This invention relates to textile manufacturing. Specifically, this invention relates to systems and methods for monitoring and controlling temperatures during textile finishing operations.
In the manufacture of textile materials, the finishing operation is often the final step. The finishing operation typically imparts the aesthetic and physical properties to the material that are desired for the particular use. These properties are achieved through a combination of chemical and mechanical processes. These processes are often designed to maintain shrinkage control, achieve stain resistance, provide water repellency, provide appropriate stiffness and maintain uniform textile consistency.
Finishing operations typically involve saturating the fabric material in a solution of chemicals. Generally, these chemicals are water-based materials. These finishing chemicals may be applied in various ways including for example, immersion of the fabric in chemical baths or through the application of foam to the fabric. Once the fabric has been treated with finishing chemicals, it is then necessary to appropriately treat the material to drive off excess moisture and to cure the materials. This is often done by passing the material through preliminary moisture removing operations and then through a curing and drying device. The curing and drying device provides heating and appropriate air flow to drive off excess moisture and to cure materials remaining on the fabric. In many textile manufacturing operations, the finishing operation includes passing a moving web of textile material through a tenter frame which mechanically acts on the material to prevent shrinkage and which also includes appropriate heating and air flow devices to achieve the desired textile properties.
Maintenance of proper temperature control within finishing operations is critical to achieving consistent, suitable quality textile materials. Failure to achieve suitable temperatures in all areas of the material can result in material that must be scrapped. Exposing material to excessive temperatures can likewise cause damage. Because in finishing operations much of the water must be driven out of the material before the fabric temperature will rise above the vaporization temperature, it can be difficult to apply the appropriate amount of heating for the appropriate period of time to achieve drying without damaging the finished product. In addition, because textiles are often produced in continuous webs that are relatively wide, consistent curing and drying temperatures across the entire transverse width of the moving web are sometimes difficult to maintain. As can be appreciated, textile finishing operations generally run at significant manufacturing rates, and if a problem in the finishing process occurs considerable off spec, poor performing scrap material may be produced before the problem can be corrected.
Conventional temperature measurement devices and techniques have been used within textile finishing equipment such as tenter frames. While temperature measuring sensors may be placed within the equipment where the textile material undergoes drying and curing, such sensors are generally unable to accurately determine temperature on the fabric surface or in close proximity thereto. Further, because of the high air flow rates that are generally imparted within a tenter frame or other drying or curing equipment, temperature sensors that are in fixed position within the tenter frame are often unable to adequately reflect the temperature and drying effects being experienced by the textile material. Tenter frames are often relatively wide, and it is sometimes difficult for conventional sensing in one location to adequately predict the drying and curing effects on the textile material in a location transversely disposed relative to the temperature sensor. Other factors, such as ambient temperatures, solution temperatures, relative humidity, air flow restrictions and other variables can also result in changes in the heating and drying capabilities of equipment during finishing operations. Such variables, which may impact the finishing operations, may not be readily detected through conventional sensing mechanisms.
Attempts have been made to attach thermocouples or other sensors directly to textile materials during finishing operations. As can be appreciated, such attempts are generally unsuitable for a number of reasons. These include the fact that tenter frames are generally enclosed to maintain consistent temperature and air flow properties. Providing an opening within the tenter frame to measure temperature of the textile web by contacting the surface of the material will generally impact the temperature and air flow properties within the tenter frame resulting in an inaccurate reading. Attempts to attach a sensor to the textile material and allow it to pass through the tenter frame is often impractical due to the need for long electrical leads which would be necessary to obtain readings from the sensor as it passes through the longitudinal path within the tenter frame. Generally, long leads serve to conduct heat which results in inaccurate readings. The resistance and other properties of long leads makes such sensing potentially inaccurate. In addition, if this were to be done, the long leads associated with the sensor could potentially damage a large amount of fabric, such as coated fabric, requiring it to be scrapped. Therefore, such approaches are generally not suitable.
Thus, there exists a need for an improved system and method for monitoring temperatures in textile finishing operations. There further exists a need for an improved method of monitoring temperatures during textile finishing operations that is more accurate, can be performed more frequently and at more locations transversely across a moving textile web, and which results in the production of less scrap material.
It is an object of an exemplary embodiment of the present invention to provide a temperature monitoring system for textile finishing operations.
It is a further object of an exemplary embodiment of the present invention to provide a temperature monitoring system for textile finishing operations that provides more accurate temperature measurement.
It is a further object of an exemplary embodiment of the present invention to provide a temperature monitoring system for textile finishing operations that can be used to determine temperatures of textile materials in numerous locations as material passes through a finishing operation.
It is a further object of an exemplary embodiment of the present invention to provide a temperature monitoring system for textile finishing operations that can be used to determine temperatures at a plurality of transverse locations on a moving textile web.
It is a further object of an exemplary embodiment of the present invention to provide a temperature monitoring system for textile finishing operations that can be used to measure temperatures more reliably both at a surface of the material, as well as at locations disposed from but in proximity to the material.
It is a further object of an exemplary embodiment of the present invention to provide a temperature monitoring system for textile finishing operations that is reliable, easy to use and that can be utilized without producing excessive scrap.
It is a further object of an exemplary embodiment of the present invention to provide methods for monitoring temperatures of textile materials in textile finishing operations.
Further objects of exemplary embodiments of the present invention will be made apparent in the following Best Modes For Carrying Out Invention and the appended claims.
The foregoing objects are accomplished in an exemplary embodiment through the use of a temperature sensing device which passes through a tenter frame with a moving web of textile material. The temperature sensing device is releasibly engageable with the moving web at a location ahead of where the fabric enters the tenter frame, and passes through the tenter frame with the moving web. In the exemplary embodiment, the temperature sensing device is operative to sense and record temperatures at a plurality of locations within the tenter frame. After the device has passed through the tenter frame, the device is disengaged from the moving web and the data analyzed.
In the exemplary embodiment, the temperature sensing device includes a positionable sensing member that extends from the body and enables a user to selectively sense temperature as desired, either at the surface of the web or in selected positions above the surface of the web. In addition, in the exemplary embodiment, the sensing device utilizes the temperature sensing member to sense temperature on the fabric ahead of the body of the device so as to minimize the effects of the device on the measurements. In addition, the exemplary embodiment has an aerodynamic shape so as to minimize the effects on the air flow due to the presence of the sensing device.
In the exemplary embodiment, data corresponding to temperature that is stored within the temperature sensing device is output to a computer after the device is disengaged from the web. The computer may be used to analyze the data and to provide visually perceivable outputs such as graphical outputs on a display or printed graphs that facilitate analysis of the temperature properties experienced by the textile material in the finishing operations. This enables an operator to adjust the conditions within the tenter frame as appropriate to maintain desirable properties. Further, in some alternative embodiments, data corresponding to temperature sensed by the device, can be manipulated by the computer and used to control the making of adjustments within the tenter frame.
In exemplary embodiments, the temperature sensing device includes an insulating body which houses a removable module. This may facilitate programming of the module with desired parameters related to data capture. It may also facilitate transferring the data from the temperature sensing device to a remote computer. In some alternative embodiments, wireless communication capability may be provided between the temperature sensing device and a remote computer so as to facilitate real time or near real time monitoring of temperature within the tenter frame.
In the exemplary embodiment, the temperature sensing device may be used repeatedly to capture temperature data at a plurality of locations relative to the moving web of textile material. This may include capturing data at the surface of the web, and thereafter capturing data related to temperature a selected distance above the web. This may be done in the exemplary embodiment by adjusting the sensing member. In addition, in the exemplary embodiment, data can be captured in a plurality of transversely disposed locations across the web. This may be done by attaching the temperature sensing device in different transverse locations relative to the web and passing it through the tenter frame. This enables reliably monitoring the drying and curing action imparted by the tenter frame in such various locations and helps to assure that the finishing process is uniform across the web. Additional advantages of exemplary embodiments will be apparent from the detailed description provided herein.
Referring now to the drawings and particularly to
In the exemplary embodiment, body 12 comprises a cover portion 14 and a base portion 16. The cover portion and base portion are relatively movable to enable access to components within the interior thereof. In the exemplary embodiment, the cover portion and base portion are separable, but in other embodiments such portions may be hinged or otherwise made relatively movable without being entirely separable.
Base portion 16 includes a bottom plate 18. Bottom plate 18 is generally permanently attached to the insulating material which in operation is positioned above the plate. Bottom plate 18 of the exemplary embodiment has extending therefrom engaging members 20 only one of which is shown. Engaging members 20 comprise a plurality of pin members which extend outward from the bottom plate 18. The engaging members 20 are adapted to releasibly engage a moving web of textile material 22 shown in phantom. In the use of the temperature sensing device 10 as later described in detail, the engaging members 20 enable the device to be releasibly attached to a moving textile web and to maintain engagement therewith as the web passes through finishing operations. In the exemplary embodiment, the web moves in the direction of Arrow M shown in
The exemplary sensing device 10 includes a fastening mechanism 24 that is used to realeasibly hold the cover portion 14 to the base portion 16. Fastening mechanism 24 includes a first latch portion 26. First latch portion 26 has inward extending end portions that are rotatable in rear ear portions 28 of bottom plate 18. (See,
Second latch portion 30 includes a finger portion 34. Finger portion 34 is releasibly engageable through U-shaped opening 36 formed in the first latch portion. In the closed position of the fastening mechanism 24 shown in
In
Returning to the discussion of the exemplary embodiment shown in
In the exemplary embodiment, the data store 44 may include RAM or other processor accessible storage. The data store is operative to hold program parameters and other instructions that are executed by the processor. Further, in the exemplary embodiment, the data store is operative to store data corresponding to temperatures sensed at a plurality of locations as the temperature sensing device 10 moves through the textile finishing operations. The data stored in the exemplary embodiment includes data corresponding to temperature readings that are made at periodic intervals in accordance with program parameters as the device travels in connection with the web of textile materials through the tenter frame. In the exemplary embodiment, the module 40 includes a data logger device, and specifically an HOBO Model H12-002 produced by MicroDAQ.com. Of course, in other embodiments, other types of processors, data stores and suitable circuitry may be used.
In the exemplary embodiment shown in
In the exemplary embodiment, sensing member 46 is comprised of a bendable wire material and the thermocouple is a K type thermocouple. Of course these approaches are exemplary, and in other embodiments, other types of sensing devices and sensing members may be used.
As shown in
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The exemplary method for use of temperature sensing device 10 is represented in
As schematically represented, tenter frame 54 includes a plurality of heating devices 56. Heating devices 56 are operative to selectively heat a plurality of areas or zones within the tenter frame. In the tenter frame, controlled air flow is provided through air moving devices schematically represented 58. Of course, it should be understood that tenter frames or other devices may include various types of heating devices, air movement devices, stretching devices or other suitable devices for purposes of mechanically acting on the material as well as chemically reacting the finishing chemicals. The heating devices 56, and air moving devices 58 are controlled by one or more controllers schematically indicated 60. Controllers 60 may be suitable computers or other types of controllers that are operative to enable selectively changing the output of heating devices included within areas of the tenter frame. The controller 60 may also be operative to control other parameters such as air flow within the various areas of the tenter frame.
In the use of device 10 as shown in
In the exemplary method of operation, the computer 62 is a personal computer which operates using a Microsoft® Windows® XP Professional operating system and a Microsoft® Excel spreadsheet program. In addition, the computer has operating therein software for programming and recovering data from the module. In the exemplary embodiment, Boxcar Pro 4.0 software is operated in the computer. Of course these items may be different in other systems.
Initially, in executing the exemplary method, the module 40 is operatively engaged with the computer 62. This is done through connection of the module with the computer through a serial connector on the module and a suitable cable. The computer operates to recognize the module and to communicate therewith. The computer program operating in the module also operates to cause the module to be programmed with data capture parameters. These parameters include in the exemplary embodiment the current time which is based on the time clock as set in the computer 62. Program parameters also include a start time at which the module will begin capturing data, as well as data corresponding to a sample rate at which the module processor will operate to capture and store in its data store, temperature readings once the start time has been reached. In the exemplary embodiment, a sample rate of one-half second intervals is used. Of course this approach is exemplary. Also, in the exemplary embodiment, the start time is generally set at a time after the then current time so as to enable the operator to have the module installed in the body and the body placed on the web at the incoming side of the tenter frame. In alternative embodiments, modules may be provided with actuators which may be manually or remotely triggered to cause the module to begin capturing temperature data.
Once the exemplary module 40 has been programmed, it is positioned with the sensing member 46 attached thereto within base portion 16 of the body 12. This is initially done by placing the module 40 in the pocket 52 of the base portion 16. This is represented by partially assembled device 70 in
In the exemplary embodiment, once the start time is reached, the module 40 has a flashing indicator that begins flashing to indicate that temperature data is now being recorded. Once the operator observes that the start time programmed has been reached, the user of the device installs the cover portion 14 on the body and secures the fastening mechanism 24. Of course, in other embodiments, the operator may take other steps to trigger an actuator to commence data capture. Thereafter, the user may adjust the sensing member 46 so that the thermocouple 48 is sensing temperature in the desired position relative to the surface of the web. This is represented by the assembled device 72 in
With the module enclosed within the insulating body and the sensing member properly positioned, the temperature sensing device 10 is engaged with the moving web 22 on the incoming side of the tenter frame 54. As represented in
Once the temperature sensing device 10 has passed through the tenter frame, the device 10 is releasibly engaged from the web. At this point, the data that has been captured may be analyzed. Alternatively, the device may be again passed through the tenter frame so as to capture additional data. In some exemplary methods, the device may be passed through the tenter frame multiple times at various distances from the transverse edges that bound the web. Alternatively, or in addition, the device 10 may have its sensing member repositioned so as to take additional readings at a different location relative to the upper surface of the web. By making additional runs through the tenter frame, additional data is captured which can be analyzed and compared to data corresponding to suitable ranges to achieve the necessary drying and curing of the particular textile material being produced.
In the exemplary embodiment when additional data is to be captured, the temperature sensing device 10 may be disengaged from the web at the outgoing end of the tenter frame and returned to the incoming end. At the incoming end, the temperature sensing device may be moved to a different transverse position relative to an edge of the web or otherwise relocated with regard to the temperature sensing thermocouple so as to gather additional data desired for purposes of analysis.
After the desired number of passes through the tenter frame, the device may be disengaged from the web, the fastening mechanism released and the body opened. This is represented by the open body 74 shown in
The computer upon receiving the data from the module may be operative to analyze the data in accordance with inputs provided by the operator. These inputs may include separating the data for each run that is made through the tenter frame. Such data may be readily separated in the exemplary embodiment based on time as recorded for the various runs as well as the temperature profiles. It will generally be apparent from the stored data when the temperature sensing device enters into proximity with the heating devices within the tenter frame as well as when the temperature sensing device passes out of the tenter frame. The computer in exemplary embodiments may be operative to include the data in a spreadsheet program, such as Microsoft® Excel, and to produce graphs of the temperature profiles which are visually perceivable. Such perceivable outputs may include outputs through the screen 66 or graphs produced by the printer 68. Such a graph is schematically represented 78 in
The graph in
Alternatively, computer 62 may be operatively connected to controller 60, so as to provide communication therewith and to enable adjustment of the heating devices and other devices within the tenter frame in response to the data captured. This may be done for example by a program operating in the computer 62 comparing the data received from the temperature sensing device to set parameters or ranges. The computer 62 may calculate the need for any adjustments based on the data received. The computer may communicate through a local network to the controller 60, and the controller may operate to adjust the appropriate devices within the tenter frame. Of course this approach is exemplary, and in other embodiments, other approaches may be used.
Although, in the exemplary embodiment, temperature data is captured by the module 40 and then later passed to the computer for analysis, in alternative, embodiments real time or near real time data capture may be achieved. This may be done for example by including a wireless communication device schematically indicated at 80 within the body 10 as shown in
As can be appreciated, the exemplary embodiments described are used in providing more accurate temperature data in textile finishing operations. Such approaches may also be used to achieve more accurate measurements without producing unsuitable amounts of scrap material. This may enable more frequent testing and more precise control which results in improved product quality. Further, although the exemplary embodiment is described as used in connection with textile finishing operations, such approaches may also be applied to other comparable processes.
Thus, the textile finishing temperature monitoring systems and methods of the exemplary embodiments achieve one or more of the above-stated objectives, eliminate difficulties encountered in the use of prior devices and systems, solve problems and attain the desirable results described herein.
In the foregoing description, certain terms have been used for brevity, clarity and understanding, however no unnecessary limitations are to be implied therefrom because such terms are for descriptive purposes and are intended to be broadly construed. Moreover, the descriptions and illustrations herein are by way of examples, and the invention is not limited to the details shown and described.
In the following claims, any feature described as a means for performing a function shall be construed as encompassing any means known to those skilled in the art to be capable of performing the recited function, and shall not be deemed limited to the structures shown in the foregoing description or mere equivalents thereof.
Having described the features, discoveries and principles of the invention, the manner in which it is constructed and operated, and the advantages and useful results attained; the new and useful structures, devices, elements, arrangements, parts, combinations, systems, equipment, operations, methods, processes and relationships are set forth in the appended claims.
This application claims priority from U.S. Provisional Application Ser. No. 60/545,462 filed on Feb. 17, 2004.
Number | Date | Country | |
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60545462 | Feb 2004 | US |