An apparatus for automatically preparing a dyeing solution

Abstract: An apparatus for automatically preparing a dyeing solution by automatically combining the desired amounts of dye stock solutions and dye auxillary solutions with a predetermined amount of water.

Description: The present invention generally relates to an apparatus for automatically preparing a dyeing solution, and more particularly, to an apparatus effective in automatically sequentially preparing dyeing solutions exhibiting desired concentrations and color tones by automatically combining a plurality of dye stock solutions, dye auxiliary solutions and a predetermined amount of water. A prior art method of preparing dyeing solutions involves the steps of empirically selecting a plurality of dyes composing color components of a desired color sample; preparing the dyeing solutions; dying a fabric; comparing the dyed color with a sample color; and deciding the final recipe of the dyeing solutions by repeating the operation more than several times in some cases. In recent years, a method referred to as a color matching method has been developed. This method is intended to effect measurement-based color matching by use of a spectrophotometer and a digital computer. By the computer color matching method, the color samples are analyzed and can quickly readily be expressed with dye concentrations based on the three primary colors. An operation indispensable for color matching is, however, a selection of the three-primary-color-based dyes employed for such an expression among a multiplicity of commercially available dyes, considering factors like fastness of the fabric and the profitability associated with costs thereof. Another indispensable operation is visual detection to identify the dyed color with the color sample. It is a real situation that the preparation of the dyeing solutions with the selected dyes relies on manual operations. This requires well-experienced and skillful operations and also a good deal of labor. Under such circumstances, in recent years apparatus for automatically preparing the dyeing solutions were disclosed in Japanese Patent Application Nos. 27515/1981 and 138566/1982. In those apparatus, the dye stock solutions are volumetrically measured. This tends to cause errors due to mixing of air bubbles and volumetric variations concomitant with changes in temperature. Problems, though such apparatuses contribute to a speed-up of operation and saving of labors, remain unsolved in terms of accuracy of measurement. Proposed by the present applicant in Japanese Patent Application No. 68117/1982 is apparatus for automatically preparing the dyeing solutions at high accuracy and efficiency, the apparatus making a measurement by the gravimetric method. Proposed also in Japanese Patent Application No. 17857/1985 are apparatus for automatically preparing the dye solutions at much higher efficiency. One apparatus is capable of sequentially consecutively performing such operations as to set a receiving vessel like a coloring pot or a beaker in a fixed position and weigh and prepare the dyeing solutions. The other apparatus is capable of automatically preparing not only the dyeing solutions but also a variety of chemicals at high accuracy and efficiency. Highly accurate and efficient preparation was attainable with the automatic dyeing solution preparing apparatus proposed in Japanese Patent Application Nos. 68117/1982 and 17857/1985. Nevertheless, the following problems arose. The automatic dyeing solution preparing apparatus is provided with containers for accommodating a multiplicity of dye stock solutions and dye auxiliary solutions. Hence, the apparatus increases in size, resulting in difficulty of selecting a location for installation thereof. Dye stock solution always stays in a pipe for outflow of the dye stock solution; even in a mere residence time of approximately 30 min., a disperse dye precipitates in the outflow pipe, thereby inducing an obstacle to impair accuracy. Since a multiplicity of outflow pipes is provided, cleaning these pipes inconveniently requires much time. Besides, a slurry-like liquid dye was unusable. The present invention, which may obviate the problems inherent in the prior art automatic dyeing solution preparing apparatus, can provide an apparatus for automatically preparing dyeing solutions, comprising: containers (1', 1'', 1'''...) for respectively accommodating solutions (2', 2'', 2'''...) selected from dye stock and dye auxiliary solutions; a transfer means (3) to be loaded with said containers; receiver vessels (20) for successively receiving measured amounts of solutions (2) from containers (1); a cleaning water tank (12) and a purge pot (18); two outflow pipes (8, 8'), each outflow pipe (8, 8') being provided with a pump (9, 9') and a valve (10, 10'), each outflow pipe being positionable in a supply position in which the suck-up end of an outflow pipe (8) is immersed in a vessel (1) containing dye stock solution or dye auxiliary solution (2) while the discharge end of the outflow pipe (8) is opened towards a receiver vessel (20) so that the solution in the container (1) is caused to flow therefrom into the vessel (20) and in a cleaning position in which the suck-up end of an outflow pipe (8') is immersed in cleaning water (13) and the discharge end of the outflow pipe (8') is opened towards the purge pot (18) so that the pipe (8') is cleaned with cleaning water (13); means (7, 11; 7', 11') associated with said outflow pipes (8; 8') which means are operable to position the pipes interchangeably in a supply or cleaning position; a weighing means (26) for converting into electric signals weight changes of said solutions which have been received in said receiving vessels (20); a transfer means (23) to be loaded with said receiving vessels (20); a control mechanism (33) for continuously or intermittently opening and closing said pump (9) and said valve (10) by making a comparison with a predetermined value in accordance with a level of said electric signal, said control mechanism (33) also controlling the operation of said transfer means (3, 23) and said means (7, 7'; 11, 11''); dilution outflow pipe (36) provided with a valve (14) for causing dilution water (16) to flow into said receiving vessels after completion of weighing said solutions therein, said valve (14) being continuously or intermittently opened and closed in accordance with a predetermined value by said control mechanism (33). According to the apparatus of this invention, the outflow pipes for flowing out the dye stock solutions and the dye auxiliary solutions are invariably kept clean. Slurry-like liquid dye is usable therein. Highly accurate and efficient preparation can be attained. The apparatus of this invention is remarkably small in size, thereby facilitating selection of a location for installation thereof. One embodiment of the apparatus of this invention will hereinafter be described in detail with reference to the accompanying drawings. FIG. 1 schematically illustrates an apparatus of the present invention. Provided are a plurality of stock solutions vessels (1) for previously accommodating desired dye stock solutions (2) and/or dye auxiliary solutions (2). A digital display means (34) specifies the stock solution vessels (1), (1'), (1''), ... (1 n' ) in conformity with a dye preparation recipe inputted to an input means (32). These stock solution vessels are placed in predetermined positions specified by the digital display means (34) in accordance with the dye preparation recipe inputted to the input means (32). The dye stock solution is likely, as in the way with a disperse dye, to precipitate when left to stand. Such dye stock solutions can be stirred by magnetic stirrer. The dye stock solutions (2, 2', 2'', 2''', ... 2 n' ) and/or dye auxiliary solutions (2, 2', 2'', 2''', ... 2 n' ) set on a stock solution vessel table (3) are stopped in supply positions with a turn of the stock solution vessel table (3). The stock solution vessel table (3) is formed with a plurality of recesses for placing the vessels (1) on the periphery of a concentric circle. The table (3) is turned upon engaging a gear secured to a rotation shaft loosely inserted into a bearing (4) with a gear secured to a rotation shaft of a motor (5) with a braking means. The motor (5) operates in response to an electric signal transmitted from a control means (33). A plurality of detection ends for a plurality of position sensors (6) is provided on an outer periphery of the table (3). In response to the sensors (6), the detection ends transmit electric signals to the control means (33). The operation of the motor (5) is thus controlled, and a command is given to stop the table (3) in a predetermined position. An air cylinder (7) operates in response to an electric signal from the control means (33). A suck-up end of an outflow pipe (8) is thereby inserted into the vessel (1) disposed in a supply position on the table (3). Concurrently, the forward end of the outflow pipe (8) is fixed upwardly of a receiver vessel (20) when the air cylinder (11) operates. The pump (9) is actuated by an electric signal transmitted from the control means (33). The electromagnetic valve (10) opens and closes in response to electric signals of the control means (33), whereby a desired amount of dye stock solution (2) is flowed out in conformity with the dye preparation recipe inputted to the input means (32). As one mode of opening/closing operation of the electromagnetic valve (10), 95% of the necessary amount of dye stock solution (2) is flowed out in a state where the electromagnetic valve (10) is opened. Subsequently, 100% of the necessary amount of solution (2), including the remaining 5%, is flowed out by repeating the instantaneous opening and closing operations of the electromagnetic valve (10)-i.e., by repeatedly effecting checks of dropping and weighing of the dye solution frequently. Based on the method discussed above, the outflow pipe (8) is formed of, preferably, a fluorocarbon resin in terms of flexibility, anticorrosiveness, liquid drop separation and prevention of intra-pipe staining and of clogging. To make the liquid drop separate completely from the forward end of the outflow pipe, preferably only the forward end thereof is formed to have a small diameter. The receiver vessels (20) are placed on a plurality of receiver dishes (22) on a turntable (23). Note that the table (23) is shown as one example of a transfer means. The transfer means may include, e.g., a rotary conveyor on condition that the transfer means is loaded with the plurality of receiver vessels on its plane part and is capable of transferring the vessels. The turntable is formed with a plurality of notched holes for placing the receiver dishes (22) on the periphery of a concentric circle. There is employed for instance, a receiving vessel with a body portion of smaller outside diameter than the notched hole. Using a receiver dish (22), though not necessary, desirably makes it possible to adequately utilize a dye pot, a beaker and the like as a receiving vessel. Preferably, the receiver dish (22) is so constructed that the outside diameter of its body portion is smaller than that of the notched hole of the turntable to assume a tapered configuration. Separation from the turntable is thereby facilitated. Besides, as will be mentioned later, the receiver dish is used together with the receiving vessel for measuring the weight and therefore formed of, preferably, a synthetic resin rather than a metal to exhibiting a smaller density. There is no problem if the table (23) is made of a metal plate or a synthetic resin plate. However, the more preferable material is synthetic resin in terms of load of power to drive the table and of anticorrosiveness. The table (23) is turned by engagement of a gear secured to a rotation shaft loosely inserted in a bearing (30) with a gear secured to a rotation shaft of a motor (24) with a braking means. The motor (24) operates in response to electric signals transmitted from the control means (33). A plurality of detection ends for a plurality of position sensors (25) is provided on an outer periphery of the table (23). In response to the sensors (25), the detection ends transmit electric signals to the control means (33). The operation of the motor (24) is thus controlled, and a command is given to stop the table (23) in a predetermined position. Among the plurality of receiving vessels (20), the vessels (20) for performing the preparation are positioned downwardly of the outflow pipe (8). An electronic balance means (26) serving as a weighing means is disposed at a constant spacing downwardly of the receiving vessels. The electronic balance means (26) transmits, to the control means (33), an electric signal representing a weight value of the object weighed. A weighed result outputted concurrently with the weighing process can, if necessary, be confirmed on a digital display means (34) incorporated in the apparatus or recorded by a printer means (35). The electronic balance means (26) is, when measuring the weight of the chemical flowing into the receiving vessel (20) or the container, lifted by rack-pinion mechanism (27) serving as a lifting-lowering means which will be described later. The receiving vessel is placed on the electronic balance means to measure the weight and make the preparation. After finishing these operations, the electronic balance means (26) is lowered down to its original position. In the apparatus of this invention, as described above, the electronic balance means conceived as the weighing means is moved to measure the weight without moving the object to be measured. Hence, the structure of the invention is simpler than, e.g., a system for moving up and down a transfer means mounted with the plurality of containers while fixing the balance means or a system for mechanically moving the receiving vessel onto a balance base. The apparatus of this invention does not cause liquid leakage due to vibrations of the object to be weighed and enables a speed-up of weighing. The weighing system of this invention is therefore efficient. The following is a detailed description of the rack-pinion mechanism serving as the lifting-lowering means for the electronic balance means (26). The electronic balance means (26) is fixed to a frame (28) moved up and down by the rack-pinion mechanism (27). Note that in this embodiment, the rack-pinion mechanism has been exemplified as a lifting-lowering means, but any kind of mechanism may be adopted on condition that it is capable of vertically moving the electronic balance means a predetermined distance. As a matter of course, for instance, a hydraulic mechanism, a pneumatic mechanism or a screw mechanism are similarly adoptable. The rack-pinion mechanism (27) is combined with a motor (29) with a braking means to thereby rotate a pinion by the electric signals from the control means (33). A pinion meshes with a rack having its upper end to which the frame (28) is fixed. The rack moves up and down when the pinion rotates. A detection end of a distance sensor is provided at a lower end of the rack to control the up-and-down moving distance of the electronic balance means (26). In response to the distance sensor (31), electric signals are transmitted to the control means (33). One example of the preparing operation by the thus constructed apparatus of this invention will be explained in greater detail. Above the electronic balance means (26), the receiver dish (22) and the receiving vessel (20) are placed on the table (23) at a predetermined spacing from the electronic balance means. The dish (22) and the vessel (20) are then put on the base of the electronic balance means (26) lifted by the rack-pinion mechanism (27) so as to be released from the table (23). The weight (tare) is measured. Subsequently, in accordance with a first dye preparation recipe inputted to the input means (32), the electromagnetic valve (10) is opened and closed so that the solution of a specified weight drops down into the receiving vessel (20). The first weighing operation is thus completed. Thereafter, the electronic balance means (26) is lowered. The receiver dish (22) and the receiving vessel (20) are placed on the table (23) and separated from the electronic balance means (26). For weighing in accordance with a second dye preparation recipe inputted to the input means (32), the table (23) is turned so that the specified vessel (20) is positioned above the electronic balance means (26) (under the outflow pipe (8)). Then the table (23) stops in a specified position. Based on the dye preparation recipe inputted to the input means (32), the electromagnetic valve (10) is opened and closed by the electric signals of the control means (33). A desired amount of dye stock solution (2) is thereby flowed out. The second weighing operation is thus finished. The third, fourth, ... n-th weighing operations of the dye stock solution (2) will hereinafter be finished in the same way according to the dye preparation recipe inputted beforehand to the input means (32). The pump (9) stops operating in response to the electric signals given from the control means (33). Subsequent to this step, on the basis of the dye preparation recipe initially inputted beforehand to the input means (32), a suck-up part of the outflow pipe (8) is raised by operating the air cylinder (7) in response to the electric signals coming from the control means (33). Subsequently, the suck-up part thereof moves upwardly of a cleaning tank (12). An outflow pipe (8') moves above a supply position on the stock solution vessel table (3) by operation of air cylinder (7'). The forward end of the pipe (8) is fixed upwardly of the purge pot (18) when an air cylinder (11) is operated by the electric signals from the control means. The suck-up part of the pipe (8) is then immersed in cleaning water by operating the air cylinder (7). Then pump (9) starts; electromagnetic valve (10) is thereby opened to effect cleaning of the pipe (8) for a predetermined period. Simultaneously with finishing the cleaning operation, the pump (9) stops. The suck-up part of the pipe (8) emerges out of the cleaning water (13) by operation of air cylinder (7). The cleaning water (13) staying in the outflow pipe (8) is discharged into the purge pot (18). After this, the electromagnetic valve (10) is closed. In the meantime, the stock solution vessel (1') disposed on the table (3) stops in the supply position with a turn of the table (3) in response to electric signals from the control means, the vessel (1') accommodating the solution to be preparation-mixed with the dye stock solution (2) which has previously been weighed. The dye stock solution of the vessel (1') flows similarly via the outflow pipe (8') pump (9'). electromagnetic valve (10') and air cylinder (11'). The plurality of dyeing solutions will hereinafter be prepared in conformity with the dye preparation recipe previously inputted to the input means (32) in the same manner. Dilution water is added to a prepared solution (21) within the receiving vessel (20) set in a fixed position on the table (23). The dilution water flows via an outflow pipe (36) into the vessel (20). The pipe (36) is provided with an electromagnetic valve (14). The valve (14) is opened and closed by electric signals coming from the control means in conformity with the dye preparation recipe inputted to the input means (32). A desired amount of dilution water (16) flows therefrom, thus finishing the first preparation. Next, for adding the dilution water on the basis of the second dye preparation recipe previously inputted to the input means (32), the table (23) is turned so that the specified receiving vessel (20) is positioned under the pipe (36). The table (23) stops in a specified position. The electromagnetic valve (14) is opened and closed by electric signals from the control means (33) in conformity with the dye preparation recipe inputted to the input means with the intention of flowing out a desired amount of dilution water (16). The second preparation is thus completed. The third, fourth, ... n-th additions of the dilution water (16) are similarly finished in accordance with the dye preparation recipe inputted beforehand to the input means (32). The desired amount of dilution water (16) is controlled depending on the time of outflow. Hence, the level of water is kept constant by continuously flowing water into an overflow pipe (17) to keep the outflow quantity per unit time to a constant value. As discussed above, in the apparatus of this invention, the outflow pipe for causing outflow of the dye stock solutions and dye auxiliary solutions is always kept clean. Slurry-like liquid dye is usable. Highly accurate and efficient preparation is attainable. The apparatus of this invention is remarkably small in size to thereby facilitate selection of an installing location thereof.

Claims: An apparatus for automatically preparing dyeing solutions, comprising: containers (1', 1'', 1'''...) for respectively accommodating solutions (2', 2'', 2'''...) selected from dye stock and dye auxiliary solutions; a transfer means (3) to be loaded with said containers; receiver vessels (20) for successively receiving measured amounts of solutions (2) from containers (1); a cleaning water tank (12) and a purge pot (18); two outflow pipes (8, 8'), each outflow pipe (8, 8') being provided with a pump (9, 9') and a valve (10, 10'), each outflow pipe being positionable in a supply position in which the suck-up end of an outflow pipe (8) is immersed in a vessel (1) containing dye stock solution or dye auxiliary solution (2) while the discharge end of the outflow pipe (8) is opened towards a receiver vessel (20) so that the solution in the container (1) is caused to flow therefrom into the vessel (20) and in a cleaning position in which the suck-up end of an outflow pipe (8') is immersed in cleaning water (13) and the discharge end of the outflow pipe (8') is opened towards the purge pot (18) so that the pipe (8') is cleaned with cleaning water (13); means (7, 11; 7', 11') associated with said outflow pipes (8; 8') which means are operable to position the pipes interchangeably in a supply or cleaning position; a weighing means (26) for converting into electric signals weight changes of said solutions which have been received in said receiving vessels (20); a transfer means (23) to be loaded with said receiving vessels (20); a control mechanism (33) for continuously or intermittently opening and closing said pump (9) and said valve (10) by making a comparison with a predetermined value in accordance with a level of said electric signal, said control mechanism (33) also controlling the operation of said transfer means (3, 23) and said means (7, 7', 11, 11'); dilution outflow pipe (36) provided with a valve (14) for causing dilution water (16) to flow into said receiving vessels after completion of weighing said solutions therein, said valve (14) being continuously or intermittently opened and closed in accordance with a predetermined value by said control mechanism (33). The apparatus as set forth in Claim 1, wherein said pump (9) is a roller pump. The apparatus as set forth in Claim 1, wherein said pump (9) is a gear pump. The apparatus as set forth in Claim 1, wherein said weighing means (26) is an electronic balance. The apparatus as set forth in Claim 1, wherein at least one of said transfer means (3, 23) is a turntable or a rotary conveyor.

Inventors: FUKUDA SUSUMU, HAYAHARA TAKURO, KATAHIRA HARUO, NISHIDA AKIYOSHI, FUKUDA, SUSUMU, HAYAHARA, TAKURO, KATAHIRA, HARUO, NISHIDA, AKIYOSHI
Applicants: EXCOM CO LTD, JAPAN EXLAN CO LTD, EXCOM CO., LTD, JAPAN EXLAN COMPANY, LTD.
Application year: 1990
Main classification: B01F13
IPC codes: B01F13, D06B23, B01F15