Abstract:
An apparatus for folding a continuous length of fabric extracted from a dyeing range. The apparatus includes a fabric receptacle for receiving the fabric from the dyeing range and a two-directional plaiting system for folding the fabric. In the preferred embodiment, a control system controls the speed and tension of the fabric to prevent tearing or sagging of the fabric during unloading. Also, a pulley and squeegee system receives the continuous fabric and extracting liquid from the fabric prior to folding. The pulley and squeegee system includes a first nip drive and a second nip drive, each of the drives including a pair of rollers spaced apart to allow the continuous fabric to feed through the nip drives to extract excess water from the fabric.

Description:
BACKGROUND OF THE INVENTION 
     (1) Field of the Invention 
     The present invention relates generally to a device for automatically unloading fabric from a dyeing or finishing range, such as a jet dyeing machine, and, more particularly, a portable device for unloading fabric which is readily adaptable to a broad range of machinery. 
     (2) Description of the Prior Art 
     The production of fabric is a generally sequential process that ultimately finishes with a completed fabric of a certain type, color, and size or other predetermined specification. One of the steps of this process may be dyeing the fabric and then unloading it from the dye system in order to move the product along to the next step in the process. To facilitate transportation, the fabric is often unloaded from the dye system into tubs where it can be transported to the next downstream process or stored until needed. During a typical day of operation, the dye systems are in continuous use but are only unloaded on a periodic basis. 
     Previous attempts to automate the unloading process have had numerous drawbacks or other constraints. The dye system and the surrounding plant facility place a size constraint on the unloader. The dye systems are often placed in close proximity to other machinery to maximize the amount of dyeing equipment at one facility and production capability. Unfortunately, the close spacing of the machinery requires that unloading devices be relatively small to fit within the close dimensions. Previous unloaders are either too cumbersome to move in the tight quarters or require too much space. 
     Another drawback of existing unloaders is that a single facility may use a variety of dyeing ranges each having different physical dimensions, such as the placement and size of fabric removal ports. Previous unloading systems were adapted to fit only one specific type of machine and are unable to be used on other machinery having different physical dimensions. This requires that specific unloaders be purchased for each type of dyeing range which is expensive and also takes additional floor space in an already congested area. Alternatively, the unloaders are placed on each individual dye systems. This usage, however, is prohibitively expensive, an inefficient use of resources that require unnecessary duplication of a resource that is only periodically used, and sometimes impossible given space constraints. 
     Previous unloading systems have also required additional material handling of the fabric. Certain unloaders induced twists and bunches in the fabric which stretched the fabric and introduced other defects that required the fabric to be detwisted before further processing can be performed. Additionally, previous unloaders could not maintain a high unloading speed to keep the process flowing efficiently. 
     One type of previous unloader used a coiled removal system. This rotational system unloaded the dyeing range into a device similar to a large funnel. The funnel then coiled the fabric into tubs which were then pushed to the next downstream process. The funnel operated in a manner similar to a rope, causing twisting and stretching problems. This removal system did not meet the speed requirements, and did not use the tubs efficiently, as the coiled placement of the fabric did not fill the tub corners and center requiring the use of additional tubs to move the material and shutting down the unloader as the tubs were changed out. 
     Thus, there remains a need for a dye system unloading device that is capable of automatically unloading fabric from a dyeing range, such as a jet dyeing machine, at a high speed and reloadable in a short period of time while, at the same time, may be easily moved from dyeing range to dyeing range as needed. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to an apparatus for folding a continuous length of fabric extracted from a dyeing range. The apparatus includes a fabric receptacle for receiving the fabric from the dyeing range and a two-directional plaiting system for folding the fabric. 
     The plaiting system has a first folder for folding the fabric in a first orientation. The first folder includes a track positioned adjacent to the fabric receptacle and a track follower movably attached to the track and movable along the length of the track. The fabric is guided by the track follower to guide and fold the fabric in the first orientation. A second folder folds the fabric in a second orientation across the fabric receptacle. The second folder includes a fabric guide for guiding the fabric; a second track extending across the width of the fabric receptacle; and a motor for reciprocating the fabric guide across the second track. Accordingly, the first folder and the second folder reciprocate simultaneously to fold the fabric being unloaded into the fabric receptacle. 
     In the preferred embodiment, a control system controls the speed and tension of the fabric to prevent tearing or sagging of the fabric during unloading. Also, a pulley and squeegee system receives the continuous fabric and extracting liquid from the fabric prior to folding. The pulley and squeegee system includes a first nip drive and a second nip drive, each of the drives including a pair of rollers spaced apart to allow the continuous fabric to feed through the nip drives to extract excess water from the fabric. 
     Accordingly, one aspect of the present invention is to provide an apparatus for folding a continuous length of fabric extracted from a dyeing range. The apparatus includes a fabric receptacle for receiving the fabric from the dyeing range; and plaiting system for folding the fabric, the plaiting system having a first folder for positioning the fabric in a first orientation, and a second folder for positioning the fabric in a second orientation; wherein the first folder and the second folder reciprocate simultaneously to fold the fabric being unloaded into the fabric receptacle. 
     Another aspect of the present invention is to provide an apparatus for removing a continuous length of fabric from a dyeing range. The apparatus includes: a fabric receptacle for receiving the fabric from the dyeing range; a first folder for folding the fabric in a first orientation, the first folder including: (i) a track positioned adjacent to the fabric receptacle; and (ii) a track follower movably attached to the track and movable along the length of the track, wherein the fabric is guided by the track follower to guide and fold the fabric in the first orientation; a second folder for folding the fabric in a second orientation across the fabric receptacle, the second folder including: (i) a fabric guide for guiding the fabric; (ii) a second track extending across the width of the fabric receptacle; and (iii) means for reciprocating the fabric guide across the second track, wherein the first folder and the second folder reciprocate simultaneously to fold the fabric being unloaded into the fabric receptacle; and a control system for controlling the speed and tension of the fabric to prevent tearing or sagging of the fabric during unloading. 
     Still another aspect of the present invention is to provide an apparatus for folding a continuous length of fabric extracted from a dyeing range. The apparatus includes: a fabric receptacle for receiving the fabric from the dyeing range; a plaiting system for folding the fabric, the plaiting system having a first folder for folding the fabric in a first orientation, the first folder including: (i) a track positioned adjacent to the fabric receptacle; and (ii) a track follower movably attached to the track and movable along the length of the track, wherein the fabric is guided by the track follower to guide and fold the fabric in the first orientation; and a second folder for folding the fabric in a second orientation across the fabric receptacle, the second folder including: (i) a fabric guide for guiding the fabric; (ii) a second track extending across the width of the fabric receptacle; and (iii) means for reciprocating the fabric guide across the second track, wherein the first folder and the second folder reciprocate simultaneously to fold the fabric being unloaded into the fabric receptacle; a control system for controlling the speed and tension of the fabric to prevent tearing or sagging of the fabric during unloading; and a pulley and squeegee system for receiving the continuous fabric and extracting liquid from the fabric, the pulley and squeegee system having a first nip drive and a second nip drive, each of the drives including a pair of rollers spaced apart to allow the continuous fabric to feed through the nip drives. 
    
    
     These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiment when considered with the drawings. 
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a front elevational view of a dyeing range unloader constructed according to the present invention; 
     FIG. 2 is a top perspective view of the dyeing range unloader shown in FIG. 1; 
     FIG. 3 is front elevational view of the first direction plaiting system of the dyeing range unloader; and 
     FIG. 4 is a top view of the fabric guide of the second direction plaiting system. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     In the following description, like reference characters designate like or corresponding parts throughout the several views. Also in the following description, it is to be understood that such terms as “forward”, “rearward”, “front”, “back”, “right”, “left”, “upwardly”, “downwardly” and the like are words of convenience and are not to be construed as limiting terms. 
     Referring now to the drawings in general and FIG. 1 in particular, it will be understood that the illustrations are for the purpose of describing a preferred embodiment of the invention and are not intended to limit the invention thereto. As best seen in FIG. 1, a dyeing range unloader, generally designated  10 , is shown according to the present invention. The unloader includes a plaiting system  12 , a pulley/squeegee system  14  and a control system  16  for controlling the speed and tension of the fabric. 
     A frame  11  supports the components of the unloading system. The frame  11  is preferably mobile and may include wheels  15  or other roller assemblies attached to the frame base or bottom to provide both support and transportability. 
     Fabric “F” is first dyed upstream in a conventional dye vat or jet (not shown). One skilled in the art will also understand that the unloading system may also be adapted to remove fabric from other types of machinery such as a bleach range. The fabric “F” in the present invention is introduced into a fabric input guide  41  of the pulley/squeegee system  14 . The fabric input guide  41  channels the fabric “F” into a first nip  40  formed by alignment of a first top roller  46  and a first bottom roller  50 . The first top roller  46  is preferably formed of a corrosion resistant material, such as stainless steel. The first bottom roller  50  is preferably also formed of a corrosion resistant material, preferably rubber having a durometer in the range of between about 70 and 85, preferably about 80. first nip  40  is sized to accommodate fabric “F” without scuffing or crushing the fabric. The space between the first top roller  46  and the first bottom roller  50  is adjustable from a position in which the rollers are touching to a position having an opening of about four inches. Preferably, the rollers have a spring-loaded shock with a locking set screw to position the distance to the desired setting to accommodate various sizes and types of fabric. It will be understood by one of ordinary skill in the art that the alignment of the rollers could be varied such as top-and-bottom, side-by-side, etc. 
     When the fabric “F” passes through the first nip  40 , liquid is pressed and extracted. A splashguard  54  is positioned downstream from the first nip  40  to divert the liquid from falling into a holding tub  21  or onto the fabric “F” during plaiting. A gutter  52  is positioned below the first nip  40  to receive liquid runoff extracted at the first nip and to channel the liquid away from the fabric F. In a preferred embodiment, the gutter  52  includes an upper funnel region  53  that tapers toward and connects with a hose  55  that directs the liquid runoff away from the unloader  10 . The gutter  52  may be further connected to the frame  11  and aligned with the splashguard  54 . 
     After the fabric “F” is driven through the first nip  40 , the fabric passes over a tension roller  44  positioned downstream of the first nip  40 . Arms  60  extend from the first nip roller  50  and arms  61  extend from the second nip roller  64  to pivotally connect to form a back support  65  and a front support  67 . An axle  63  extends between the front support  65  and back support  67  for rotationally mounting the tension roller providing for rotation as the fabric passes between the first nip drive  40  and second nip drive  42 . 
     The front and back supports  65 ,  67  of the tension system are connected to the first direction plaiting system as best illustrated in FIG.  3 . As the plaiting system reciprocates, the tension roller is moved up and down to help maintain the tension of the fabric. In a preferred embodiment, the tension roller  44  and the drive roller are geared together in a one-to-one gear ration. One skilled in the art will recognize that the rollers may be geared in a number of arrangements including running independent of one another, depending upon the requirements of the system. 
     After passing over the tension roller  44 , the fabric passes into a second nip  42  formed by alignment of a second left roller  66  and a second right roller  64 . The second nip  42  is substantially identical to the first nip  40 . The second right roller  64  is formed of a corrosion resistant material, preferably stainless steel. The second left roller  66  is formed of a corrosion resistant material, preferably rubber having a durometer between about 70 and 85, preferably 80. The second nip  42  is spaced to accommodate fabric “F” without scuffing or crushing the fabric. The space between the second left roller  66  and the second right roller  64  is adjustable from a position in which the rollers are touching to a position having an opening of about four inches. Preferably, the rollers have a spring-loaded shock with a locking set screw to position the distance to the desired setting to accommodate various sizes and types of fabric. 
     The plaiting system  12  includes a first direction plaiting system  20  and a second direction plaiting system  22  that function simultaneously to systematically and controllably distribute the fabric “F” into a receptacle, such as a tub  21 , substantially filling the volume of the tub with fabric. As illustrated in FIG. 3, the first direction plaiting system  20  is formed by a first track  24 , a first track follower  26 , and the second nip  42 , including both second right and left rollers,  64  and  66 , respectively. In a preferred embodiment, the first track  24  includes a pair of spaced apart, parallel first tracks  90  and  92  aligned with the front and back edges of the second nip rollers  64 ,  66 . Correspondingly, the first track follower  26  includes a pair of track followers  94  and  96  to interface with the parallel first tracks  90  and  92 , respectively. Preferably, the pair of first track followers  94  and  96  arc toothed wheels which interface with corresponding toothed parallel first tracks  90  and  92  for providing controlled transverse movement thereon, as well as controlled stopping. 
     The track follower  26  reciprocates back and forth along the rails resulting in the fabric being folded in the first direction. The track follower  26  is geared with the second nip  42  to provide for the first direction plaiting system to move relative to the speed that fabric is pulled through the second nip  42 . In one embodiment, the track follower  26  and the second nip  42  are both independently driven with single-phase servomotors. Limit switches are positioned on each of the ends of the rails to reverse the motion of the track follower  26  and maintain the plaiting system in a reciprocating maimer. 
     As illustrated in FIG. 4, the second direction plaiting system  22  is formed by a fabric guide  30  which reciprocates over the nip point  42 . Support bars  35  extend outward from the fabric guide  30  and movably attach to rails  37  to maintain positioning and alignment. One of the support bars  35  is further connected to a pulley chain  33  which extends between a pair of pulleys  32 . The pulleys  32  move the chain  33 , and therefore the fabric guide  30 , back and forth along the length of the rollers  64 ,  66  to plait the fabric in the second direction. 
     As the first direction plaiting system reciprocates in a left-to-right motion in relation to FIG. 1, the second direction plaiting system simultaneously reciprocates in a in-and-out motion to allow for the dual reciprocation and loading of the fabric holder  21 . Preferably, the first direction and second direction plaiters are independently driven with single-phase servomotors. 
     In a preferred embodiment, the fabric guide  30  is a circular guide or ring having a smooth inner circumference with convex surfaces to prevent fabric snagging, scuffing or stretching. Preferably, the fabric guide is formed of non-corrosion resistant material, such as stainless steel. 
     Both the first and second direction plaiting systems  20 ,  22  are configured and collected to synchronously move with the second nip rollers  64 ,  66  so that a predetermined fabric plait pattern distributes the fabric “F” uniformly and consistently at any speed into the tub  21 . By distributing the fabric “F” efficiently into the tub  21 , the present invention is a substantial improvement over the previous plaiting systems. Table 1 lists plaiting systems with corresponding tub use efficiency. 
     The efficiency of tub usage of the present invention was compared to conventional rotational and half-plaiting. This was done by measuring the amount of fabric in yards which could be received by a tub of similar size. It was surprisingly discovered that the two-direction movement of the present invention was able to load twice as much fabric from the dyeing range into a similar size container. 
     
       
         
               
             
               
               
               
             
           
               
                 TABLE 1 
               
             
             
               
                   
               
               
                 Relative Percentage of Volume of Tub filled in 1 hour 
               
             
          
           
               
                   
                 Plaiting System type 
                 Relative Tub Use Efficiency 
               
               
                   
                   
               
               
                   
                 Rotational Plaiting System 
                 45% (1.0) 
               
               
                   
                 (prior art) 
               
               
                   
                 Half-Plaiting System 
                 50% (1.1) 
               
               
                   
                 (prior art) 
               
               
                   
                 Present Invention 
                 Substantially 100% (2.2) 
               
               
                   
                   
               
             
          
         
       
     
     Control system  16  electro-mechanically connects the plaiting system  12  and pulley/squeegee system  14  for controlling the unloader speed, movement and fabric tension. T he control system  16  synchronizes the speed of first and second nip driven rollers  50 ,  64  to ensure the fabric is pulled through the system at an even pace to prevent tearing or sagging of the fabric which would result with uneven nip drive speeds. Preferably, drive motors are adjustable speed motors capable of pulling fabric at a rate between about 0 to about 300 yards per minute. One example of a motor used in the present invention is Model No. CP3661T-4 manufactured by Baldor. Also preferably, the control system  16  includes a brake or shut-off (not shown) for automatic unloader stopping and agog speed for rethreading or inputting fabric into the unloader. If a knot, tangle, fabric end or other situation occurs that causes a tension above or below a preselected amount, the control system  16  automatically stops the driven nip rolls  50 ,  64  and the plaiting system  12 . further, the control system coordinates movement of the first and second direction plaiting systems  20 ,  22 . 
     The control system  16 , plaiting system  12  and squeegee system  14  are connected to a conventional AC power supply (not shown) and may be disconnected and reconnected to accommodate unloader  10  movement between dyeing range machines. 
     Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description. By way of example, while in the preferred embodiment a dyeing range unloader constructed according to the present invention is mobile and adaptable to multiple types of dyeing ranges or vats for fabric unloading, the unloader may be constructed for selective attachment to a single dyeing range or type of dyeing range. Alternatively, the frame may be adapted to movably connect with a track system (not shown) for selective movement along a linear arrangement of dye vats. Preferably, a track system would support the frame from above the dye vats. It should be understood that all such modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the following claims.