INTELLIGENT COMPOSITE SYSTEM OF LABORATORY DROPPER AND COLOR TEST MACHINE

Abstract

 A composite system comprising a laboratory dropper (20) and a color test machine (50) including a control unit (10), a dropper (20), a dye preparation area (30) provided with sample cloths (32) to be dyed and defining a cup cap placing area (33) and a staining cup combination temporary storage area (34), a robot arm (40) and a color test machine (50) with a plurality of color test machine staining cup positions (51), whereby, according to a process step instructions set by the control unit (10), the robot arm (40) picks up a staining cup (1) that has completed the dripping operation, moves it to the dye preparation area (30) and then puts the staining cup (1) into the color test machine (50).

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention:

[0001] The present invention relates to a laboratory intelligent composite system, in particular to an intelligent composite system of laboratory dropper and color test machine related to the intelligent, modular, automated, unmanned, and precise control of the dyeing and finishing plant laboratory operation process/

2. Description of the Related Art:

[0002] The general dyeing and finishing plant laboratory color test process has the following common problems:

1. Although there is an automatic dropper that can do accurate measurement, manpower is still needed to put the sample cloth into the color test cup, lock the cup cap, and manually take the color test cup and put it into the designated color test machine, and manually set the dyeing temperature rise and fall. After the dyeing process is finished, it is necessary to manually take out the cup and put it into the next batch of color test cups. The entire operation is time-consuming, labor-intensive and error-prone.

2. Referring to FIG. 12, the traditional dropper emphasizes the design of dosing & dye. Its structure includes a dripping area 91, a dyeing area 92 and sample cloths 93 to be dyed located between the dripping area 91 and the dyeing area 92, and a robotic arm 94 that can move and imitate the human arm function. The internal integration of the dropper includes the function of the dyeing machine, in order to expect unmanned operation. But there are the following limitations and problems:

(a) The mother liquid, dripping and dyeing are all placed on the same machine, and a robotic arm 94 can only do one thing at the same time, which is inefficient.

(b) The structure is complex, the volume is too large, and the investment cost is high.

(c) The dripping area 91 can produce 30-60 dyeing recipes per hour, but for each cup position in the dyeing area, only one cup is produced every 2-3 hours, and the efficiency cannot be matched.

(d) The number of dyeing areas is limited. If you want to expand many dyeing areas on the same machine, the structure of the entire machine will become huge and the cost will be too high.

3. Referring to FIG. 13, in the prior art, there is a design that after the dropper 95 drops the liquid, the pipe distributor 96 is used to pipe the dye solution to the dyeing machine 97, and the dye solution completed by the dropper 95 is piped to the dyeing machine 97, in order to expect unmanned operation. However, there are the following limitations and problems, as shown in FIG. 13:

(a) Because the fiber weight of the dyed sample in the laboratory is very small, between a few grams to tens of grams, the dye solution or chemicals are also very small according to the proportion of fiber consumption, and they are also between a few grams to tens of grams. Therefore, even if there is little residue in pipeline transportation, it will cause loss in proportion and affect accuracy.

(b) In addition, the liquor ratio limits the total water volume, which makes it impossible to clean the pipeline with a large amount of water, resulting in residual impact on accuracy.

(c) The distance of the pipeline is limited. The longer the length, the more washing water is needed. In addition, there are valves to control the pipeline switch to increase the cost.

[0003] The above-mentioned problem in the dyeing and finishing plant laboratory color test process really need to be overcome.

SUMMARY OF THE INVENTION

[0004] The present invention has been accomplished under the circumstances in view. It is therefore an object of the present invention to provide an intelligent composite system of laboratory dropper and color test machine that integrates the automatic control of the dyeing process of a dropper, a robotic arm and a color test machine.

[0005] To achieve this and other objects of the present invention, an intelligent composite system of laboratory dropper and color test machine comprises at least one control unit, at least one dropper used to drip out a required dye solution to a plurality of staining cups, at least one dye preparation area adjacent to the at least one dropper, each dye preparation area comprising a plurality of sample cloths to be dyed and defining a cup cap placing area and a staining cup combination temporary storage area, at least one robotic arm adjacent to the at least one dye preparation area, and at least one color test machine adjacent to the at least one robotic arm. Each color test machine comprises a plurality of color test machine staining cup positions. The at least one control unit is electrically connected to the at least one dropper, the at least one robotic arm and the at least one color test machine. The robotic arm picks up each staining cup that has completed the dripping operation and places the saining cup in the staining cup combination temporary storage area according to the process step instructions set by the control unit, and then picks up one sample cloth and puts the sample cloth into the staining cup, and then the robotic arm takes out one cup cap from the cup cap placing area and locks the cup cap to the staining cup, and then the robotic arm puts the staining cup into one designated color test machine staining cup position of the color test machine.

[0006] The beneficial effects of the present invention are: With the connection of the control unit and the robotic arm, the automatic dripper and color test machine of the dyeing and finishing plant laboratory are integrated into intelligent modular and unmanned operations.

[0007] The comparative advantages of the present invention and the prior art are as follows:

Compare items	Traditional dosing & dye all in one machine	Traditional dye solution pipeline delivery to the dyeing machine	The invention
Scalability of the cup position of the dyeing machine	Low.	High.	High.
	The model is fixed and cannot be expanded.	It can be transported to individual dyeing machines using multiple pipelines.	It uses conveying device+robotic arm to link dropper and dyeing machine, and it can be expanded indefinitely.
Dye solution delivery loss	None.	High.	None.
	Directly drop dye solution into dye cup.	Pipeline residue increases pipeline cleaning work and cleaning water volume	It directly drops the dye solution into the staining cup.
Cost of investment	Highest.	Second highest	General
	100 cups of dye solution dropper +18 cups of dye machine about USD250-300 thousands.	100 cups of dye solution dropper +18 cups of dye machine about USD200-250 thousands.	100 cups of dye solution dropper +18 cups of dye machine about USD150-200 thousands.
Degree of automation and unmanned	Limited.	High.	Highest.
	Both the objects to be dyed and the dyed objects are in the machine.	It can continuously deliver dy e solution to the dye machine.	Through the conveying device and the robotic arm, it can automatically output staining cups, automatically fill the objects to be dyed and automatically put the cups in the dyeing machine, to achieve unlimited expansion.
Expanding flexibility	Limited.	Second highest.	Highest.
	Fixed model.	Limited by pipeline cleaning water volume and distance	Through the conveying device and the robotic arm, it can combine multiple droppers and dyeing machine to achieve unlimited expansion.
Central control integration	Single machine control	Single machine control	control unit" 1.Combined with production order scheduling. 2.The dripping formula can be imported from the color measurement and matching system. 3.Schedual setting of conveying device. 4.Direct download of the dyeing process of all dyeing machines.

[0008] Below only by specific embodiments, and accompanied by drawings for detailed description, so that the review committee can have a further understanding of the various functions and features of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] 

FIG. 1 is a top view of an intelligent composite system of laboratory dropper and color test machine in accordance with the present invention.

FIG. 2 is an elevational view of the present invention.

FIGS. 3 to 6 are diagrams of examples of use of the present invention.

FIG. 7 is a top view of the present invention, illustrating the robotic arm installed on the robotic arm moving rails.

FIG. 8 is a top view of the present invention, illustrating the dye preparation area and the robotic arm set on the robotic arm mobile AGV.

FIGS. 9 to 11 are the functional screens displayed on the main-machine interface of the control unit of the present invention.

FIG. 12 is a top view of a conventional dyeing technology and structure.

FIG. 13 is a schematic diagram of the conventional dyeing technology and structure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0010] Referring to FIGS. 1 and 2, an intelligent composite system of laboratory dropper and color test machine in accordance with the present invention comprises a control unit 10, a dropper 20, a dye preparation area 30, a robotic arm 40, and a color test machine 50.

[0011] The dropper 20 is used to drop the required dye solution into several staining cups 1.

[0012] The dye preparation area 30 is adjacent to the dropper 20. The dye preparation area 30 comprises a number of sample cloths 32 to be dyed, a cup cap placing area 33 and a staining cup combination temporary storage area 34.

[0013] The robotic arm 40 is adjacent to the dye preparation area 30.

[0014] The color test machine 50 is adjacent to the robotic arm 40. The color test machine 50 comprises a plurality of color test machine staining cup position 51.

[0015] The control unit 10 is electrically connected to the dropper 20, the robotic arm 40 and the color test machine 50.

[0016] According to the process step instructions set by the control unit 10, the robotic arm 40 picks up the staining cup 1 that has been dripped and places it in the staining cup combination temporary storage area 34, and then picks up the sample cloth 32 and places it into the staining cup 1. Then, the robotic arm 40 picks up a cup cap 331 from the cup cap placing area 33 and locks the cup cap 331 to the staining cup 1. Then, the robotic arm 40 puts the staining cup 1 into the color test machine 50 in the designated position of the color test machine staining cup positions 51.

[0017] In one embodiment, the dropper 20 comprises a conveying device 21 for conveying the staining cup 1 that has completed the dripping operation and receives the dye solution to a dripping completion color test cup area 31 on one side of the dropper 20.

[0018] Accordingly, the staining cup 1 including the dye solution is made closer to the robotic arm 40 and the dye preparation area 30 to facilitate subsequent dye preparation operations.

[0019] In one embodiment, the dye preparation area 30 defines a dye-finished area 35. With the robotic arm 40, the staining cup 1 that has completed the staining operation in the color test machine staining cup position 51 is taken out and placed and collected in the dye-finished area 35.

[0020] The above is an introduction to the composition of each part of the present invention, and then various embodiments, features, and benefits of the present invention are introduced as follows:

[0021] Referring to FIGS. 2, 3, 7 and 9, the gripper of the robotic arm 40 can sequentially take out the staining cups 1 from the dripping completion color test cup area 31 at one side of the dropper 20 and put the staining cups 1 into the staining cup combination temporary storage area 34 of the dye preparation area 30.

[0022] Referring to FIG. 4, the gripper of the robotic arm 40 picks up the sample cloths 32 to be dyed from the dye preparation area 30 and puts them into the respective staining cups 1 in the staining cup combination temporary storage area 34.

[0023] Referring to FIG. 5, then, the gripper of the robotic arm 40 picks up the corresponding cup caps 331 from the cup cap placing area 33 and locks them to the respective staining cups 1 in the staining cup combination temporary storage area 34.

[0024] Referring to FIG. 6, then, the gripper of the robotic arm 40 sequentially picks up the staining cup 1 from the staining cup combination temporary storage area 34 and places them in the respective designated color test machine staining cup positions 51 in the color test machine 50.

[0025] Referring to FIGS. 6 and 7, in one embodiment, the dye preparation area 30 defines a dripping completion color test cup area 31 for the placement of the staining cups 1 that has completed the dripping operation and receives the dye solution.

[0026] The conveying device 21 of the dropper 20 can extend to the dripping completion color test cup area 31 to directly deliver the staining cups 1 that has completed the dripping operation and receives the dye solution to the dripping completion color test cup area 31.

[0027] In one embodiment, the robotic arm 40 is installed on two robotic arm moving rails 41 and can be moved through the robotic arm moving rails 41, which is conducive to putting the staining cups 1 in the dye preparation area 30 into the designated color test machine staining cup positions 51 in the color test machine 50.

[0028] Referring to FIG. 8, in one embodiment, the dye preparation area 30 and the robotic arm 40 are set on a robotic arm mobile AGV (Auto Guided Vehicle) 42. With the mobility of the robotic arm mobile AGV 42, it is conducive to putting the staining cups 1 in the dye preparation area 30 into the designated color test machine staining cup positions 51 in the color test machine 50.

[0029] Referring to FIG. 1, in one embodiment, the control unit 10 comprises a sequential arranging operation control module to control the sequential arranging operation of dyeing. Please refer to the function screen displayed on the human-machine interface of the control unit 10 shown in FIG. 9:
Background: The sequential arranging operation control module responds to customer needs such as fast, small quantity, diversification, fast response, and B2C. It needs to be flexible and reasonably planned according to the production capacity and process flow of the production machine.

[0030] Example: Taking time as the main axis, according to different order requirements, such as material, sample cylinder size, capacity load and other conditions, select a suitable color test machine 50 for proper cylinder work.

[0031] For example, H11 and H12 in FIG. 9 are staining cups 1 stained with 500cc; H23 and H25 are staining cups 1 stained with 1000 cc. The order staff arranges different orders on their respective machines according to the cloths to be proofed and the total bath volume. After the dye solution dripping operation of the dropper 20, the robotic arm 40 will put the staining cups 1 of different sizes into different color test machines 50, and the color test machines 50 will perform temperature control according to the coloring process required for the temperature rise and fall on the order.

[0032] Efficacy: Deploying and improving the overall dyeing time, energy and other benefits, and improving the accuracy of color matching.

[0033] Referring to FIG. 1, in one embodiment, the control unit 10 comprises a drop sequence and recipe control module to control the drop sequence and recipe arrangement of the dropper 20.

[0034] Please refer to the function screen displayed on the human-machine interface of the control unit 10 shown in FIG. 10:
Background: Select the suitable staining cups 1 according to the different dyeing volume requirements and place the staining cups 1 on the dropper 20 for dripping according to the color order requirements of the current order.

[0035] Example: The dropper 20 drops the required dyes and additives into each staining cup 1 according to the formula, as shown in FIG. 10:

1. For example, 1-6 staining cups 1 can all be the same 500cc size cups, so they are placed in the same batch.

2. For example, 1-6 staining cups 1 can all be stained with the same cloth, so they are placed in the same batch.

3. For example, 1-6 staining cups 1 can all be placed in the color test machine staining cup positions 51 of the same color test machine 50, so they are placed in the same batch.

4. For example, 1-6 staining cups 1 can all use the same reagent together, so put them in the same batch. For example, the fourth staining cup and the sixth staining cup have repeated No.94 bottle mother liquid, which can reduce the action of taking reagents and increase the speed of the entire dripping.

[0036] When the dripping is completed and the staining cup 1 is delivered to the dripping completion color test cup area 31, the control unit 10 will notify the robotic arm 40 to move the staining cup 1 to the staining cup combination temporary storage area 34 and put the sample cloth 32 into the staining cup 1, and take a cup cap 331 from the cup cap placing area 33 and lock the cup cap 331 to the staining cup 1, and then the robotic arm 40 will take the staining cup 1 to the designated color test machine 50 according to the instruction of the control unit 10.

[0037] Efficacy: Effectively and accurately arrange the reagents required for rapid drip metering, reducing errors and improving dyeing reproducibility.

[0038] Referring to FIG. 1, in one embodiment, the control unit 10 comprises a dyeing temperature rise and fall control module, used to control and set the dyeing temperature rise and fall curve of the color test machine 50.

[0039] Please refer to the function screen displayed on the human-machine interface of the control unit 10 shown in FIG. 11:
Background: Because different materials (such as cotton, polyester fibers) correspond to dyes correspond to different dyes (such as acid dyes, disperse dyes) and different colors (such as light colors, dark colors), they must be controlled according to the specific temperature rise and fall to achieve correct dyeing.

[0040] Example: According to the control unit 10 list setting, load the set different temperature rising and falling dyeing process to control the dyeing to avoid human setting errors. When the dyeing process is completed, the control unit 10 is notified, and the control unit 10 calls the robotic arm 40 to take out the staining cup 1 to the dye-finished area 35.

[0041] Efficacy: Improve the accuracy of dyeing, and change the formula conditions to the benefit of more accurate color matching when mass production.

[0042] The invention can include more than one dropper 20, and the data and control between various droppers 20 can communicate with one another or with the control unit 10.

[0043] The invention can include more than one robotic arm 40. The robotic arm 40 can be replaced by a similar drive mechanism for upper and lower objects. The data and control between various robotic arms 40 can communicate with one another or with the control unit 10.

[0044] The invention can include more than one color test machine 50 or similar color test mechanism. The data and control between color test machines 50 can communicate with one another or with the control unit 10.

[0045] Although particular embodiments of the present invention have been described in detail for purposes of illustration, various modifications and enhancements may be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be limited except as by the appended claims.

Claims

1. An intelligent composite system of laboratory dropper and color test machine, comprising:

at least one control unit;

at least one dropper, used to drip out a required dye solution to a plurality of staining cups;

at least one dye preparation area adjacent to said at least one dropper, each said dye preparation area comprising a plurality of sample cloths to be dyed and defining a cup cap placing area and a staining cup combination temporary storage area;

at least one robotic arm adjacent to said at least one dye preparation area; and

at least one color test machine adjacent to said at least one robotic arm, each said color test machine comprising a plurality of color test machine staining cup positions;

wherein said at least one control unit is electrically connected to said at least one dropper, said at least one robotic arm and said at least one color test machine; said at least one robotic arm picks up each said staining cup that has completed the dripping operation and places the said saining cup in said staining cup combination temporary storage area according to the process step instructions set by said at least one control unit, and then picks up one said sample cloth and puts the said sample cloth into the said staining cup, and then the said robotic arm takes out one cup cap from said cup cap placing area and locks said cup cap to the said staining cup, and then the said robotic arm puts the said staining cup into one designated color test machine staining cup position of said color test machine.

2. The intelligent composite system of laboratory dropper and color test machine as claimed in claim 1, wherein each said dropper comprises a conveying device used to deliver each said staining cup that has completed the dripping operation and receives said dye solution to said dripping completion color test cup area at one side of said at least one dropper.

3. The intelligent composite system of laboratory dropper and color test machine as claimed in claim 1, wherein each said dye preparation area defines a dye-finished area; each said robotic arm is controllable by said at least one control unit to take out each said staining cup that has completed the staining operation at one said color test machine staining cup position and place the said staining cup in said dye-finished area.

4. The intelligent composite system of laboratory dropper and color test machine as claimed in claim 1, wherein each said dye preparation area defines a dripping completion color test cup area for the placement of each said staining cup that has completed the dripping operation and receives said dye solution.

5. The intelligent composite system of laboratory dropper and color test machine as claimed in claim 1, wherein each said robotic arm is installed on two robotic arm moving rails.

6. The intelligent composite system of laboratory dropper and color test machine as claimed in claim 1, wherein said at least one dye preparation area and said at least one robotic arm are set on a robotic arm mobile auto guided vehicle.

7. The intelligent composite system of laboratory dropper and color test machine as claimed in claim 1, wherein each said control unit comprises a sequential arranging operation control module to control the sequential arranging operation of dyeing.

8. The intelligent composite system of laboratory dropper and color test machine as claimed in claim 1, wherein each said control unit comprises a drop sequence and recipe control module, used to control the drop sequence and recipe arrangement of said at least one dropper.

9. The intelligent composite system of laboratory dropper and color test machine as claimed in claim 1, wherein each said control unit comprises a dyeing temperature rise and fall control module, used to control and set the dyeing temperature rise and fall curve of said at least one color test machine.

Drawing