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1968

The theory and development of a dyeing machineemploying the rotary pendulumAshley Paul Smith

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Recommended CitationSmith, Ashley Paul, "The theory and development of a dyeing machine employing the rotary pendulum" (1968). Master's Theses. Paper1053.

THE THEORY AND DEVELOPMENT OF A DYEING MACHINE EMPLOYING THE

ROTARY PENDULUM

BY

ASHLEY PAUL SMITH

A THESIS SUBMITTED TO THE GRADUATE FACULTY

OF THE UNIVERSITY OF RICHMOND IN CANDIDACY

FOR THE DEGREE OF MASTER OF SCIENCE IN PHYSICS

AUGUST, 1968

LI OR.lH~Y

· UNIVC::RS r 1· ,. o ;:- R lCHMONC \.'lRGlNIA

ABSTRACT

A review of dyeing methods for carpet is made with the

objective that the requirements of a new machine could be

formulated. The proposal for a new machin e i s made in the

light of the above review using a pendulum as the basic com­

ponent. A theory is developed for the motion of the pendulum

which is mounted on a rotating disc , and the experimental

work built on theory is outlined. A prototype machine based

on the r otary pendulum mechanism was used to dye impregnate

carpet.

-

TABLE OF CONTENTS

Introduction

Theory ·

S~lution of ~quation of Motion

Machine Design and Testing

Conclusions

Glossary of Textile Terms

·References

Bibliography

Vita

Acknowledgements

U CR/\!~Y

UNl\/~RSIT Y C l- f"\ IC HMONC V l flGl;-..J lt\

ii

1

14

20

29

40

42

44

46

.f ie;ure

1.

2 .

3.

4 .

5.

LIST' OF FIGURES

Production flow charts of package~ skein, piece, a nd impact dyeing.

Diagram of a dyebeck unit .

Diagram of a beam dyei ng un i t. Cit

Nip conditions fo r impact dye expression .

Fabric dye i mpregnated by roller padder.

6 . Effect of lump on rigid r ollers and correcti v·e measures.

7.

8.

9.

10.

11 .

12.

13 .

14 .

15.

16.

17 .

18.

19.

Pictorial drawing of rotary pendulum .

Forces on rotary pendulum in flight.

Dimension relationship of rotary pendulum sys­tem .

Equations and parameters used to determine initial .v alues of rotary pendulum systen .

Imagina ry analog plot for guideline to in ­terpret actual plots~

Graph of hub radius versus percentage of K for radial impact .

Graph showing pendulum response insensitive to speed of rotation .

Run 36 of analog plots .

Hub tessellation.

Illustration of obtaining information for escapement openings .

Layout of rotary pendulum assembly.

Illustration of six pendulum arrangement.

Flight of an icpacter at v a r ious escapement openings.

iii

3

4

6

8

9

11

15

18

21

23

25

27

28

· 33

36

37

38

39

I • . INTRODUCTION

The object of the investigation reported here is the de­

velopment of a rotary pendulum form of impacting device for

the application of dye liquor to fabrics, particularly carpet­

ing.

The re a sons for undertaking the development of a differ­

ent desi gn of dyeing macnine are centered around the increas­

ing demands of the textile dyeing and finishing industries

for more capabilities in industrial equipment. These desired

capabilities are the applicability of equipment to non-uniform

surfaces and to all fibers, the adaptability of rn~chincs to

shade changing with minimum down time (less than 10 minutes) ,

the reduction of water consunption per square yard of fabric,

an increase in the speed of dyeing (more than 5 running yards

per minute), and a reduction of costs per square yard of dyed

material .

Currently, the carpet dyeing processes used in the tex­

tile industry are stock, skein, package, and piece dyeing.

(See Glossary of Textile Terms, page 42, for definitions of

these and other terns.) Production flow charts of dyeing

2.

1 processes are shown in Figure 1 . Stock dyeing is not shown;

howeve~, it is the most lengthy of the p~ocesses for the car-

pet manufacturer.

Piece dyeing has important economies over stock, skein, ·2

and package dyeing and also has the following capabilities:

l. Custom dyeing in a complete range of shades from a

single greige inventory;

2. Greater flexibility in introducing new shades; 3

3. More rapid deliveries of carpet to consumers •

Thus, the proposed new machine ideally should employ a piece

dyeing process . A brief review of the existing piece dyeing

processes used on carpets, including their good end bad points ,

is included to point up the need for a new design. Beck and

.beam dyeing, two existing piece-dyeing processes, will be

reviewed in addition to the roller padding process which is

being developed actively in Europe. These processes were

studied in order to formulate operating parameters for the

proposed new process~

In the beck dyeing process the greige carpet, approxi -

mately 150 running yards, is fed into the dye bath over a

reel. The ends of the carpet are st~tched together to form a

continuous length which is immersed repeatedly into the dye 4

liquor . Figure 2 is a diagram of a dyebeck unit.

The primary advantage of the beck dyeing process is the

consistency of uniform results from lot to lot, with economic 5

reasons being of secondary _i mportance . The negative features

i · ?~~~·ic;E · ~~~N..~J l .... YARN AS RECEiVED "' l '- -or--, ... ---·"""'--, ... - -·"· ---. ..J . l ._ .... ... .. -.

· ! SKEIN t : ! ----···---'I ·-

BULK

. _ .. ··:~·::-~··~·- :~·~ ~1 ! :- . ~ . ... . -.- ... - .......

• ·· - . .... __ __; r · I

. 1 DYE, ... . . ' .. .... ; I

PACK ACE

··-·--.. ~-- -·-- ~·--____ ) . .. . ........ EXTRACT .• - ---· :

: .. ~--~~~=-.] . ;~ :-·-~·-.'. : DRY i ... - ... - .. -. ·· -· · ·-· · .. · .. ~ · . - . . -- ----. j BACKWIND j ····· --~-·- --· -'" ' i .... -

:. ~~ - ~-~-~--:.-.~ .-~N ; ~~- - .... ... . ... ! . . --- -- ·-··-"'

l~YENTORY

COLOR A COLOR B COLOR C

· · ETC. (a dozen 9r more colors fOr l ine}

··- ·- - · · · - - --- p

CREEL ...... ----·---·-- --­-- -...-···--- i 1..---- .. -

. 1 . TUFT I ______ ... ---- - -- - , ... - -·- .. . ,. .. - -·--··-' L --

1 FINISH i .. ---------.. ] r-·---: .. ··--·-· r----- ----· " ·- .. -------~~~- .. ....... --i

. I ........ - SKEIN DYEING I ~~J . , :.~~·--:-:-:-: L.. YARN As R~=~~vep _ (

.. ..... .... .. _ ... ... J ..... -- ... . - .. I . SKEIN - ·· ~ r ---~ " .• _ .... __ _ .... _ .. ..i . . . .... .... .... ••

I_ DY~_ .. ___ J .

I _ ........ .... EXTRACT . I . ~----.

• -· .............. . J ' .

r DRY ,_ ,--· -·-- ·

' r·· --·_ .. BACK WIND · · · · ·

·~--~.-:-~ . · ·-· ---a>NE

·----- ' INVENTORY

COLOR A COLOR B I COLOR c i .

! ETC. ; I( a dozen or more colors for l ine) ; ~-~-:.=::~-::; .- : :..:..:~==~:··· .~·

~ CREEL 1 _-.... ::::.:..-.==::i - .. =:.-==:-~: I TUFT ' ..,_ .. _ ... -··--- -

1 .. .. . . ..... "' .. -·-- -·-·· • I FINISH ! !_-·-:-:-.::..-.::·:::-.s1 :.:=:.:::::-.::.-.1

SHIP

~ . PIECE DYEING i l .. . .. .. ... .

----··-···· .. --· ··- ·-- - ...l

l;. YA~·N ~-~ REf::~~~~~=-j ' . : ....... ...... - • " • .. .. . ..... .. f

l . c~eE:__ ___ _ l 1· .... _,, . ' ........ ..... '

-=-.~:.:·-.:-~uF~ · ·- · ~-. _I

\

INVENTORY I (one item for each pattem) ., j

--·- ·- .. , --------· OYE .......... .. . j

I .. . .. .... I · - .. - ·-- - ---

i . EXTRACT 1 _ _ __ .. _ , ;----

1· ......... -..... DRY-- --~ ... - -)

I,._. • .. -----'

{--. - .- .1 L--·- -- . l FINISH I

J r----

L __ .~· SHI~-·- .. -·==!

IMPACT DYEING I r.

L. .. .. YARN A.is RECEIVED ~ j ----·-1 - ···-----

. .. . . ·' ... ... -· . __ ..

I CREEL - -··---

!.. . .. " • ••• • • • '... • '. . I

TUFT

I ·-·-· ~'- -~ - ----------· INVENTORY , :-···------"'

.. --: ·;-····· .DYE . ;· .. ,,_ ... - ... ,

.... ...---·- -' . ' . .... --- ----. . ......... . . .. , f_ STE~~ _j

... . - ... - . ·--- ... i l ... ·- ·- ·-·--!__ FINISH __ . ___ I I ·.-~~- --·--·SHIP '--------·

.. .. _ ..... ____ _

.FIGURE

~

4 •

FIGURE 2

REEL

CARPET ·, ..

S UPPLEM ENTA RY ~J_E_AM _l:.l __ N_E ______ -· ~©--

........ ' -·-·-

D.YEBECK U NJT

5.

are the slowness of the process (for medium shades an average

dyeing · time of 4 hours per lot of 250 square yards}, large

water consumption (approximate ly 1,500 gallons per lot), and

prolonged exposure of fibers to near boiling temperatures

vhich tend to vea~en the yarn. Temperature variations of the

dye bath (a difference of 3° to 4°F. from point to point) can

adversely affect the finish or texture of the carpet by pro-

ducing pile distortion and variation o f shading across the 6,7

carpet vidth

In beam dyeine, the greige carpet, vound on a special

perforated beam, is placed in a dye machine . The dye liquor

is pumped through the carpet from the center of the beam out-

ward, and then from the .outside carpet surface to the center 8

of the beam · (Figure 3) . Beam dyeing is especially useful

for particularly textured carpet, such as cut-pile and frieze

style, where loss of twist is not as pronounced as in beck

dyeing. Positive results obtained when beam dyeing carpet~

are as follovs:

l. Minimum handling of carpet;

2 . tess mending involved as carpet is stationary;

3. Virtual elimination of side-to-side shading;

4. Considerable savings in dyestuff, chemicals, water

and steam because of a lover dye liquor weight to

carnet wei ght ratio (5:1 compared to 20:i or 30:1 - 9

for beck dyeing) • .

As in beck dyeing, the disadvantages of the process are

FIGURE 3

----· ... ··-··· - --- ···~·· · - - · ·-· · '" · · - · - · . ... . .

6 .

PERFORATED .---1-- BEAM

,...q. ___ , __ FORCED DYE FLOW

'"'---STEAM LI NE

BEAM DYEING u·NIT

7 .

the slowness of the procedure (which is approximately that of

the beck process) and prolonged exposure to elevated tempera-

tures.

In the roller padder process a set of sque~ze r olle r s is

used to impregnate the carpet with dye liquor by continuous

passage of the carpet throueh the liquid and then between the

rollers. The carpet is then fed into an oven for dye fixa-10

tion As the use of the roller padder is currently under

development, definite advantages and disadvantages are not yet

known.

One major disadvantage of all the above processes is that

the dyed carpet mus t be dried. Present vacuum systems are

capable of re ducin e moisture in the carpeting to only about

1 25% of the original carpet weight, and the removal of the

remaining water mus t be accomplished through evaporation.

Application of the dye liquor to the carpet in low per-

centage amounts (lesa than 100% moisture content) can be

accomplished using the roller padder technique. In orde r to

apply dyes in low percentages, the voids in the carpet must

be reduced in volume at the time of dye application in order

that the liquor is spread over the fiber surfaces rather than

into the voids. The dye liquor .should not be applied to the

carpet until the voids a re rnini~ized. This can be done by

expressing (injecting) the dye liquor into the carpet at the

same tine the voids are minimized by the pressure exerted by

the rollers.. Figures 4 and 5 show conditions ~or expressing

TIME---~

The nip width N, is proportional to the

average radius of curvature R, and the

deformability %, of the rolls and also to their linear loading L.

Noel.!. E

Jhus, at constant loading, fhe nip width can be decreased by reducing both the

diameter and. deformability of the rolls~

a.1-"C "C

TI ~1 E ------

Impact c,,nditions are obtained when the rate of rise of pressure in the nip

a.

is high. Clearly the nip has to be small and the rolls must turn at a · high speed.

FIGURE .:4

-:,~ . . ~,, ... : ".:~~= . ;., . ;:.: .. - " . ":.::.:'.'-.. "" . "'!t. .. . .. .. . .. . . . ' : ,..,: .. . t·~ ~~----.,.. ·------\ ••l;i, •• i.;,,..,,,..,J•,• 1._......._ . ..-1 _ .. ,., .. ' • .... v - .-.t#,".:'i" L: .. _ ·' •c , -~•'• ' • • ·~"" ._ , , ., ,. '• • I, 1' .. ,r, •••H • ..,,_ ,, ,, ... \_ ~ . ' \ :: . . ~ ' .· . ' ,,. . . : . ··.

. . ' ~ , . . . .. . ', . . . .. · ~ .. ~ ~- . ...... . \ . ., . " ' < :~, ''~~.. : . . . . . : .; . ... '\t . ·. '. .

. "" "\ ' . '

· .. \

'\,

" . ).. . .. ·. "·~ . ' !. . .

~ ',\ ~ ; : .. ~. \ • '\ . \

· .. '-'·\_ "\... ·1.\ . . " . .. ~~ ... • '\ .•

. ; ·~ - ~ . ' "' . ~ . '\ . "., ". . . ~

'~ \. . ' .. . ·\ \. . " ' -~ . ~' '"'- , ' 'I · . .:.- ., '\ \ : \ . ""·.~~.~ \\ . :::: ~~ ' · ~· .. ' /~' '., ~ . "· ·. \ \ > \ ~ "-:,

. ~ '\ ·-·· . •. . . ~ ' . ,,: . \ "

. . • \. .~ . ~- " .. '" ., \\'\\ ·t \ ~ D 1lJ '~\,: /:-:~·> "· .. ' ~- : \ ... \ \.: )\ \" ~1 ) \· ... } \. J_j:~ l .. ~ )i· ) ! .. ,! ~\ . )~~ ~. -~ ··I· ' \. . ·\ ,.. . ,. "1 J I . I U-:.. \ . " " ' l " j ' ' 1 · ( I ' "-' ' · , ' · · l \ , . "· • t .. · l · 'r· i ·. j , . \:. / I ' .... · .. - ... . · . '\ "

t 1 ' I 1

' \I ,., ' , , \ \ ' ! I. I / _:...,_:;.-- : ·:~ ;._ . . "· . .. " . '-\ ) .,. --· r~·..,\ . · \ ·• . J ;.r----- . . '. ·~ '\ . . :1 . ._ .. ·... I ':': .. :<, . . . .· :,, " ' : J \ ... ·"

('

. '·. ' .. " ' . . '\ . . . . ,..t ---": .. . ·.,. ' · . . · ~ ~ . \ '\ ' . .. ·; " . . . ~, ...

. ~. .. !J__-----'J .... . 'l_. ! \. .. . ,.. ~, . , ' . ~ . . '

~~~-~ . >'\·, '·,., . . -;·,·. 0. • , •. , _,/ "·\. : '.' \ ' . . -,. . ":. :-: . . .. . "'-· . . \ '.'.;. "" . ' '\, \. ·.,\'.,. . . .. · ,. . '<~ .... , · 30 YD/MIN

.... ' '\ . ·" .. ~ -.; .,. . ..

"'-.\ _,,,. \, \ ,W:.~~:.~ ... ;5YD/M\N WE\.L DEFINED

\ \. ...- --· ~- < IRREGULAR PENETRATlON ~......... 7 !1, YD /M\N PENETRATION PR\NT

NO PENETRATlON ONL '{ /(f CENTER OF PR.INT FACES

FIGURE s co

10.

dye liquor into a voven fab-ric by the roller padder method.

This roller application of the dye necessit a tes running 11

the carpet at speeds in excess of 100 yards per minute (To

provide the reader with a basis for comparison, the general

magnitudes of production speeds for various carpet manufac-

turing machines are: tufter, 33 yards per hour; knitter, 18 12

yards per hour;0

loom, 3 yards per hour · .) The presence of

small protuberances (e.g., a knot in yarn) vould cause pene­

tration bridging (undyed areas) to occur as high speeds vhen

long rigid faces, such as the tvo faces forming a nip in the

roller . padder, are used. As can be seen in Figure 6, the

divisions of the rigid rol l into smaller units vould add flexi-

bility in the dyeine of the various carpet styles that should

be processed on the proposed machine.

After reviewing the various dyeing processes, the require-

ments for a nev design vere formulated. These requirements

are:

1. Applicability to any fiber;

2. Lov weight ratio of dye liquor to c a rpet (less

than 50%);

3. Applicability to non-uniforc surfaces;

4. Dyeing speed of 10 runnin ~ yards per minute;

5. Minimum color change~over time {less than 10

minutes);

6. Impact intensity independent or carpet speed;

7. Reduction· of time the fibers are exposed to ele-

vated temperatures.

f 1 BRlDGING \N THESE. REGlONS

.. ·-~~ ·~ ·~ , u " r'Wi' •rrc•nt i* 1.agw•Mj+F ffkM 'RiFP :m:1w11 $ 1 +

F ? A&e e H e ' • @••t~ .4np1 'W If . ¥ '*f5SID WN#i##¥Zi¢¥ '*W'S'4'£21.i"E 2#11Wt«u:;nmn

APPLlCATtON TO Hl-LO CARPET\NG \S A PARTICULAR, ALTHOUGH EXTReME, CASE IN WHICH TH\S TECHN\QUE CAN BE APPLIED.

. FIGURE 6

11. .

12.

These requirements of the proposed dyeing process dictate

the establishment of specifications for the machine. A lov

weight of dye liquor to carpet weight infers impact appli­

cation methods. This low moisture content redu~es the heat

requi red for drying the carpet. Furthermore, impact appli­

cation of dye liquor in these lov perc entages al l ows the use

of additives which further shorten the d r yi ng time. App lica­

bility to non-uniform surfaces means dividing the impacting

face into areas having maximum dimension of 1-1/2 inches

instead of a long rigid face. Impact intensity should be

independent of carpet speed but the impacting frequency must

be related to the carpet speed to achieve complete carpet

cover.

To illustrate the complete carpet coverage. assume an

impactor face one inch wide . This would require 12 faces per

linear foot disposed · in a row transverse to the advancing

carpet. Assuming a striking l ength of 3/16 inch in the direc ­

tion of the advancing carpet, a figure indicated by previous

experiments, and an advancing rate of 10 yards per minute , a

striking frequency of 32 impacts per second (or 1,920 pe r

minute) would be needed to obtain continuous c over of a strip

the width of one impactor face. The fo r o of impactor system

proposed for the new dye - application equipment must neet cer­

ta.in criteria, 'namely-:

1 . Ability to p roduce the required im~actinp, fre ~uency;

2. Su·fficient im:;iact intensity for dye pe'netration;

. 13.

3. Adaptability of impact unit size to a machine frame;

4 . Capital cost of machine construction.

Several possible impacting systems were considered, and

comparisons were made using the above criteria. From this

consideration the system designated as the · " rotary pendulum"

was selected as one of the prime candidates. The rotary pen~

dulum had been attempted on an early prototype mach ine for

print application but vas set aside because of the difficulty

in obtaining continuous i mpacting at the desired position.

However, th e basic simpli6ity of the rotary pendulum indi-

cated that a mathenatical study of such a system to obtain an

understanding of its operation was worthwhile. Thus, control

of this system in a repetitive manner for use in the propQsed

machine migh t be achieved . Fron an understanding of the

rotary pendulum, i mpact at the desired position with correct

radial positioning of the pendulum, might be achi eved if the

proper paraneters could be determined.

Thus, the object of this research was to develop an equa-

tion describing the motion of the rotary pendulun , solve the

eouation a nd annly the solution, if feasible, to the construe-- --tion of a device to achieve dye application to carpet by

impe.ct.

14.

II. THEORY

A pictorial drawing o~ the various coreponents of the

rotary pendulum system, indicating hov they are arranged rela-

tive to one another, is shown in Figure 7, Rotation of the

hub moves the pendulum head along the impacting ~oll-carpet

surface until reaching the point at which the pendulum can

swing tree . The p~ndulum , swinging freely about the pivot on

the hub as it rotates, strikes the carpet and dye reservoir

which are passing over the i mpa cting roll simultaneously .

The impact expresses the dye, carried in the reservoir, into

the carpet .

It vas planned to heve the pendulum strike the carpet

when it was in or near its radial position, then follow the

moving carpet surface until it lost contact with it and finally

swing freely into the radial position again at the time the

hub has completed one revolution froQ the previous impact.

Any tendency to swing past the radial position co~ld cause

jamming of the pendulum into the impacting roll .

This plan demanded that there be a certain relationship· . .

betveen the hub radius (a) and the pendulum length (L).

I I

I /

Pl CT ORI AL DRAWING OF ROTARY PENDULUM

I

--............. ., '·""' "-',, "-,.

/ /' -·-f. . . 7.5d' / ./ ,. _. . -· -- ; . ... -....

'·" \ \ \ \ ~

' \ \ l -t -- L \ . '

I \ _l Pivot /11· ~---------cl Pendulum

roeai---- H C?ad \ ! I . . .. . - r . ·-.. \ \ !' I ..-

\ \ I / . I ·,,'·,. \ / / . ·, ·, / I . \ \ . / ".

'\ ·-.,, /"· / I/ '-- \ ,,....-4.50 '- ·, ., / I ....-1 ----...__ /<, • , / ' F • :V \ '· ' . __,,, . ..... \ " ·~ ..

\ I ; I

I

--¥- I ~-~~~~-----" ~

~ . FIGURE 7

Impacting Ro ll -

16.

Furthermore, believing that the physical quantity required

to express the dye from its reservoir into the carpet vas the

momentum of the pendulum, an exper iment was performed with

impactors used in an earlier prototype machine and the magni - . 14

tude of the momentum needed was determined to be 13 kgm-m/sec

In order to facilitate fabrication in the shop the dimen-

sional limits *ere placed on the sum ' of the hub radius and

pendulum length et 7,50 inches, and the impacting roll diameter

at 9.00 inches: This meant that the sum of the hub radius,

pendulum head diameter, and impacting roll radius could not be

greater than the distance between the centers of the hub and

the roll . Othervise, the pendulum head would not pass between

the hub and the roll . Assuming one pendulum per unit width,

with the above dimensions, a pendulum head mass of approxi -

mately 225 grams would be required to produce the momentum

believed necessary at 1,920 revolut ions per minute for conplete @

penetration of the heavy carpet (45 oz/square yard of Acrilan

by the dye liquor. The size of the pendulum head neeting the

above mass r equirements end dimensions is 1-1/2 inches in

diame ter by 1 inch in length.

In order to determine the effect of the hub radius (a)

and pendulum length. (L) on the motion of the pendulum it v as

necessary to derive and solve the equation o f motion for the

system and then ascert a in if the desi red operAting conditions

could be fulfilled.

These operat io nal condi tions a r e that the impact occur

17.

near or at the radial position, that the angle the pendulum

makes with th e hub radius be decreasing, and that there be no

undetermined velocity c omponent upon r elease from the impact-

ing roll.

Figure 8 is a diagratl of the rotar y pendulum at· some

point in its notion showing the forces acting on the pendulum

head . To simplify the problec initially , the total mass of

the pendulum will be considered located at the center of the

pendulum head and gravity was n eg lected. These assumptions

are justified later .

The horizontal and v e rtical components of the force (F)

exerted on the pendulum head produce correspondinr, acceler-

ations of the mass (m), and the resulting equations of notion

are:

mx = :..F cos o<

my = Fsino<

Relative to an origin at the center of the disc

x = asi n0 + Lsin(e+¢) where e = - wt

also

y = -acose - Lcos(e+~}

Taking the second derivatives of x and y, and putting them

into the equations of motion give

m[ - av2 sin(-wt) - L(w+i)2sin{-vt+¢) + L~cos( -wt+¢)] = - Fcos~

m[ av2cos(-wt) + L ( -w+i) 2cos(-wt+~) + Lisin(-vt+¢)] = Fsin«

Multiplying the first e quation above by sin<'( and the second

by cos<>< , adding and si:tplifyin5 g ives

u n ;,,'1.RY UNIVERSITY 01=' rtlCHMOMC

ViHG1NIA

a ---

FORCES ·oN ROT ARY PENDULUM IN

FL IGHT

I I I I

-+-i e I I I I'

1\ I I \ : \~ I ~, G , '/J o< : ; /.ef\/-4···- --4-"'

1 Fsin<><1--/\ I I \

I . : I I

I I I

\

FIGURE

18.

~Fcos~

-m

8

19 .

.. ¢ ::: -

~hich is the equation for a simple pendulum when g is replaced

by w2 a • The de s criptive name of the i~pact device or rotary ~·

pendulum naturally evolved from the fact that its equation of

motion is related to that of a simple pendulum ~

20.

III. SOLUTION OF EQUATION OF MOTI ON

This section deals with the method used to obtain the

specific solution to the equation of motion of the rotary pen­

dulum which vould position the pendulum radially at the moment

it strikes the impacting roll subject to the condition that

the pendulum started its outward swing upon release from the

surface of the impacting roll . The rotary pendulum arrange­

ment on which the computer study is based is shown in Figure

9. The angle K is the arc the pendulum pivot traverses from

the moment the pendulum head swings free of the impacting roll

until the pendulum, if it were in a radial position, would

strike the impacting roll when the pivot was in a horizontal

position. The angle ¢ 0 is measured from the extension of the

radius passing through the pendulum pivot around to the line

from the pivot to the center of the head (CM) at the moment of

swing free. A is the angle between the line connecting the

centers of the hub and the impacting roll (00') a~d the line

from the pendulum pivot to the cent e r o! the i mpacting roll

(CO') at the momen t of penduluo release. The equations and

parameters used to ~etermine the initial values at pendulum

____ ....__. __ ,._,,_ _____ ..,._ ..,. __ .. 4.-. ... _ _ __ , _ ...,,_,-~~ - - - ...... ..-... .. _ ·- -

~ ··--··- -----~ -~ .

/_,/ ~

_a \ I

\

/ ...... -~·-··---·-/ ____ ,,...... ····-.

/

/ --------, ... ,

/ II

K. ' '\.,\

I I

I ( .

I ! I

~ L\ I

\ \ c \.--~

\..--- ----- '---00 ~ \

~-~

-.............. --- --FIGLJRE 9

........ ... _

\

'.

ROTARY PENDULUM ARRA ~~GEMENT /\f\JD

PA RAME TE RS ON WHICH THE COMPUTER

STUDY IS BASED

cf

OC=a

CM=L

a+ L = 7. 50"

I\)

I-' .

22.

release in finding solutiobs to the equation of motion are

shown in Figure 10. The purpose of the series of solutions

to the equation is to determine if the specific solution de-

·sired can be obtained in the range of possible parameters.

Other than the physical parameter possibilities, the series

also includes rotational velocity changes in representative

steps up to th; maximum projected velocity of 209 rad/sec (1920

rpm). Thus, from start-up of the rotary nendulum to the final

operational speed of 1920 rpm would involve a transition

through lower speeds; any existing condition whi ch might

cause difficulties should be anticipated.

The computer group of the company was requested to assist

in the study by using the Pace 231R analog computer to plot

the curves of the pendulum motion fo r a series o f cases . The

computations were based on initial values obtained from the

equations and parameters in Figure 10.

Figure 11 is an exa~ple of the graphs obtained in the

series of case studies. In each s tudy the an F, le ¢ between the

pendulum arm (L) and the extension of the hub radius (a) is

shovn, alon g vith the sine and cosine of ¢, and the eneular

velocity, a¢/dt . The aneular velocity of the hub is w radians

per second. The inclusion of scale factors (i.e., 1.4 x io- 3

in Figure 11) is the practice of the computer group in making

permanent recordings . The horiz ontal axis of the graph is the

time axis, where one machine unit is the ti~e interval meas­

ured from the inst an t the pendulum swings free of the impacting

23 .

~FIGURE 10

The folloving equations and parameters were used to determine the initial v alues to-be supplied to the com­puter group for use in programing the analog computer.

Radius of Circle 0 is 7.50" Radius of Circle O' is 4.50" Pendulum h ead diameter is 1. 5011

a+ L = 7.50" Radius of pendulum head center around Circle O'

center is 4.50" + .75" = 5.25"

¢0

is the angle the pendulum relative to the exten­sion of the bub radius at the moment the pendulum is released from the impacting roll sur face.

From Figure 9, it can be determined that

0 . = cos-1 [ 83 . 81 - _a_~ _ _-:_{_1.1._~7~-=~] o · 2a(l2.75 - aJ

and

A = sin-1 [ ~ sin ¢ 0 ]

83.81

K (in degrees)= 360 - (~ 0 - A+ 35°0') o r 325° + A-• 0

35° is determined from the geometry of the me chanism. K (in radians) is equal to the angular velocity {w) times the time (t) to r otate through the anele K.

Hence, the time can be determin ed by

t = K (in radians). lot

1. ! . I. I i i ! . I

24.

roll surface to the time the exten~ion of the hub radius is

in the impacting position (horizontal). To find the value of

any one of the plott ed variables in terms of the original

problem, divide the included scale factor into the correspon-

.... rtnen

ding value on the vertical axis. The sign of ~ has been chosen

positive when L 11

la.gs11

a, and when L "leads" :a, ~ is negative.

Figur e 11 shows the pendulum (1) l agging the radius extension,

(2) passing through the radial position, and (3) leading the

radius extens ion.

Figure 1 2 shows the percentage of the angle K to obtain

r adial positioning of the pendulum as a function of hub radius.

A plot of the rotational speed of the hub egeinst the percent-

age of the angle K for radial positioning for various hub radii

shows the pendulum response to be insensitive to the speed of

rotation (see Figure 13). The case study plots can be divided

into two separate groups which are (1) p lot s to deter mine if

the specific solution desired could be obtained in the range

of possible parameters (a= 2.0 to 4. 5 inches) ; and, if so ,

then (2) plots converging on the specific solution found by

reducing the increments of a in the indicated r ange .

The specific solution desired is where ¢ is zero in 1.0

machine time unit. Case 36 (Figure 14) sho~s ¢ has decreased

a l mos t to z e ro and L is lagg ing slightly . In this case study

the hub . radius ·is 2.25 inches and the pendulum length is 5 . 25

inches . The dimensions used in this case study were used to

fabricate ~he first rotary pendulum.

~~.·~~~ ! .

+ 1.0 ---·- · · ··· · ......... .. ... .. ~ :-- -·-····· ··--- ... -~ • ...:..-..·· --·--·· •• k • • •

M t.8 A c + .6 H I

· ~ +.4 lj '· u +.2 j ..

N . i I · 0 i ··· · · T . ! . ·-··-· ·--

! - z L • I

! .

I .- .4 t

-.6J !

-.8 t I

-1.0 --------.---. I. . . 2. . 3 .4 .5 .6 .7 .8

MACHINE UNIT

---Pivot

-----Hub

\ LO COS~ ,, Cl '-:: 6.0 L= 1.5''

~ .. Time Re-q uired To RotatE' . . Through An g le K

<D Lagg·i ng •a•

cP Lt>~ding ~cs·

. .ia ['s· l'h . il \\"""' 0.3 q ':3 = \f' = 0.6 ra~

\-ii l.OSIN~

J.4x 10·3 ~ ·

,9 1.0

FIGURE II

I\) Vl

PERCEf.ITAGE OF K FOR Rl\DIAL lr~PACT

w w .ea .;.. Ul Ul en en ....... ~ en ~ · : ~ ~ ~ ~ ~ ~ ~ ~ ~ ~

-~:~.;~~1 .. _'t itill :·· I' !:B. t f ... j I rtr ·wt. lfl. t : .. : . ·H"· -:r1nun ~1~~ f~~ . . .i i. ~ . ·m . . .': . . : .. t' : : : . '.I:~ ·~ : .. -~- ;ft :Lt . >r r IL . l tu . .t . ittl .. I· f~ I . . .. t .8rr fttt t . IT{ . t rr . . t ff

I I l l ~ . 1 . l: . . . .. . . • t . f. i-~ 1 I • : L . . . • . . ' . . . . . : : . : . • i :~. ·t L t-:-1 ~ '. :I'· . 'T . Ii.. . . .. ' . . . I • • . . . • . 1 ~ ., . iti . 'I t I . t I:! T: . . . . . . . . ~-~ BJ ... ~ H . i1 t , -t .. . 1 a i . . . . . . . . . . . ~ · 1 [1

1

m t ~i I !· I . . . • If, • t . 1. . '

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1.u J ~ · , H 1 Ii 1- t - . - . . . 1 · · ·: . . · . . . ..t

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l.:.p · _i: i , u. J. • .J. i:i-· li. tf · · 1~.d U: ll-+ U: u l± · .1tll ii .. f . . . . . ~ ' f£! -Hl ll-ttl i.1 · ·ry ··

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1 .. 11 11 1 11~?.;1 • · 1J · 1 i\ i1 ul1 ~- · • t · ~I H 1· r. ·· · · • · · ·! ·

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1

en f'" U. 1u! l . 1·,· t ll Ul .. i.:)~·: '." ! !ll ttHI l L · lllllJ !:h~~ ti. 1.f-! t . 11. - · I · ~ . . t . ·1 ). ri i , . t ::

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1 .,.. • ... .._ p- ~I , ...._ IL;~] l • ,_,_ :Tl t :r Cl.I ,_, f 1 H+t .

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1: f : . · .1:1: . J • . ~: ~rt ~ 1 . T + T n : I·· ; . 1 . . I . . . Ii . . l . . ' ·- . I 1 1 .. I ~ ( . . 1 " ·' '" - iLJJ ~ ,_ ~ -- ~----• • •-• ___ lt~u- I

~

·!'"

RESPONC E of the ROTARY PE No·u LUM to 27.

SPEED of ROTATION

T.. . ... ·r .. I

3.0'' I : . ! . i . . i ! ·: . f

- ___ ...... .... "·!· -·····--.-· .. -· .. : ... . ·- -... - ..... -::······ ·--·--.. -.. ---·-i ---------~-.. - -- -·-·--· ... -............ 1 .. - -.. --

i I ! ; I I t

~20

20

I 4;0''

'

II

4.5.

· 1 l: I !

; i Ii ~ 8 i ~ i . . ' ~---; -------·--;--· ---·-----~- ---_ .. ____ .. ·---,------·---!-··--- .. ··--· ........ _ ..... . ~ ........ .

0 w w Q.. l/)

_Jl2 <(

z a

~10 d CV.

8

1 1 I ! : I ' ! l . f

.! j i ! ...... r I, ···-----··--·---~ ... -·-------·---~. -·-.. ---·-· .. - ---1 ----· ·- --.. ---··: ·-- .. ·-·--· -- ··- . , .. ·--···--"-· . I • I : . ! ; I .

! • ' I ! I

• ! l 1 • ! i I

. f \ t ~ i - --- .. --.~ - ----------·- ;,...._ -·----.-.+-·--.--· ---·· ·---·----·-~ ·- - ~···-·- · · · - ·· -.. ........ -~-- _..._ __ _

: I \ . r :1: . . ~

. j

I I

--ii------. - --··-- - · --.. --.!--- -----·---.. -·;-----· -----· -· --·t-···-· ..... ... --·--1··--.. -------i---... i i l { : I ! 1 1

' !I ' I 1 ~ . I i l j I I

·-------- .. ·-i .. ___ ,__, ___ --· -1-·-· . --·---··-·--·1 -------·~· - ---l----·------·· j··- .. --------·-:--~--.. ------' , 1· : I . . t l ! I : t I : I . . • I t I •' I I I . . I ·; . I I I ; ; I i I • I I I . ' ' ' I ! · i I . . I I ~ I i I . : . . I j , I i I I I 1 1 I i I + __ ·- -f-·--·--··-·-·· .. ···'··-·--l--... --1r -·----·-·1-:--·-.----·· .. -·1·····-·-···:·· .. -·1-· - l i : l 1 I I ! I l I ~ I ; I i I : I I ' . . : ; I . I : 1, · I

[ 1 ) i ! i I . . I '1 I l

. I i 1 I : . . I

50,3_2~·~~-4~~---~~4Jl8_1!.-..~~5,~6-- ~-1-~6-~4~~--72· 80 PERCENTAGE OF K

. FIGUR.E: 13

a

29,

IV. MACHINE DESIGN ARD TESTING

The first rotary pendulum fabricated vas a dimens i onal

model in plexiglas using the values of a and L determined in

Run 36. The hub was rotated at speeds up to 100 rpm to deter­

mine how nearly the pendulum was responding to the theoretical

prediction. By means of a strobe li ght and a polaroid camera,

photographs were made which showed the motion of the pendulum .

These photographs indicated that in over two-thirds of the

trials the pendulum was lagging the pivot radius by 20 ° or less

at the moment the pivot radius was horizontal. Some interfer­

ing facto r was causitig the pendulum to lead the r ad ius extension

sometimes and then lag by over 20° in other instances.

This variation in angles was believed to be due to the

low power of the motor as surging of the hub was viewed follow­

ing the i mpact of the pendulum on the impacti ng roll. · novever,

wi th a favorable percentage of the photographs shoving accept­

ab le operation, it was decided to fabricate the pe~dulum in

steel using the relationships of Run 36~

Using this se cond pendulum, attempts were made to obtain

noderate ro~ational sp eeds compared to the desired 1920 rpm.

30.

These attempts were failures. Pendulum arms broke and pivot

bearing shoved danage. In an attempt to · reduce these effects

the cross-section of the arm was continually increased, but

this did not solve the problem of arm breakage or damage to the

bearing. Furthermore, the increase in the size of the arm

affected the .motion of the pendulum. The larger arm in effect

was moving the center of mass toward the pivot, vhich, in turn

was changing the r~tio of a to L causing the pendulum to lag ~S$£,e

the pivot radius to a ~eaier degree.

The damage to the p ivot bearing indicated that the im-

pact was not taking place at the center of percussion. Once

the pendulum design was modified . so that the point of impact

and the center of percussion coincided, the rotational speed

could be increased without damage. The .center of mass of the

pendulum was maintained at ~.70 inches froM the pivot, but the

.overall pendulun length was increased sienificantly to 6.10

inches. This increased length delayed the time of release

fron the impacting roll and, hence, the result was that the

pendulum lagged the pivot radius at impact.

An additional problem evolved as the rotational speed

increased. This w~s the rebounding of the pendulum off of the

impacting roll at these higher speeds. Not only did the pen-

dulum rebound off the im9acting roll but also off the h~b

surface. The continual· rebounding between the impacting roll

and the hub surface meant the pendulun was not being released

from the im!?acting roll surface with zero relatiYe velocity.

31 .

Release of the pendulum wfth some initial re l ative velocity ,

-whether in the direction of decreasing ~ or not, meant that

the pendulum ' s motion was no longer repetitive. Some ~eans

had to be devised to control the point end velocity at which

the pendulum was re l eased . A mechanism called an escapement

was installed o n this second rotary pendulum (see Figur e 17 ).

The escapement ar r ested t he suc cessiv e r ebounds between t he

hub and impacting rol l , a n d provided, a definite point of r e -

lease fo r the pendulum.

~ow, it was found that at rotational speeds in the gen-

eral range of 700 rpm, the carpet backing wns being da~aged and

the tufts vere bein~ pulled out and lover operation speeds were

indicated. However, a pendulum with the same nass as required

by the 1920 rpm condition would not produce dye impregnation

of the car pet at lower speeds if momentum was the physical

quantity required. Previous experimentation with dye expres -

sion had been carried out at low velocities using large masses .

This experience showed that carpet damage did not occur when

dye expression was achieved at these lov velocities. This led

to the consideration of energy as the pertinent physical quan-

tity involved in dye expression and penetration . The magnitude

of impactor energy but not the momentum at 300 rpm for the 225

gram pendulum vas near that of the machines from vhich experi -

ence had been dravn. Hence it appeared that the physica~

quantity desired was not momentum as originally believed, and

th~s ... l .o_we!' angula,r ~pe_e~s .. ":P_P~_ared feasible~ th the above !U'lal•. ysie it ta ~seumed that the stopping ot the hammei- in each c.ase · · waa· undatt eimilar conditions.

32.

The energy magnitude at approximately 300 r~m suggested

the idea of replacing the single pendulum with six pendulums

per unit width equally spaced around the hub •. This last ·

problem was solved by replacing the single pendulum per trans­

verse position, which called for 1920 rpm, by six pendulums

which required the easily obtainable rotational speed of 320

rpm.

To ascertain if the above idea was feasible, a dyeing run

was made using the existing one pendulum machine, and a carpet

speed of 1/6 of the proposed 1 0 yards per minute. This run

vas successful and a continuous strip of dye impregnated car­

pet the width of the pendulum head was obtained .

When considering the usage of the six pendulu ms per posi­

tion in - a machine which ultimately would be 180 in~hes wide,

the problem of positioning the pendulums so that they would

not interfere with one another arose. A satisfactory tessel­

lation for positioning the pendulums was found using impactor

faces 1 -1/8 inches wide and is shown i n Figure 15. This

tessellation h a d the advantageous built-in feature that pro­

vided for overlapping of the impact areas. This overlapping

meant tha t a carpet would be dyed uniformly. The pendulum

arrangement and pendulum head width was such that the total

area of the carpet would be .uniformly i mpac ted with the ex­

ception . of three-fourths of an inch on each outside edge.

However, this portion of the carpet is trimmed during further

finishing steps and presents no problem .

180°

TWO IMPACTons 180° APART LIE ON EACH 3/8" LONGITUDINAL POSITION

r;•c;c:;c~;· .~ -;~~~~t~ ··~~~:~~~~~·~•m••~•

• _ :. ·~'::f:".::-~;:::~?..::. ::::::~·z~::-~7. .. ~ ~:~: --· ; ·:-.~·1-- r;;i~9- -- - - - - -t .::~ . .J-.: ~·~~· - · ·~ :..~-~-- -i; ~ ::-. : ,- - - ·- - -r l

j I • - . • • ~ j ;..,.__. . - - ·· ·

L1MPACTOR HEAD IMPACTOR PIVOT ;.... .. , ...... -· ... ...:

180° EXPANS\ON OF lMPACTOR DRUM SHOW\NG IMPACTOR TESSELLATlON

THE ORUM 15 OtVIDEO LONGITUDINALLY INTO 3/a" DIVISIONS AND TV'JO IMPACTORS 160° APART ARE CENTEnED ON EACH 3/811 DIVISION. THE IMPACTOR HEADS ARE Sx3/s''( IYa11

) \VIOE so THAT IN ONE REVOLUTlO.N OFTHE ORUM EACH 2/8" LONG\TUOINAL POS\T\ON OS: THE MATERIAl UNDERGOING IMPACT RECEIVES SlX IMPACTOR BLOWS.

SCALE: ~ULL SIZ.E

FIGURE 15 --.

34.

Intermeshing of the impactors vithout collision among

themselves is dependent upon control of ~he pendulum motioh,

both before and after i~pact. Control of a pendulum means

that the pendulum ·must be arrested and released unfailingly

from a predetermined pos ition. A mechanism called an escape­

ment was e mployed to assist in arresting the rebounding pen-· .

dulums and to provide a definite release point. The escapement

is a flexible surface which moves in a circle around the hub

axis. A feature of this escapement device is thet the pendulum

release point can be varied, thus causing the pendulum to strike

fr om the radial position or any other desired position in its

flight. This feature of the escapement is used to vary the

striking velocity making it possible to regulate the impact

energy to . the penetration requirement of the particular carpet

being dye impregnated .

With the employment · of the escap ement the requireme nt that

the pendulum be radial in one machine unit of time from the

ori g inal release position was removed. A ratio · of pendulum

len gth to hub radius vhich p roduces a more rapid closure rate

of ¢ was now needed since an effective escapement would reduce

the angle traversed by the pendulum during free fli eht . Since

the equation of motion involves only a ratio of the hub radius

and pendulum leneth, any values of a and L can be used as long

as the ratio is within the limits of the original solutions.

Information on the mo tion of the pendulum can be deter mined

for any values of a and L f rom those ~lready calculated by the

computer. Figure 16 is an example of how to obtain this in­

formation for any ratio within the above limits. The layout

of the rotary pendulum assembly is shown in Fi gure 17. Fig­

ure 18 illustrates the arrangement of six pendulums which would

be found in a cross - section of tbe machine 1-1/8 inches wide.

Figure 19 shows the flight of a rotary pendulum from

various escapement openings. From photographs similar to

these, the velocity ·of ' the pendulum relative to the pivot

radius at . impact could be determined by knowing the flash

frequency of the strobe and measuring the distance between the

pendulum head centers. Such .measurements of the velocity in

the above manner show agreement with the velocities that are

predicted by the plots.

36.

FIGURE 16

Th i s figure is an example of how to extract p endulum motion information from the analog plots. A &iroi lar exercise vas ·carried out in· order to obtain the escapement ppening required. fo r radial positioning of the pendulum. Using this opening, the release point relative to the im­pact ing roll could . be determined . An adjustible escapement a l ong with a stat i onary section, could be designed so any position o f the pendulum up to radial could be used for impacting the carpet.

For example, using the present parameters of the mach ine

L = 4.45" a = 6.31"

a + L = 1 0 .76 "

the escapement opening for radial positioning can be cal­culated. To convert the present parameters to those of a n analog plot , sett i ng u p a ratio using a/(a+L ).

Pr esen t parameters : 6 .31" 10. 76''

Plot: a 7.50"

Equate th e tvo ratios and solve for the hub r adius , a

or a = 4.40" .

Ho anal os plot exists for ~ = 4.40''. Using the i nfor­mation in Figure 10, the angle K is 27 5°. However, the percentage o~ the hub rota tion, K, for r ad i a l posi tioning can be obtained for Figure · l3. The percentage of K for radial positioning vhen a is 4.40'' (and L = 3 .10 " ) i s 34 . 7 . The desired percentage of K = 275° x .347 = 95°.

The escapement must be opened 49° more than the desired perc entage of K to release the pendulum when the p ivot is at K, in order to allow for the pendul um arm . The escape­ment opening therefore is 95° + 49° or 1 44° in order to r adially position the pendulum at i mpact.

LAYOUT OF· THE ·IMPA.CTOR ·ASSEMBLY lf\l THE MACHINE

;-ESCAPEMENT . f ~,--------1 2.0 i" ~

,, l • 6.31 ~

- - - - - - ----- -- - '[_'='_J ____ -- --- -- -5~-:- PENDULUM

HU 8----------

STA Tl ONA RY PORTION OF __ ESCAPEMENT

IMPACTING ROLL:--

· FIGURE 17

w -4 .

I i 1-I ·

t ' \ . \ \

( -. . .\ \...::. }

~-- _.,,,/ ------

' .,

-

-

2

40.

V. CONCLUSIONS

A prototype machine as proposed in the introduction to ·

dye carpet was fabricated using the rotary pendulum as the. im­

pacting device. The machine would impregnate a carpet strip

4-1/8 inches wide. The six pendulums per position (l-1/8 in­

ches in width) concept of the hub roll was used, with the

maximum speed of rotation b~ing 300 rpm. The tessellation

shown in Figure 15 was used to locate the pendulum pivots on

the hub. The hub had a radius of 6.31 inches, and the indi­

vidual rotary pendulums (22 in all) had a center of gravity

4.45 inches from the ~ivot, and a center of percussion 5,70

inches from the pivot. The center of percussion co i ncided

with the striking point.

Carpet was fed through the machine simultaneously with

the dye reservoir at 10 yards per minute. The ~scapement was

opened and slowly increased until the rotary pendulums were

impacting in a radial position. The carpet was impregnated

with dye from the reservoir using the rotary pendulum impact i ng

devices.

Conclu~ions which can be drawn from the developments

41.

leadins up to and through the above test are:

1. The rotary pendulum can be controlled and us ed as

a machine component;

2. Carpet can be dye impregnated using the r otary

pendulum machine;

3. The theoretically determined values o f velocity~

position and escapement opening, u s ing the equation

of motion for the rotary pendulum and other infor­

mation obtainable from the analog plots vary no more

than 7 percent f rom the measured values.

42.

• GLOSSARY OF TEXTILE TERMS16

BEAM DYEING - The greige carpet wound on a special perforated beam is placed in a dye machine. The dye soluti on is pumped through the carpet from the center of the beam outward and then from the outside carpet surface to the center of the beam.

CUT-PILE CARPETS - These have a surface of brushlike tufts which stand up from the backing , as in corduroy and velveteen fabrics.

DRYER - Various applications of heat to evaporate moisture.

DYE, DY ESTUFF - The name given to solutions or naterials that color textiles.

DYEING - P r ocess of add~ng a comparatively permanent color to any fiber or fabric. Dyes may be either natural or synthet ic, and differ in effectiveness and metho ds of a~~lication .

FIBER - A basic complete unit in the fabrication of a textile yarn or f abric.

FRIEZE - Heavy, rough, fuzzy, wiry faced material .

GREIGE GOODS (GRAY, GREY, ~RIEGE) ·- Fabrics, irrespective of color, that have not received any wet processing.

LEVEL DYEING - The dyeing of fabric to p roduce uniformity of color with no streaks or shaded areas.

MOISTURE CONTENT - The moisture present in a textile material expressed as a percentage of the material weieht.

PACKAGE DYEING - A method of dyeing yarn . The yarn is vound uniformly on nerforated spools or tubes . These p a cka8eS are then placed i~ a special dyeing machine in wh i ch the liquor · is circulated through the yarn alternately from the .outside of the packase to the center and then from the center to th e outside.

PADDER - A set of squee ze rollers used to impregnate any fabric vith a liquid by continuous passage of th e ~abric ~hrough the liquid and then between the rollers.

PIECE · - A length of fabric.

PIECE DYEING - The fabric is dyed a solid color by complete immersion.

PILE ~ The cut thread~ of uncut loops which make the surface of a pile fabric~

RUNNING YARD - One yard of ·cloth regardless of width in vbicb it is constructed.

SHADED GOODS - A finishing defect in which the fabric shovs uneven coloring.

SKEIN DYEING - Dyeing yarn that has been reeled into hanks .

STOCK DYEING - Dyeing loose fibers in bulk form, before any yarn manufactur ing operations have begun.

TWIST - The number of turns per unit len s th of yarn, such as turns per inch~

WET FINISHING - Generally applied to ell finishing operati ons in ~hich the .fabric or yarn encounters liquids as any part of the operation.

44 .

REFERENCES

1 . Barvick- Chemst r and Car net Se mi nar, p . 32 .

2. Ibid ., p . 1 1 .

3. Ibid., p . 11.

4. Carnet Manufacture, p. 1 09.

5 . Barwick- Chemstrand Carnet Seminar, p . 1 1.

6 . Personal conveyance ·rrom E . V. Burnthall, Monsanto Company .

7. Personal conveyance from Egan Hacklander, Monsanto Company.

8 . Encyclopedia of Textiles, p . 505 .

9, Barv ick- Chemstrand Carnet Seminal:, p. 15 .

10 . Encyclopedia of Texti~cs , p . 505 .

11. Paterson, J.G.T . , and Smith , A. P . , A Compendium Report on _!;he Design a~e~_lopment of l!!roa_ct Dyeing Machinery, p. 11 . .

12. Personal conveyance from J. E . Hendricks, Monsanto Company .

13. Paterson, J . G.T., and Smith , A . P . , A Comnendium . . . Dyeing ?·1 a c h i n e r .l , p • 4 O •

1 4 . Smith, A. P . , La.borator_.y_ .. lfotebook C- 47 , p . 44 . ----- -· .

1 5 . Paterson, J.G . T., and Smith, A. P . , A Compendium .__!_J)~...!EJl Machincri, p . 10 , ·

16. Encyclo_pedia of Te~til~, pp . 505-522 .

BIBLIOGRAPHY

1. Barwick-Chemstrand Carnet Seminar. Decatur, Alabama, Monsanto Company, 196b.

2~ Carpet Manufacture. Decat~r, Alabama, Monsanto Company, 19-63.

3. Encyclopedi~_of _Textiles • . Englevood Cliffs, N. J., Prentice-Ball, Incorporated, 1960.

4. Smith, A. Paul. Laboratorv Notebook C-47. Decatur, Alabana, Monsanto Company, 1965.

5. Paterson, James G. T., and Smith, A. P. A Comnendium Report on · the DesiP,n and Develonment of Imn act Dyeing Machiner~. Decatur, Alabama, Monsanto Company, 1967.

46.

VITA

Ashley Paul Smith was .born July 24, 1937· in Charleston~ West Virginia, to Coleman Ashley Smith and Helen Caldwell Smith. While in elementary school he became a Christian and joined a Baptist church. Paul graduated from Thomas Jefferson High School, Richmond, Virginia in 1955.

Paul entered the University of Richmond, Virginia in September, 1955. lie ran cross country and track for the uni­versity. In June, 1960 he · graduate d from the University of Richmond with a bachelor of science degree in Physics . While doing graduate work in Physics at the university he was elected to member ship in Sigma Pi Sigma.

Durine the tvo years of graduate study from 1960 through 1962, he vas a laboratory instructor in Physics · at the Medical C~llege of Virginia. In 1961 the instruction of a Physics course at Saint Patrick's High School vas added to his experi­ence. In 1961 he married Sharon Anne Slate of Petersburg, Virginia. They have three sons~ Steven Paul, Scott Ashley, and David Irby; their ages respectively are 6, 3 and 1.

In 1962 Paul accepted an instructor's position in Physics in the Physical Science Department of Northwestern Stete College of Louisiana, at Natchitoches, Louisiana. The following year he joined Chemstrand Company (now the Textile Division of Monsanto Company) in Decatur, Alabama, as a textile eng ineer in th~ Creative Products Group. In 1968, Paul chan g ed to his present employer and location, Northrop Carolina, Inc., Ashe­ville, North Carolina , as a machinery design eng ineer in the Textile Machinery Design Group.

Re is a member of the Land of the Sky Chapter of American Society .of Textile and Manufacturing Eng~neers.

ACKNOWLEDGEMENTS

In addition to those .already ment ioned as r efer e n ces ,

others have contributed signifi c a ntly to the theoreticai de­

vel opment and fabrication of the r otary pendulun dyeing mach ine.

Appreciation is extendea to Monsant o Company for the use of this

material and under whose auspices the research vas carried out.

In particular, R . E . Opfer kuch , James G. T . Pate r son, W. T .

Pigot, a nd Bill Washington were major suppor ter s of t his

project.

Dr. Addison D. Campbell, as advisor, and Mmes . T. S .

Boughman and Way ne Burleson, who prepared the manuscript , are

acknowledsed for their valuable assistance in th is thesis

presentation.

A special word o f appreciation is due my wi fe , Shar on,

and my parents for the i r encouragement in this endeavor.