of the thread illustrating a dyed state of the thread when the liquid is applied to the thread in the same manner as inFIG. 7 ; -
FIG. 10 is a block diagram illustrating a portion related to control of a state checking operation according to a second embodiment of the present disclosure; -
FIG. 11 is a flowchart illustrating an example of a control of the state check operation in the second embodiment; -
FIG. 12 is a flowchart illustrating an example of a control of the state check operation according to a third embodiment of the present disclosure; -
FIG. 13 is a schematic side view of the winder illustrating the state check unit of the winder according to a fourth embodiment of the present disclosure; -
FIG. 14 is a schematic side view of the state check unit according to a fifth embodiment of the present disclosure; and -
FIG. 15 is a schematic side view of a dyeing apparatus according to an embodiment of the present disclosure. - The accompanying drawings are intended to depict embodiments of the present invention and should not be interpreted to limit the scope thereof. The accompanying drawings are not to be considered as drawn to scale unless explicitly noted. Also, identical or similar reference numerals designate identical or similar components throughout the several views.
- In describing embodiments illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the disclosure of this specification is not intended to be limited to the specific terminology so selected and it is to be understood that each specific element includes all technical equivalents that have a similar function, operate in a similar manner, and achieve a similar result.
- Referring now to the drawings, embodiments of the present disclosure are described below. As used herein, the singular forms "a", "an", and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise.
- Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, embodiments of the present disclosure are described below. First, an example of a liquid discharge apparatus according to a first embodiment of the present disclosure is described with reference to
FIGS. 1 to 3 . -
FIG. 1 is a schematic side view of theliquid discharge apparatus 100 according to the first embodiment of the present disclosure. -
FIG. 2 is a schematic side view of aliquid application unit 300 of the liquid discharge apparatus illustrated inFIG. 1 . -
FIG. 3 is a plan view of a head array of theliquid application unit 300 as viewed from below. - The
liquid discharge apparatus 100 is an in-line embroidery device. Theliquid discharge apparatus 100 includes asupply unit 200, aliquid application unit 300, afixing unit 400, apost-processing unit 500, and anembroidery unit 600. - The
supply unit 200 includes asupply reel 210 androllers thread 10 as a linear member is wound around thesupply reel 210. Therollers thread 10 to theliquid application unit 300. Theroller 230 includes anencoder 231 including anencoder wheel 231b and anencoder sensor 231a in theroller 230. - The
liquid application unit 300 applies a liquid to thethread 10 to dye (color) thethread 10 in a desired color. Theliquid application unit 300 includes multiple heads 310 (3 10a to 310d) that discharge liquid of a desired color and multiple maintenance units 320 (320a to 320d) that respectively perform maintenance of the multiple heads 310 (310a to 310d) as illustrated inFIG. 2 . Theheads 310a to 310d discharge, for example, cyan (C), magenta (M), yellow (Y), and black (K) color liquids. - As illustrated in
FIG. 3 , each of the heads 310 (310a to 310d) includes anozzle surface 312 in which anozzle array 313 is formed. Thenozzle array 313 includesmultiple nozzles 311, from which a liquid is discharged, are arranged in one line in a conveyance direction as indicated by arrow inFIG. 3 . Eachhead 310 is disposed such that a direction of the nozzle array 313 (nozzle arrangement direction) is along the conveyance direction of thethread 10. -
FIG. 3 illustrates thehead 310 in the first embodiment including onenozzle array 313 on thenozzle surface 312 as an example. Thehead 310 may include multiple row ofnozzles arrays 313 disposed on thenozzle surface 312 of thehead 310. Thehead 310 may be configured to move in a direction orthogonal to the conveyance direction of thethread 10. Thus, thenozzle surface 312 of thehead 310 may be capped by a cap 325 (seeFIG. 4 ) of themaintenance unit 320 or may discharge a liquid from thenozzles 311 indifferent nozzle arrays 313 to apply liquid on thethread 10. - The
liquid discharge apparatus 100 according to the first embodiment includes a state check unit 700 (state check region) having a path along which thethreads 10 are arranged in a direction orthogonal to a radial direction. - The
liquid discharge apparatus 100 according to the first embodiment may include astate check unit 700 having a path along which thethread 10 is bent multiple times in a radial direction or tangential direction orthogonal to the conveyance direction. Thebent thread 10 is arrayed in the conveyance direction. - The
state check unit 700 is disposed downstream of theliquid application unit 300 and upstream of a fixingunit 400 in the conveyance direction. Thestate check unit 700 is not particularly limited as long as thestate check unit 700 is disposed downstream of theliquid application unit 300 in the conveyance direction. - With reference to
FIG. 1 , the fixingunit 400 performs a fixing process (drying process) on thethread 10 to which the liquid discharged from theheads 310 of theliquid application unit 300 is applied. The fixingunit 400 includes, for example, a heater such as an infrared irradiator and a hot air sprayer to heat and dry thethread 10. - The
post-processing unit 500 includes, for example, a cleaning device that cleans thethread 10, a tension adjustment device that adjusts a tension of thethread 10, a feed amount detector that detects an amount of movement of thethread 10, and a lubricant application device that lubricates a surface of thethread 10. - The
embroidery unit 600 includes a needle 610 (embroidery needle) and a needle driver 620 (needle drive mechanism). Theembroidery unit 600 vertically movably supports theneedle 610. Theneedle driver 620 vertically moves theneedle 610. Theembroidery unit 600 sews the dyedthread 10 as an upper thread on the medium 20 (embroidery medium) such as cloth according to an embroidery pattern to perform an embroidery process. - The
embroidery unit 600 includes a windingcollector 630 that winds and collects thethread 10 serving as an upper thread to be sewn on the medium 20 after passing through a hole of theneedle 610. - In the present embodiment, an example is described in which the
liquid discharge apparatus 100 serves as an embroidery apparatus. Theliquid discharge apparatus 100 according to the first embodiment is not limited to the embroidery apparatus. - The
liquid discharge apparatus 100 may be applicable to, e.g., an apparatus using a linear object such as a thread, for example, an apparatus such as a loom, a sewing machine, or a printer to print image on a general sheet material. - Further, aspects of the present disclosure can be applied not only to apparatuses having a post-process, such as an embroidery machine, but also to dyeing apparatuses and the like that dye and the
wind threads 10, etc. as described below. - Examples of "thread" include glass fiber thread, wool thread, cotton thread, synthetic thread, metal thread, mixed thread of wool, cotton, polymer, or metal, thread, filament, and linear member (continuous base materials) to which liquid can be applied. Example of the "thread" further includes braids and flat cords (flat braids).
- Next, an example of a part relating to a movement of the
head 310 is described with reference toFIG. 4 . -
FIG. 4 is a schematic perspective view of the part of theliquid application unit 300 relating to the movement of onehead 310 according to the first embodiment. - The
head 310 is mounted on acarriage 351. Thecarriage 351 is reciprocally movable in an X-direction indicated by arrow "X" inFIG. 4 . Thus, thehead 310 is movable between a home position at which thehead 310 is capped with thecap 325 of anindividual maintenance unit 320 and a discharge position (dyeing position) at which thehead 310 discharges the liquid onto thethread 10. - The
carriage 351 is reciprocally movably held by amain guide rod 352 and asub-guide member 353. - The
liquid application unit 300 includes adriver 360 to reciprocally move thecarriage 351. Thedriver 360 includes amotor 361 and acrank 362. Thecrank 362 is a drive force transmission member moved by themotor 361. Themotor 361 includes amotor shaft 361a coupled to anarm 363. - A rear end of the
crank 362 is rotatably attached to thearm 363 with ashaft 364. Thearm 363 is coupled to themotor shaft 361a. A leading end of thecrank 362 is rotatably coupled to thecarriage 351 by asupport shaft 365 on thecarriage 351. - A
tension coil spring 370, which is an elastic member, is disposed between thecarriage 351 and a fixed portion. - With such a structure, the
motor 361 reciprocally moves thecarriage 351 along themain guide rod 352 and thesub-guide member 353 via thecrank 362 as thedriver 360 drives themotor 361. - The
carriage 351 repeatedly moves and stops between the home position and the discharge position to maintain and recover thehead 310. Thehead 310 faces thecap 325 and thecap 325 caps thehead 310 at the home position. Thehead 310 discharges a liquid onto thethread 10 to dye thethread 10 as an application target at the discharge position. - The
maintenance unit 320 includes thecap 325 and awiper 326. Thecap 325 caps thenozzle surface 312 of thehead 310. Thewiper 326 wipes thenozzle surface 312. When the liquid is not discharged from thehead 310, thedriver 360 moves thehead 310 to the home position facing thecap 325. Then, themaintenance unit 320 caps thenozzle surface 312 with thecap 325. Thedriver 360 moves thehead 310 to wipe thenozzle surface 312 of thehead 310 with thewiper 326 when thehead 310 performs a dummy discharge operation (discharges a dummy liquid), for example. - The
maintenance unit 320 includes adummy discharge receptacle 321 having an opening on a top of thedischarge receptacle 321 as illustrated inFIG. 4 . Thehead 310 discharges the dummy liquid into the opening in thedummy discharge receptacle 321. The dummy liquid is a liquid not discharged onto thethread 10 and does not contribute to a dyeing process of thethread 10. - A
state check unit 700 according to the first embodiment of the present disclosure is described with reference toFIGS. 5 and6 . -
FIG. 5 is a schematic perspective view of thestate check unit 700. -
FIG. 6 is a schematic perspective view of awinder 710. - The
winder 710 around which thethread 10 is wound is disposed in thestate check unit 700. Thewinder 710 is a device to form a path. Thewinder 710 forms a path in which thethread 10 is arranged such that the liquid droplets discharged from anidentical nozzle 311 of thenozzle array 313 of thehead 310 are linearly arranged in the conveyance direction orthogonal to a radial direction (width direction) of thethread 10. - Thus, a
liquid discharge apparatus 100 includes thehead 310 includingnozzles 311 from which a liquid is discharged onto the thread 10 (linear member) conveyed in a conveyance direction, and thestate check unit 700 downstream of thehead 310 in the conveyance direction. - The
thread 10 is bent multiple times in a direction different from the conveyance direction to form a two-dimensional surface 730 in thestate check unit 700, wherein thenozzles 311 are arrayed along the conveyance direction in thehead 310. The direction different from the conveyance direction includes the radial direction (width direction) of thethread 10 and a tangential direction (winding direction) of thethread 10. - The
winder 710 is a roller-shaped member around which thethread 10 is to be wound without overlap to form the two-dimensional surface 730. Thethread 10 is wound around thewinder 710 a plurality of times (here, four times) in the first embodiment inFIG. 5 . A part of a surface of thewinder 710 around which thethread 10 has been wound forms the two-dimensional surface 730. - Thus, the
state check unit 700 is configured to guide the thread 10 (linear member) to form the two-dimensional surface 730 with the thread 10 (linear member). - A circumferential length of one turn of the
thread 10 in a state wound around thewinder 710 is equal to a length of thenozzle array 313 of thehead 310 in thewinder 710. The circumferential length of one turn of thethread 10 does not have to be equal to the length of thenozzle array 313 in thewinder 710. For example, a region onto which the liquid is not applied may be interposed between regions to which the liquid is applied by all thenozzles 311 in thenozzle array 313. - Thus, a part of the thread 10 (linear member) wound around a circumferential surface of the
winder 710 one turn has a length equal to a length of thenozzle array 313. - Thus, the
winder 710 can arrange a region of thethread 10 onto which the liquid is applied while making the circumferential length of one turn of thethread 10 to be longer than the length of thenozzle array 313. - Thus, the
winder 710 is a path former in thestate check unit 700. The winder 710 (path former) is configured to form a path that forms the two-dimensional surface 730 by thethread 10. The multiple portions of thethread 10 to which the liquid is discharged from anidentical nozzle 311 of thenozzles 311 of thehead 310 for multiple times are linearly arranged in the conveyance direction in the two-dimensional surface 730 of thestate check unit 700. - Thus, in the two-
dimensional surface 730, multiple portions of the thread 10 (linear member) onto which the liquid has been discharged from anidentical nozzle 311 of thenozzles 311 are linearly arranged in the conveyance direction. - The
winder 710 includesgrooves 710a that guide thethread 10 in a coil shape around thewinder 710. - The
state check unit 700 includes areader 720 such as a CCD sensor to read thethread 10 wound around thewinder 710. Thus, thereader 720 in thestate check unit 700 reads thethread 10 in the two-dimensional surface 730. - Next, an effect of the
winder 710 according to the first embodiment is illustrated with reference toFIGS. 7 and 8 . -
FIG. 7 is a schematic side view of an example of theliquid application unit 300 in a discharge state to illustrate the effect of thewinder 710 according to the first embodiment. -
FIG. 8 is a schematic plan view of theliquid application unit 300 illustrating a portion of thethread 10, wound around thewinder 710, to which the liquid is applied by theliquid application unit 300. - When the
liquid discharge apparatus 100 performs a nozzle check operation to detect a discharge state of thenozzles 311 of thehead 310, for example, theliquid discharge apparatus 100 performs a liquid application operation to discharge liquid 315 from all thenozzles 311 of thenozzle array 313 of thehead 310 to apply the liquid 315 to thethread 10 as illustrated inFIG. 7 . - When there is a
nozzle 311 having a discharge failure as illustrated inFIGS. 3 and7 , anundyed region 111b in thethread 10 to which a liquid is not applied is generated together with a dyedregion 111a in thethread 10 to which a liquid is applied in aliquid application region 111 in thethread 10. A length of theliquid application region 111 in thethread 10 corresponds to a length of thenozzle array 313. The discharge failure means non-discharge, bent discharge, or the like. - This nozzle check operation is performed the number of times of winding around the winder 710 (here, four times as illustrated in
FIG. 8 ). - At this time, a circumferential length of the
winder 710 in a circumferential direction of thewinder 710 is substantially the same as the length of thenozzle array 313. Therefore, thethread 10 is wound around thewinder 710 side by side such that the droplets discharged from an identical (same)nozzle 311 are arranged linearly in the conveyance direction as illustrated inFIG. 8 . - The
undyed region 111b (white portion inFIG. 8 ) appears in thethread 101 wound around thewinder 710 such that theundyed regions 111b linearly aligned in one line in an arrangement direction (conveyance direction) of thethread 10 whereas thethread 10 is wound around thewinder 710 in a direction orthogonal to the conveyance direction if there is theundyed region 111b in thethread 10 when thethread 10 is wound around thewinder 710 as illustrated inFIG. 8 . - Thus, the
liquid discharge apparatus 100 can increase an area of a check unit in thethread 10 to be checked when theliquid discharge apparatus 100 check a discharge failure of anozzle 311, a dyeing failure, or the like by a visual checking or by detection by a reading device. Thus, theliquid discharge apparatus 100 can easily check an application state ofliquid 315 on thethread 10. - A liquid discharge apparatus according to a comparative example is described below with reference to
FIG. 9 . -
FIG. 9 is a schematic plan view of thethread 10 illustrating a dyed state of thethread 10 when the liquid 315 is applied to thethread 10 in the same manner as inFIG. 7 . - The liquid discharge apparatus in the comparative example does not include the
state check unit 700 and thewinder 710. Thus, thethread 10 is linearly conveyed as it is in the conveyance direction of thethread 10 without wound around thewinder 710. Therefore, theundyed regions 111b appear at intervals (dispersed manner) of thenozzle array 313 in thethread 10 as illustrated inFIG. 9 when theundyed regions 111b are generated in thethread 10. - In this way, the
undyed regions 111b appear in a dispersed manner in thethread 10 in the comparative example, unlike the first embodiment of the present disclosure. Thus, the liquid discharge apparatus in the comparative example cannot easily check the dyed state (application state) of the liquid on thethread 10. - The
liquid discharge apparatus 100 according to a second embodiment of the present disclosure is described with reference toFIG. 10 . -
FIG. 10 is a block diagram illustrating a portion related to control of the state checking operation in the second embodiment. - The
liquid discharge apparatus 100 includes amain controller 801 to control thehead 310 to discharge liquid 315 from all thenozzles 311 in thenozzle array 313 of thehead 310 via ahead drive controller 802 in the nozzle check operation. Themain controller 801 controls thehead 310 to perform a dummy discharge operation from thenozzles 311, the discharged liquid of which does not contribute to an image formation, in a recovery operation of thenozzle 311 having the discharge failure of thehead 310. - When the
main controller 801 performs the nozzle check operation, themain controller 801 drives a windingcollector 630 to wind and collect thethread 10 via a winding-collector drive controller 803 to discharge the liquid from allnozzles 311 in thehead 310 for a plurality of times. Thus, themain controller 801 drives a windingcollector 630 to convey thethread 10 for each length of thenozzle array 313 to update a liquid application position at which thehead 310 discharge the liquid from thenozzles 311 onto thethread 10. Themain controller 801 may not include the windingcollector 630, and themain controller 801 may drive theneedle 610 to feed thethread 10 to update the liquid application position. - The
main controller 801 receives a start instruction to start the nozzle check operation from anoperation part 820. The nozzle check operation is started not only in response to the start instruction from the user but also at a predetermined timing. - The
main controller 801 controls areader 720 to read a state of thethread 10 on thewinder 710. Further, themain controller 801 inputs read information that is obtained by image processing a read output of thereader 720 by animage processor 804. - The
main controller 801 determines whether a recovery operation (maintenance operation) of thehead 310 has to be performed according to the read information input to themain controller 801. When themain controller 801 determines that the recovery operation has to be performed, themain controller 801 executes the recovery operation and displays information such as the occurrence of the discharge failure on thedisplay 830 to notify the user of the occurrence of the discharge failure. - Next, an example of a control of the state check operation (nozzle check operation) in the second embodiment is described below with reference to a flowchart illustrated in
FIG. 11 . - The
main controller 801 starts a process as illustrated inFIG. 11 when themain controller 801 receives the start instruction to start the nozzle check operation from theoperation part 820. Themain controller 801 may start a process as illustrated inFIG. 11 at a predetermined timing. The predetermined timing includes, for example, a cumulative number of discharge of the liquid from thenozzles 311 of thehead 310 reaching to a predetermined amount, a cumulative discharge amount of the liquid from thenozzles 311 of thehead 310 reaching to a predetermined amount, or elapsed time of a standby state reaching to a predetermined time. - When the
main controller 801 starts the nozzle check operation, themain controller 801 applies liquid according to a nozzle check pattern to the thread 10 (step S1).
Hereinafter, the step S1 is also simply referred to as "S1". The nozzle check pattern is a pattern in which liquid is discharged from all thenozzles 311 of thenozzle array 313 of thehead 310 and applied to thethread 10. - Then, the
main controller 801 drives and controls, for example, the windingcollector 630 to convey thethread 10 by a predetermined amount (S2). The predetermined amount corresponds to the length of thenozzle array 313. - Next, the
main controller 801 determines whether thehead 310 has discharged the liquid according to the nozzle check pattern for a predetermined number of times (S3). When thehead 310 has not discharged the liquid according to the nozzle check pattern for a predetermined number of times (S3, NO), themain controller 801 returns the nozzle check operation to step S1. - When the
head 310 discharges the liquid according to the nozzle check pattern for a predetermined number of times (S3, YES), themain controller 801 conveys thethread 10 until a portion of thethread 10 applied with (corresponding to) the nozzle check pattern has been wound around the winder 710 (S4). - Then, the
main controller 801 controls thereader 720 to read the state of thethread 10 wound around thewinder 710. Then, themain controller 801 captures read information obtained by performing image processing on the read result by the image processor 804 (S5). - Then, the
main controller 801 checks whether there is thenozzle 311 having a discharge failure based on captured read information and determines whether there is an abnormal discharge (S6). - At this time, if there is an abnormal discharge (S6, YES), the
main controller 801 performs a dummy discharge operation as a recovery operation. The dummy discharge operation performs a dummy discharge in which themain controller 801 controls thehead 310 to discharge a liquid fromnozzles 311 in which a discharge failure has occurred (S7). Then, themain controller 801 returns the process to step S1 to apply the liquid according to the nozzle check pattern on thethread 10. - If there is no abnormal discharge (S6, NO), the
main controller 801 ends this state check operation (nozzle check operation). - The recovery operation may be performed by, for example, the
main controller 801 notifying the user of the discharge failure through thedisplay 830. Then, themain controller 801 performs the recovery operation after an instruction of the recovery operation is input from theoperation part 820. - The above describes the liquid discharge apparatus according to the second embodiment that reads a state of the
thread 10 in thestate check unit 700 by thereader 720 to check the state of the nozzles 311 (discharge state) of thehead 310, as an example. However, the state check operation (nozzle check operation) of theliquid discharge apparatus 100 according to the second embodiment is not limited to the embodiments as described above. - For example, the
main controller 801 may detect a state of thethread 10 such as a dyeing density or a color (using a color sensor) of thethread 10 to which the liquid is applied by using the read result of thereader 720. Then, themain controller 801 may control adjustment of the discharge amount for each color, for example, and correction of a density and a color tone of the thread according to the detection result. - Next, the
liquid discharge apparatus 100 according to a third embodiment of the present disclosure is described with reference toFIG. 12 . -
FIG. 12 is a flowchart illustrating a control of the state check operation in the third embodiment. - A portion related to a control of the state check operation in the third embodiment is the same as a portion related to a control of the state check operation as described in the second embodiment. However, the liquid discharge apparatus in the third embodiment does not use the
reader 720 in the nozzle check operation. - In steps S11 to S14, the
main controller 801 performs the same processing as in the steps S1 to S4 of the second embodiment (seeFIG. 11 ). Thus, a portion of thethread 10 to which the nozzle check patterns for times are formed is wound around thewinder 710. - Thus, the user visually checks (confirms) whether there is a nozzle omission (discharge failure) as described above. The nozzle omission is occurred when the
nozzle 311 is clogged by hardened ink or foreign material so that the ink may not be discharged from the cloggednozzle 311. At this time, when the user determines that there is a discharge failure and a recovery operation has to be performed, the user instructs themain controller 801 to perform the recovery operation from theoperation part 820. - The
main controller 801 determines whether there is an instruction input of a recovery operation from the operation part 820 (S15). At this time, if there is the instruction input of the recovery operation, themain controller 801 performs the dummy discharge operation as the recovery operation similarly to the step S6 (seeFIG. 11 ) in the second embodiment (S16). Then, themain controller 801 returns the process to step S11 to apply the liquid according to the nozzle check pattern on thethread 10 after the step S16. - Conversely, if there is no instruction input of the recovery operation from the operation part 820 (S15, NO), the
main controller 801 ends the state check operation (nozzle check operation). Themain controller 801 can determine an absence of the instruction input of the recovery operation in any way so that a state of the absence of the instruction input may include a state when the instruction for recovery operation is input, when another instruction is input, or when the instruction for recovery operation is not input for a predetermined time. - In the above manner, the
liquid discharge apparatus 100 can improve visibility of theundyed region 11 1b in thethread 10 that is a region corresponding to the discharge failure also when the user visually checks the discharge failure since theundyed region 111b is linearly aligned in one line in thethread 10 wound around thewinder 710. - Next, the
liquid discharge apparatus 100 according to a fourth embodiment of the present disclosure is described with reference toFIG. 13 . -
FIG. 13 is a schematic side view of thewinder 710 illustrating the state check unit of thewinder 710 in the fourth embodiment. - The
liquid discharge apparatus 100 in the fourth embodiment includes thewinder 710 around which thethread 10 is spirally wound. Thewinder 710 in the fourth embodiment has a shape in which an outer diameter of thewinder 710 is varied stepwise in the conveyance direction. - In such a configuration as illustrated in
FIG. 13 , thethread 10 is wound around thewinder 710 side by side so that positions of the liquid discharged from the same (identical)nozzle 311 on thethread 10 are linearly arranged while being obliquely shifted in the winding direction orthogonal to the conveyance direction when thethread 10 is wound around thewinder 710. - Thus, the
liquid discharge apparatus 100 according to the third embodiment can obtain the same effect of easily detecting the discharge failure as the effect of theliquid discharge apparatus 100 according to each of the above described embodiment. - Next, the
liquid discharge apparatus 100 according to a fifth embodiment of the present disclosure is described with reference toFIG. 14 . -
FIG. 14 is a schematic side view of the state check unit according to the fifth embodiment. - The
liquid discharge apparatus 100 according to the fifth embodiment includesmultiple guides 740 to guide thethread 10. Themultiple guides 740 guides thethread 10 while folding back thethread 10 for a plurality of times (two times inFIG. 14 ). At this time, themultiple guides 740 form a path along which thethread 10 is folded back side by side such that positions of the liquid discharged from the same (identical)nozzle 311 of thehead 310 on thethread 10 are linearly arranged in one line in the conveyance direction. - The
multiple guides 740 as the path former guides thethread 10 while bending thethread 10 multiple times to form the two-dimensional surface 730. - Thus, the
liquid discharge apparatus 100 according to the fifth embodiment can obtain the same effect of easily detecting the discharge failure as the effect of theliquid discharge apparatus 100 according to each of the above described embodiment. - Next, a
dyeing apparatus 1000 according to an embodiment of the present disclosure is described with reference toFIG. 15 . -
FIG. 15 is a schematic side view of thedyeing apparatus 1000. - This
dyeing apparatus 1000 includes a windingunit 1200 to wind thethread 10 after thethread 10 is dyed instead of theembroidery unit 600 in theliquid discharge apparatus 100. - The
dyeing apparatus 1000 supplies thethread 10 from asupply reel 210 of thesupply unit 200, discharges and applies a liquid of a desired color from theliquid application unit 300 onto thethread 10 to dye thethread 10 into a target color, and winds the dyedthread 10 with a windingreel 1220 of the windingunit 1200. - The
liquid discharge apparatus 100 according to the present embodiment is not limited to theembroidery unit 600 or thedyeing apparatus 1000. - The above-described embodiments are illustrative and do not limit the present invention. Thus, numerous additional modifications and variations are possible in light of the above teachings. For example, elements and/or features of different illustrative embodiments may be combined with each other and/or substituted for each other within the scope of the present invention. Any one of the above-described operations may be performed in various other ways, for example, in an order different from the one described above.
- Each of the functions of the described embodiments such as the
main controller 801 may be implemented by one or more processing circuits or circuitry. Processing circuitry includes a programmed processor, as a processor includes circuitry. A processing circuit also includes devices such as an application specific integrated circuit (ASIC), a digital signal processor (DSP), a field programmable gate array (FPGA), and conventional circuit components arranged to perform the recited functions.
Claims (9)
- A liquid discharge apparatus (100) comprising:a head (310) configured to discharge a liquid from nozzles (311) onto a linear member (10) conveyed in a conveyance direction, the head (310) including a nozzle array (313) including the nozzles (311) arrayed along the conveyance direction; anda state check unit (700) downstream of the head (310) in the conveyance direction and configured to guide the linear member (10) to form a two-dimensional surface (730) with the linear member (10); characterized in thatthe state check unit (700) includes a path former (710, 740) forming a path that guides the linear member (10) to form the two-dimensional surface (730),wherein, in the two-dimensional surface (730), multiple portions of the linear member (10) onto which the liquid has been discharged from an identical nozzle (311) of the nozzles (311) are linearly arranged in the conveyance direction.
- The liquid discharge apparatus (100) according to claim 1, wherein the state check unit (700) is for facilitating a nozzle check operation to detect a discharge state of the nozzles (311).
- The liquid discharge apparatus (100) according to claim 1 or 2,
wherein the path former (710) includes a winder (710) around which the linear member (10) is to be wound without overlap to form the two-dimensional surface (730). - The liquid discharge apparatus (100) according to claim 3,
wherein a part of the linear member (10) wound around a circumferential surface of the winder (710) one turn has a length equal to a length of the nozzle array (313). - The liquid discharge apparatus (100) according to claim 3,
wherein an outer diameter of the winder (710) is varied stepwise in the conveyance direction. - The liquid discharge apparatus (500) according to any one of claims 3 to 5,
wherein the winder (710) includes grooves (710a) that guide the linear member (10) to wind around the winder (710). - The liquid discharge apparatus (500) according to claim 2,
wherein the path former (710, 740) includes multiple guides (740) configured to bend the linear member (10) multiple times to form the two-dimensional surface (730). - The liquid discharge apparatus (100) according to any one of claims 1 to 7,
wherein the state check unit (700) further includes a reader (720) configured to read the linear member (10) in the two-dimensional surface. - A dyeing apparatus (1000) comprising:the liquid discharge apparatus according to claim 1,wherein the head (310) discharges the liquid from the nozzles (311) to dye the linear member (10).
Applications Claiming Priority (1)
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JP2020173614A JP2022064780A (en) | 2020-10-14 | 2020-10-14 | Liquid discharging device, dyeing device |
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EP3984757A1 EP3984757A1 (en) | 2022-04-20 |
EP3984757B1 true EP3984757B1 (en) | 2023-08-09 |
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EP21202550.6A Active EP3984757B1 (en) | 2020-10-14 | 2021-10-14 | Liquid discharge apparatus and dyeing apparatus |
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EP (1) | EP3984757B1 (en) |
JP (1) | JP2022064780A (en) |
Family Cites Families (2)
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JP2006299462A (en) | 2005-04-21 | 2006-11-02 | Gifu Prefecture | Flat knitting machine for colored pattern |
WO2020137383A1 (en) * | 2018-12-28 | 2020-07-02 | Ricoh Company, Ltd. | Liquid discharge apparatus, dyeing apparatus, embroidery machine, and maintenance device |
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2020
- 2020-10-14 JP JP2020173614A patent/JP2022064780A/en active Pending
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EP3984757A1 (en) | 2022-04-20 |
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