CN113039320A

CN113039320A - System and method for on-line processing of one or more wires for use with wire consuming equipment

Info

Publication number: CN113039320A
Application number: CN201980060411.0A
Authority: CN
Inventors: M·伊克林德; J·斯泰伯格
Original assignee: Coloreel Group AB
Current assignee: Coloreel Group AB
Priority date: 2018-09-15
Filing date: 2019-08-27
Publication date: 2021-06-25
Anticipated expiration: 2039-08-27
Also published as: JP2021535968A; KR20210057164A; AU2019337356A1; CA3112827A1; EP3850134A4; ZA202102275B; EP3850134A1; TW202030394A; AR116386A1; WO2020055300A1; CN113039320B; SE1851097A1; SE543831C2; IL281386A; US20220056626A1

Abstract

A system (10) for online processing of one or more wires (20a-b) is provided for use with a wire consuming device (15). The system comprises: a treatment device (100) having a plurality of nozzles (152a-f) distributed in at least a first and a second distribution area (154a-b), the distribution areas (154a-b) being separated in a direction perpendicular to the longitudinal direction of the at least one wire (20a-b), the wires (20a-b) being in motion in use, each nozzle (152a-f) being configured to distribute one or more coating substances at least onto the at least one wire (20a-b) when activated; and a control unit (190) configured to independently control activation of each dispensing zone (154a-b) of the nozzles (152 a-f). A method is further provided.

Description

System and method for on-line processing of one or more wires for use with wire consuming equipment

Technical Field

The invention relates to the technical field of wire consumption equipment. In particular, the invention relates to a system comprising a processing unit for use in connection with such a wire consuming apparatus.

Background

It has been proposed to provide a thread consuming device, such as an embroidery machine or the like, with an in-line apparatus designed to provide some treatment to the thread. Such in-line devices may be used, for example, to color thread such that multiple color nozzles may replace multiple pre-colored threads currently in use when producing multi-color patterns using embroidery machines. In prior art systems using wires of different colors, one wire with a first designated color is used for certain stitches (stiches) and another wire with a second designated color is used for other stitches.

In order to obviate the apparent disadvantage of requiring a plurality of wires of different colours, the applicant has already filed a number of patent applications relating to the in-line colouring (in-line colouring) technology of wires, such as WO2016204687 and WO 2016204686. The proposed solution provides an improvement in the quality of the color while also reducing the complexity of the wire consuming equipment.

However, in order to further improve the quality and efficiency of the in-line coloring of the wire, it would be advantageous if the in-line coloring apparatus could process multiple wires simultaneously.

Disclosure of Invention

It is therefore an object of the present invention to provide a solution that overcomes the drawbacks of the prior art. More specifically, the invention provides a solution wherein a system for online processing of wire is configured to: by dividing the nozzle into different dispensing zones which can be controlled individually, more than one strand can be treated simultaneously.

In a first aspect, a system for online processing of one or more wires for use with a wire consuming device is provided. The system comprises: a processing unit having a plurality of nozzles distributed in at least first and second distribution areas, which can be separated in a direction perpendicular to the longitudinal direction of the at least one wire, which is in motion in use, each nozzle being configured to distribute one or more coating substances at least onto the at least one wire when activated; and a control unit configured to independently control activation of each dispensing zone of the nozzle.

Some wire consuming devices require the use of multiple individual wires simultaneously. The solution of equipping each wire with a separate system is not advantageous because it is both expensive and space consuming. There are therefore advantages to having a single system that can treat multiple wires simultaneously with a coating substance. With the system described herein, it is possible to simultaneously coat multiple wires, for example, with different coating substances (e.g., different colors).

The plurality of nozzles may be arranged in one or more nozzle arrays. In one embodiment, the plurality of nozzles are arranged in a nozzle array, and wherein the nozzle array is arranged at an angle with respect to the direction of the at least one wire.

The plurality of nozzles may be arranged in at least two nozzle arrays. The at least two nozzle arrays may be parallel to each other.

The nozzle array may be disposed at an angle with respect to a direction of the at least one wire.

In one embodiment, at least a portion of the nozzles of the first nozzle array are distributed in the first distribution area and at least a portion of the nozzles of the second nozzle array are distributed in the second distribution area.

In one embodiment, all nozzles of the first nozzle array are distributed in the first distribution area and all nozzles of the second nozzle array are distributed in the second distribution area.

In one embodiment, the system is provided for in-line processing of at least a first and a second wire, and wherein the control unit is configured to independently control activation of the nozzles of each distribution area such that the first wire may be processed by the first distribution area and the second wire may be processed simultaneously by the second distribution area.

In one embodiment, the control unit is configured to: activation of each dispensing zone is controlled by sending a trigger signal to a nozzle disposed in the particular dispensing zone.

The control unit may be configured to activate the nozzles of one dispensing zone individually.

The control unit may be configured to: the nozzles of one dispensing zone are individually enabled with a predetermined offset (offset) from receiving the trigger signal.

In one embodiment, the first and second wires are different from each other.

In one embodiment, the nozzles are inkjet nozzles.

In one embodiment, the system further comprises a wire consuming device. The thread consuming device may be an embroidery machine, a sewing machine, a knitting machine, a loom, a tufting machine, a winding machine and or any combination thereof.

In a second aspect, a method for in-line processing of at least one wire is provided. The method comprises the following steps: providing a treatment unit having a plurality of nozzles distributed in at least first and second distribution areas, the distribution areas being separated in a direction substantially perpendicular to a longitudinal direction of the at least one wire, the wires being in motion in use, each nozzle being configured to, when activated, distribute one or more coating substances at least onto the at least one wire; and providing a control unit configured to independently control activation of each dispensing zone of the nozzle.

Definition of

A wire consuming device in this context refers to any device that consumes wire when in use. It may be, for example, an embroidery machine (weaving machine), a weaving machine (weaving machine), a sewing machine (weaving machine), a knitting machine (knitting machine), a weaving machine (weaving machine), a tufting machine (tufting machine), a winding machine (winding machine), or any other wire consuming device that may benefit from surface treatment or coating or any other process involving subjecting the wire to the influence of a substance, such as dyeing.

By treatment is meant in this context any process designed to cause a change in the properties of the wire. Such processes include, but are not limited to, coloring, wetting, lubricating, cleaning, fixing, heating, curing, dyeing, and the like.

A wire in this context is a flexible, elongated member or substrate that is thin in width and height directions and has a longitudinal extension that is significantly greater than the longitudinal extension of any component of the system described herein as well as its own width and height dimensions. In general, a wire may be composed of multiple strands (plies) that are bundled or twisted (twisted) together. Thus, the term wire includes yarns (yarn), threads (wire), strands (strand), filaments (filament), etc. made of various materials, such as glass fibers, wool, cotton, synthetic materials such as polymers, metals, polyesters, viscose, or mixtures of, for example, wool, cotton, polymers or metals, or any combination thereof.

In this specification, all references to upstream and/or downstream should be interpreted as relative positions during normal operation of the wire consuming apparatus (i.e. when the apparatus is operating to process an elongate substrate such as a wire moving continuously through the apparatus in a normal direction of operation). Thus, the upstream member is arranged such that a certain portion of the wire passes through the upstream member before it passes through the downstream member.

Drawings

Embodiments of the present invention will be described in the following description of the present invention; reference is made to the accompanying drawings that illustrate non-limiting examples of how the inventive concepts can be reduced to practice.

FIG. 1a is a schematic of a system for in-line processing of wire according to one embodiment;

FIG. 1b is a perspective view of a system having a wire consuming device and a processing unit according to one embodiment;

FIG. 2 is a schematic diagram of a processing unit for use with the system, according to one embodiment;

FIG. 3 is a schematic view of a release device forming part of the processing unit;

FIG. 4a is a schematic top view of a portion of a release device according to one embodiment;

FIG. 4b is a schematic top view of a portion of a release device according to one embodiment;

FIG. 5a is a schematic diagram of a portion of a processing unit, according to one embodiment;

FIG. 5b is a schematic diagram of a portion of a processing unit, according to one embodiment;

FIG. 5c is a schematic diagram of a portion of a processing unit, according to one embodiment;

FIG. 5d is a schematic diagram of a portion of a processing unit, according to an embodiment;

FIG. 5e is a schematic diagram of a portion of a processing unit, according to one embodiment;

FIG. 5f is a schematic diagram of a portion of a processing unit, according to an embodiment;

FIG. 6a is a schematic diagram of a system, according to an embodiment, an

FIG. 6b is a schematic diagram of a system according to one embodiment.

Detailed Description

The concept of the present invention is to provide a system and method for distributing a coating substance onto a wire in a controlled manner for use with a wire consuming device. Beginning with fig. 1a, a schematic diagram of a system 10 for in-line processing of wire is shown. The system 10 includes: a processing unit 100 for dispensing one or more coating substances onto at least one wire. The system 10 further comprises: at least one thread consuming device 15, which may be in the form of, for example, one or more embroidery machines, looms, sewing machines, knitting machines, tufting machines, winding machines, etc. The system thus constitutes a wire consuming unit, which comprises the at least one wire consuming device 15 and the processing unit 100. It should be noted that more than one wire may be used in the wire consuming apparatus.

It should be noted that aspects of the system are described in this specification and need not include the wire consuming device 15. As will be further understood from the following, for all embodiments, the system for the on-line treatment of wire requires a treatment unit 100 to be used with the wire consuming device 15.

Referring now to fig. 1b, the thread consuming device 15 is exemplified by an embroidery machine, here illustrated as a single head embroidery machine, which is equipped with a processing unit 100. The embroidery machine 15 comprises a movable stage 2b which carries the fabric to be embroidered. During operation, the movable stage 2b is controlled to rapidly change its position in the X and Y directions (i.e. in this case a horizontal plane, but may also be in a vertical plane).

The processing unit 100 enables the embroidery machine 15 to operate without requiring a unique supply of pre-colored thread material as is required with conventional embroidery machines. Instead, the processing unit 100 provides an on-line coloring of the thread 20 according to a predetermined coloring pattern, so that colored embroidery can be produced. Thus, the processing unit replaces the individual wire volumes (thread returns) present in prior art systems.

As shown in fig. 1b, the only connections between the processing unit 100 and the embroidery machine 15 are the thread 20 and the electrical connections (not shown). Thus, the processing unit 100 is provided as a separate unit without mechanical connection to the movable stage 2 b. In an alternative embodiment, the separate processing unit 100 is mounted to the wire consuming device 15 via a suspension arrangement to reduce the vibrations transmitted to the processing unit 100.

The system 10 described herein is capable of treating one or more wires 20a-c with a coating substance using only one treatment unit 100. If multiple wires are used in the system 10, different coating substances may be dispensed onto different wires 20a-c simultaneously. Additionally or alternatively, the coating substance may be dispensed in different patterns for different wires 20 a-c.

The various components of a processing unit 100 configured to process one or more wires are shown in fig. 2. In the following, the system will be described for the use example of two wires, however it should be understood that the system may be applied to a single wire or more than two wires.

Most or all of the components of the system 10 may be disposed within the housing.

Each wire 20a-b is arranged to pass through a respective coil 120 a-b. Immediately downstream of the coils 120a-b, wire feeders 130a-b are provided — one wire feeder 130a-b for each wire 20 a-b. The wire feeder 130 may be configured to pull the wire forward through the processing unit 100. The wire feeders 130 are not further described herein, but for a more general understanding, each wire feeder 130 receives and advances its respective wire 20 a-b. To this end, the wire feeder 130 may be controlled by a control unit 190, described further below. After the wires 10a-b have passed through their respective wire feeders 130, each wire 20a-b is engaged with a respective wire guide 140 a-b. Each wire guide 140a-b may, for example, be in the form of one or more guide rollers or in the form of other suitable means which ensure that its wire 20a-b is aligned with one or more treatment nozzles which form part of at least one discharge device 150. The two wires 20a-b then pass through the common release 150.

The release device 150 is configured to: the release device 150 releases a treatment substance (e.g., a coloring substance) onto the wire 20 as the wire 20 passes through the release device 150. For this purpose, the nozzles are preferably arranged in the longitudinal direction of the wire 20, as will be further explained in connection with fig. 3 to 5.

The release device 150, or parts of the release device 150, such as the print heads 151a-d (shown in fig. 3), may be movable by means of a drive unit (not shown). With a drive unit, this makes it possible: the release device 150 or parts of the release device 150 are arranged in different operating states in order to perform different tasks, such as a first state (dispensing coating substance to the wire) and a second state (performing a cleaning cycle or other maintenance or idling (idling)).

Downstream of the release device 150, the wires 20a-b are separated onto respective wire guides 160 a-b. The second wire guides 160a-b cooperate with the respective first wire guides 140a-b such that the position of the respective wires 20a-b during their travel along the release device 150 is correct. The second wire guide 160 may, for example, be in the form of one or more guide rollers, although it may also be designed to guide the wire 20 in rotation along its longitudinal axis.

The system 10 may further include a common, or two separate, or any number of wire speed sensors (not shown) configured to measure the speed of the wires 20a-b through the system 10.

Furthermore, a common, or two separate, light detection systems (not shown) may be provided downstream of the release device 150 in the direction of travel of the wires 20 a-b. The light detection system is arranged to illuminate the wires 20a-b so as to receive light reflected from the wires 20a-b when the wires 20a-b are illuminated. The information gathered from the light detection signals may be used, for example, to determine the position of the wires relative to the nozzles 152a-f, the width of each wire, and/or the properties of each wire. This information, in turn, may be used, for example, to detect nozzles that require maintenance, nozzles that require repositioning, and/or to detect changes in coating material. Additionally or alternatively, the light detection system may be used to determine different properties of a wire that has been coated with one or several coating substances.

The wires 20a-b are then advanced to pass through one or more securing units 170 provided for securing a treatment substance to the wires 20 a-b. The fixing unit may be common to both wires or provided as two separate units-one fixing unit being provided for each wire 20 a-b. The fixing unit 170 preferably includes a heating device, such as a hot air supply or a heating element, or an ultraviolet light source, in order to cure or fix the treatment substance (e.g., coloring substance) to the wire 20. As shown in fig. 2, the fixing unit 170 may be disposed horizontally, vertically, or at an angle between horizontal and vertical.

The wires 20a-b may pass through a cleaning unit 180 (e.g., an ultrasonic bath) before exiting the housing where unwanted particles are removed from the wires 20 a-b. The cleaning unit may be common to both wires or provided as two separate units-one cleaning unit being provided for each wire 20 a-b. Since the treatment substance is immobilized on the wires 20a-b, the cleaning unit 180 will leave the treatment substance unaffected.

The processing unit 100 may further include a lubrication unit (not shown). The lubricating unit may be common to both wires or provided as two separate units-one lubricating unit being provided for each wire 20 a-b. Additional wire buffers (buffers) and feeders (not shown) may also be included in the processing unit 100, disposed at different locations in the wire path.

The thread 20a-b preferably leaves the processing unit 100 via a hole or the like, whereby the thread 20a-b is advanced to an associated thread consuming device (e.g. the embroidery machine 15 shown in fig. 1 a-1 b).

A control unit 190 with associated electronics (e.g., power electronics, communication module, memory, etc.) is also provided. The control unit 190 is connected to the wire feeders 130a-b, the releasing means 150 and the fixing unit 170 to allow the operation of these components to be controlled. Further, the control unit 190 is configured to control the operation of the entire processing unit 100 (including the cleaning unit 180, the lubricating unit), the interruption of the wires 20a-b, the speed of the wires at various positions along the processing unit 100, wire buffers, etc. The control unit 190 may also be configured to receive control signals from one or more components of the processing unit 100, such as control signals for triggering specific controls, or other information related to, for example, the consumption of thread by the embroidery machine 15.

The control unit 190 may be implemented by any commercially available CPU ("central processing unit"), DSP ("digital signal processor") or any other electronic programmable logic device, or a combination of these processors or other electronic programmable logic devices. The control unit 190 may be implemented using instructions capable of performing hardware functions, for example, by using executable computer program instructions in a general-purpose or special-purpose processor, which instructions may be stored on a computer readable storage medium (disk, memory, etc.) for execution by such a processor. The storage medium is preferably in operative communication with the control unit 190.

In one embodiment, a user interface is also provided, preferably via a display provided at the front end of the housing. The display allows a user to interact with and thus interface with the control unit 190 so that control parameters of the wire feeder 130, the releasing device 150, the fixing unit 170, etc. may be set according to process specifications. The display may also preferably be used to alert the user to an event of interest, whereby the display may be used to control unit 190 to issue an alarm or the like.

It should be noted that the above-mentioned components may not necessarily be included in a separate processing unit 100, but the components of the processing unit 100 may be divided into several units. Preferably, the separate unit comprises at least said at least one release means 150. In one embodiment, these components are not provided as separate units, but are integrated with the wire consuming device 15.

In fig. 3, a release device 150 is shown, which forms part of the above-described processing unit 100. The solid arrows in fig. 3 indicate the direction of movement of the wires 20a-b in use. As will be described in greater detail, the release device 150 includes a plurality of nozzles 152a-f, the plurality of nozzles 152a-f being disposed at different longitudinal positions (e.g., spaced apart by a distance d 1) along the wire 20 that passes through the processing unit 100 during use.

Each nozzle 152a-f is configured to: when the nozzle is activated, a coating substance (e.g., ink) is dispensed onto the wire 20. The coating substance is absorbed by the wire 20, for example, at different circumferential positions of the wire 20 when the wire 20 is twisted about its longitudinal axis. The relative positions of two adjacently dispensed droplets of coating substance may be selected such that the two droplets will overlap.

The processing unit 100 includes one or more release devices 150. Each discharge device 150 is preferably formed as a series of inkjet print heads 151a-d, each print head 151a-d having one or more nozzle arrays. Each nozzle array typically includes hundreds or thousands of nozzles. For illustrative purposes, only six nozzles 152a-f are shown for one printhead 151 a-d; it should be appreciated, however, that each nozzle array may be individually provided with hundreds or thousands of nozzles 152. As an example, each printhead 151a-d may be associated with a single color; in the example shown, the discharge device 150 has four print heads 151a-d, each print head 151a-d being associated with a particular color according to the CMYK standard. However, other coloring models may be used.

The specific configuration of the processing unit 100 may vary. For example, the processing unit 100 is provided with a single discharge device 150 having a plurality of print heads 151 a-d. Each print head 151a-d is in turn provided with a plurality of nozzles 152 a-f.

In another embodiment, the processing unit 100 is provided with a plurality of release devices 150, which may be arranged in series or in parallel. Each discharge device 150 is then provided with a plurality of print heads 151 a-d. If arranged in series, the upstream discharge 150 may have print heads 151a-d associated with one or more colors of a particular color standard, while the downstream discharge 150 has print heads 151a-d associated with other colors of the same color standard. If arranged in parallel, each discharge device 150 may have print heads 151a-d associated with all colors of a particular color standard, but associated with different wires 20. For such embodiments, two separate wires 20 may be processed simultaneously in parallel. Of course, a combination of parallel/series configurations is also possible.

In another embodiment, the discharge device 150 has only a single print head 151 a-d; thus, dynamic coloring of the wire 20 would require multiple releases 150 of the processing unit 100.

Each nozzle 152a-f may dispense a coating substance having a color according to a CMYK color model, wherein the primary colors are Cyan (Cyan), Magenta (Magenta), Yellow (Yellow) and Black (Black). Thus, multiple colors may be dispensed onto the strand by activating the nozzles 152a-f such that the total coloring matter of a particular length of the strand 20 will be a mixture of the coloring matter dispensed by the nozzles 152 a-f. As explained earlier, this is preferably achieved by having a plurality of print heads 151a-d arranged in series, whereby the nozzles 152a-f of a particular print head 151a-d are dedicated to a single color.

In another embodiment, each nozzle 152a-f dispenses a coating substance having a color that is a mixture of two or more primary colors of the CMYK color model.

The control unit 190 is configured to control activation of the nozzles 152a-f such that: as the wire 20 passes through the processing unit 100, in particular through the release device 150, the coating substance is emitted onto the wire 20. With such a configuration it is possible to color the thread 20 very precisely, for example in order to provide, by means of the coloration provided by the processing unit 100, high-grade embroidery patterns that are extremely visually complex.

For a shading operation, the control unit 190 receives one or more input signals specifying a desired color and/or shading effect. The color input preferably comprises information about: the exact color, and the longitudinal starting and stopping positions of the wire 20 for that particular color. The longitudinal start and stop positions may be represented by specific time values if the wire speed is determined.

Fig. 4a to 4b show respective top views of the print heads 151 a. The print head 151a has a planar surface on which the nozzles 152 are disposed. As previously mentioned, the total number of nozzles 152 of a single print head can reach thousands, being arranged on the print head 151a in the size of a few centimeters. In the illustrated example, a much smaller number of nozzles 152 are shown. The nozzles 152 may be distributed in one or more nozzle arrays 153 a-b. In FIG. 4a, the nozzles 152 are distributed in two parallel arrays 153 a-b. The arrays 153a-b are aligned with each other such that the nozzles 152 of one array 153a-b are disposed adjacent to the nozzles 152 of another array 153 a-b.

FIG. 4b shows a similar example, however with a longitudinal offset between the two arrays 153 a-b.

The dispensing of the coating substance onto the plurality of wires is preferably achieved by arranging the nozzle of the delivery device 150 in several dispensing zones 154a-c which can be controlled independently. Some example embodiments will now be described with reference to fig. 5a to 5 f. In fig. 5a to 5f, the print head 151a is arranged to dispense a coating substance onto at least two wires 20a-b, and in fig. 5d, a situation with three wires 20a-c is shown.

It should be noted that the following also applies to a larger number of wires, such as four, five, etc. In a preferred embodiment, the wires 20a-c are parallel to each other. Further, all of the wires 20a-c used in the system may be of the same thickness, or of different thicknesses. Furthermore, all wires 20a-c used in the system may be of the same type or of different types having different properties.

Figure 5a shows a print head 151a with two nozzle arrays 153 a-b. In this embodiment, nozzle arrays 153a-b are arranged parallel to one another. The nozzles 152a-f of the nozzle arrays 153a-b are arranged in two distribution areas 154 a-b. The distribution areas 154a-b are divided in a direction perpendicular to the longitudinal direction of the wires 20 a-b. In the present embodiment, the nozzles of the first nozzle array 153a are distributed in the first distribution area 154a, and the nozzles of the second nozzle array 153b are distributed in the second distribution area 154 b. In the illustrated example, all of the nozzles 152a-f of each nozzle array are part of the same distribution area 153 a-b. However, as shown in FIGS. 5 b-5 c, not all nozzles 152a-f of the same array 153a-b necessarily belong to the same distribution area 154 a-b. In this example, the first distribution area 154a is configured to distribute the coating substance onto the first wire 20a, while the second distribution area 154b is configured to distribute the coating substance onto the second wire 20 b.

In fig. 5a, the print head 151a is arranged along the length of the wires 20 a-b. The nozzle arrays 153a-b are aligned with the length of the wires 20 a-b.

It should be noted that the print head 151a shown in fig. 5a may also be defined to have ten nozzle arrays each including two nozzles. Under this definition, the nozzle array is perpendicular to the length of the wires 20a, b. This situation is shown in fig. 5 f.

Fig. 5b shows a print head 151a with a single nozzle array 153 a. The nozzles 152a-f of the nozzle arrays 153a-b are arranged in three distribution zones 154 a-c. In this embodiment, the nozzles covering (i.e. capable of dispensing a coating to) the first wire 20a are distributed in a first distribution area 154a, while the nozzles covering the second wire 20b are distributed in a second distribution area 154 b. Here, the intermediate distribution area 154c is provided for those nozzles that are not covered by any of the wires 20 a-b.

In fig. 5b, the print head 151a and its nozzle array 153a are arranged: which is inclined compared to the length of the wires 20 a-b. Thus, the nozzle array 153a is disposed at an angle relative to the length of the parallel wires 20 a-b. The angle is greater than or less than 0 degrees. The nozzle arrays are inclined with respect to the direction of the wire so that more than one wire can be processed simultaneously using a single nozzle array. The larger the angle between the nozzle array and the strand, the more strands that are possible to color with one nozzle array. The trade-off with larger angles is: each strand 20a-b can be colored with fewer nozzles per nozzle array.

The length of the nozzle array may preferably be at least as long as the distance taken up by the wire 20 rotating one turn around itself by 180 deg., more preferably at least as long as the distance taken up by the wire 20 rotating 360 deg. around itself. To this end, some mechanism may be provided to cause rotation of the wire as it passes through the processing unit.

Fig. 5c shows a print head 151a similar to that of fig. 5a, except that: the print head 151a and its parallel nozzle arrays 153a-b are arranged at an angle compared to the parallel wires 20a-b and not all nozzles 152a-f of the same array 153a-b are part of the same dispensing zone 154 a-b. Having both nozzle arrays inclined with respect to the direction of the wire allows the nozzles of both nozzle arrays to dispense a coating onto both wires 20 a-b. The larger the angle between the nozzle array and the strand, the more strands can be colored with each nozzle array. The trade-off with larger angles is: each strand 20a-b can be colored with fewer nozzles per nozzle array.

Fig. 5d shows a print head 151a similar to that of fig. 5a, except that: the printhead includes three parallel nozzle arrays 153a-c and three dispensing zones 154 a-c. Furthermore, in fig. 5d, the print head 151a is arranged to dispense the coating substance onto at least three parallel wires 20 a-c.

Fig. 5e shows a print head 151a similar to that of fig. 5a, except that: the nozzles are distributed in six different distribution areas 154 a-f. Each

nozzle array

153a, 153b comprises different segmented nozzles containing different coating substances, such as different colors, as shown by the pattern-filled nozzles in fig. 5 e. Each segmented nozzle having a different coating substance is considered a distribution zone 154 a-f. Thus, each

nozzle array

153a, 153b may comprise a different color, with each dispensing zone 154a-f being a different color. Although fig. 5e shows a print head 151 comprising two identical nozzle arrays, it should be noted that the nozzle arrays need not be identical to each other.

Fig. 5f shows a print head 151a similar to that of fig. 5a, having two dispensing zones 154a-b, each covering one wire 20 a-b. Here, the wires 20a-b are shown as having different thicknesses. Depending on the thickness or width of the wires 20a-b, different numbers of nozzles will cover the wires 20 a-b. It should be noted that the dimensions of the nozzle of fig. 3-5 are drawn exaggerated relative to the thickness and/or width of the

wires

20a, 20b for illustrative purposes only.

In addition to the components described with reference to FIG. 2, the system 10 may also include one or more encoders (not shown). In one embodiment, the number of wires 20a-b and the number of encoders in the system 10 are the same, thereby providing one encoder for each wire 20 a-b. Each encoder is arranged to trigger a dispense signal to each nozzle of the dispense zone. In yet another embodiment, one single encoder is provided for all wires 20 a-b. Thus, the one encoder is configured to trigger the dispensing signal to individual (individual) nozzles of the dispensing zone and/or to all dispensing zones.

The encoder may include or be in communication with a wheel, such as a pulley or guide roller. For example, the encoder may be a rotary encoder or a shaft encoder.

The control unit 190 is configured to independently control the activation and deactivation of each of the dispensing zones 154a-c of the nozzles 152 a-f. To this end, the control unit 190 may be configured to: a trigger signal is sent to the nozzles 152a-f that are disposed in a particular dispensing zone 154 a-c. Additionally or alternatively, if the nozzles disposed in one nozzle array 153a-c are distributed into one single dispensing zone 154a-c, the control unit 190 may be configured to send a trigger signal to each nozzle array 153a-c to activate or deactivate that array and the nozzles of that dispensing zone.

The control unit 190 may be further configured to: the activation and deactivation of the nozzles 152a-f in each distribution zone 154a-b is individually controlled by sending a trigger signal to the nozzles 152a-f disposed in that particular distribution zone 154 a-c.

The control unit 190 may be further configured to: the nozzles of one dispensing zone 154a-c are individually enabled using a predetermined offset from receipt of the trigger signal. The offset may be, for example, a particular time, length, or a combination of both.

In one embodiment, the first wire 20a-b is provided with a trigger for activating the nozzles 152a-f distributed in the first distribution area 154a, while the second wire 20b is provided with a trigger for activating the nozzles 152a-f distributed in the second distribution area 154 b.

Each wire 20a-b may have its own trigger for activating the nozzle of its dispensing zone, i.e. the nozzle arranged in the dispensing zone covering the wire 20 a-b. In one embodiment, all allocation zones are provided with one common trigger.

The control unit 190 may be further configured to change the size of the allocation zones 154 a-c. Further, the control unit 190 may be configured to change which nozzles are to be distributed in the distribution areas 154 a-c. These changes may be based on, for example, the thickness of the wire, the density of the wire, the number of wires to be processed, the properties of the coating substance, calibration results, and/or on the number of nozzles that are activated.

The control unit 190 may be further configured to: the angle of the print head 151a or its nozzle array 153a-c relative to the wire 20a-c to be treated is changed. The control unit 190 may be configured to: the angle is varied based on the thickness of the wire, the density of the wire, the number of wires to be treated, the properties of the coating substance and/or based on the number of nozzles activated.

In the above, one or more wires 20a-c are mentioned. In one embodiment, all wires disposed through the system 10 require on-line processing. In yet another embodiment, when multiple wires are used, it is sufficient if one of the wires needs to be treated in-line (such as a non-pre-colored wire). Thus, the system 10 is configured to handle both uniquely pretreated wire and wire that requires on-line processing. For example, an embroidery machine may combine in-line processed thread with pre-processed thread to create a specific pattern on a substrate. Such pretreated wire may be, for example, metallic, thick, thin, neon wire.

Thus, the control unit 190 may be configured to: it is determined whether the wire should be processed as it passes through the releasing device 150. It should be noted, however, that not all wires need to pass through the processing unit 100. This is the case, for example, when the wire does not need to be treated with a coating substance.

Although the invention has been described primarily with reference to a system comprising one treatment unit 100 and one wire consuming device 15, it will be appreciated by those skilled in the art that the features of the invention may also be applied to other systems. Fig. 6a to 6b show two examples of such alternative systems.

In fig. 6a, the system 10 comprises first and

second processing units

100a, 100b and first and second wire consuming devices 15 a-b. Each

processing unit

100a, 100b is controlling and executing the operation of each wire consuming device 15 a-b. It should be noted that the first and second processing units 100a, although separated, may share one or more components. In one embodiment, the control unit 190 is provided as a separate unit from the first and

second process units

100a, 100b, and thus, one control unit 190 is configured to control the operation of both

process units

100a, 100b and correspondingly the operation of both wire consuming devices 15 a-b.

In fig. 6b, the system 10 comprises a processing unit 100a and first and second wire consuming devices 15 a-b. In this embodiment, one processing unit 100a is configured to control and perform the operation of two wire consuming devices 15 a-b.

It should be noted that although only two processing units and two wire consuming devices are shown in fig. 6a, and only one processing unit and two wire consuming devices are shown in fig. 6b, it should be understood that any reasonable number of processing units and/or wire consuming devices may be present in the system 10.

Although the present invention has been described above with reference to specific embodiments, it is not intended to be limited to the specific form set forth herein. Rather, the invention is limited only by the following claims.

In the claims, the term "comprising" does not exclude the presence of other elements or steps. Furthermore, although individual features may be included in different claims, these may possibly advantageously be combined, and the inclusion in different claims does not imply that a combination of features is not feasible and/or advantageous. Furthermore, singular references do not exclude a plurality. The terms "first", "second", etc. do not exclude a plurality. Reference signs in the claims are provided merely as a clarifying example and shall not be construed as limiting the scope of the claims in any way.

Claims

1. A system (10) for online processing of one or more wires (20a-b) for use with a wire consuming device (15), comprising:

a processing unit (100) having a plurality of nozzles (152a-f) distributed in at least a first and a second distribution area (154a-b), said distribution areas (154a-b) being separated in a direction substantially perpendicular to the longitudinal direction of at least one wire (20a-b), said wire (20a-b) being in motion in use, each nozzle (152a-f) being configured to distribute, when activated, one or more coating substances at least onto said at least one wire (20 a-b); and

a control unit (190) configured to independently control activation of each dispensing zone (154a-b) of the nozzles (152 a-f).

2. The system of claim 1, wherein the plurality of nozzles (152a-f) are arranged in one or more nozzle arrays (153 a-b).

3. The system of claim 2, wherein the plurality of nozzles (152a-f) are arranged in one nozzle array (153a-b), and wherein the nozzle array (153a-b) is arranged at an angle relative to a direction of the at least one wire (20 a-b).

4. The system of claim 2, wherein the plurality of nozzles (152a-f) are arranged in at least two nozzle arrays (153 a-b).

5. The system of claim 4, wherein the at least two nozzle arrays (153a-b) are parallel to each other.

6. The system of any of claims 2, 4 or 5, wherein the nozzle array (153a-b) is disposed at an angle relative to a direction of the at least one wire (20 a-b).

7. The system of any of claims 4 to 6, wherein at least a portion of the nozzles (152a-f) of the first nozzle array (153a) are distributed in the first distribution area (154a) and at least a portion of the nozzles (152a-f) of the second nozzle array (153b) are distributed in the second distribution area (154 b).

8. The system of claim 7, wherein all nozzles (152a-f) of the first nozzle array (153a) are distributed in the first distribution area (154a) and all nozzles (152a-f) of the second nozzle array (153b) are distributed in the second distribution area (154 b).

9. The system of any preceding claim, wherein the system is provided for in-line processing of at least a first wire (20a) and a second wire (20b), and wherein the control unit (190) is configured to independently control activation of the nozzles (152a-f) of each distribution area (154a-b) such that the first wire (20a) can be processed by the first distribution area (154a) while the second wire (20b) can be processed simultaneously by the second distribution area (154 b).

10. The system of claim 9, wherein the control unit (190) is configured to: activation of each dispensing zone (154a-b) is controlled by sending a trigger signal to a nozzle (152a-f) disposed in a particular dispensing zone (154 a-c).

11. The system of claim 10, wherein the control unit (190) is further configured to individually activate the nozzles of one dispensing zone (154 a-c).

12. The system of claim 11, wherein the control unit (190) is further configured to: the nozzles of one dispensing zone (154a-c) are individually enabled with a predetermined offset from receiving the trigger signal.

13. The system of any one of claims 9 to 12, wherein the first and second wires (20a, 20b) are different from each other.

14. The system of any preceding claim, wherein the nozzles (152a-f) are inkjet nozzles.

15. The system of any preceding claim, further comprising a wire consuming device (15).

16. The system according to claim 15, wherein the wire consuming device (15) is an embroidery machine, a sewing machine, a knitting machine, a loom, a tufting machine, a winding machine and or any combination thereof.

17. A method for in-line processing of at least one wire (20), comprising:

providing a processing unit (100), the processing unit (100) having a plurality of nozzles (152a-f) distributed in at least first and second distribution areas (154a-b), the distribution areas (154a-b) being separated in a direction perpendicular to a longitudinal direction of at least one wire (20a-b), the wires (20a-b) being in motion in use, each nozzle (152a-f) being configured to distribute one or more coating substances at least onto the at least one wire (20a-b) when activated; and

a control unit (190) is provided, the control unit (190) being configured to independently control activation of each dispensing zone (154a-b) of the nozzles (152 a-f).