Multi-layer composite weaving method of worsted wool fabric

Abstract

The invention relates to the technical field of textile weaving, and discloses a multi-layer composite weaving method for worsted wool fabric, which comprises the following steps: preparing plush warp yarns, composite weft yarns and shaping warp yarns which are formed by blending various fibers; sequentially carrying out dyeing and sizing treatment on the yarns; a weaving machine is transformed to meet the multi-layer composite weaving requirement; applying the transformed weaving machine to implement multi-layer composite weaving, including warping, drafting and reed passing and weaving, and controlling corresponding process parameters; and carrying out on-line detection in the weaving process and quality detection on the woven gray fabric. The plush warp yarn, the composite weft yarn and the shaped warp yarn are formed by blending various fibers, the yarn performance is enriched, the plush warp yarn has the warm-keeping and soft characteristics, the composite weft yarn has the antibacterial and health-care functions, microorganism breeding is inhibited, the warm-keeping performance is improved, and human body microcirculation is promoted, and the shaped warp yarn enhances the strength and stiff and smooth degree. The overall quality of the worsted wool fabric is improved, and the market diversification requirements are met. The problem of performance limitation of a single fiber is solved.

Description

Technical Field

[0001] The present invention relates to the technical field of textile weaving, and specifically to a multi-layer composite weaving method for worsted woolen fabrics. Background Art

[0002] As a high-grade textile fabric, worsted woolen fabrics have long been widely and importantly used in many fields such as clothing and decoration. In the development process of the textile industry, yarns made of single fibers have many limitations in performance and are difficult to meet the increasingly diverse market demands.

[0003] People mostly use natural fibers such as wool, cotton, and silk for textile. Wool fibers have good warmth retention but not delicate enough handfeel, and are vulnerable to moth-eating and mildew; cotton has strong hygroscopicity but poor elasticity and insufficient gloss; silk is soft, smooth, and has beautiful gloss, but has limited production and high price. With the emergence of chemical fibers, although polyester fibers, polyamides, etc. have advantages such as high strength, wear resistance, easy washing and quick drying, their hygroscopicity and air permeability are poor, the wearing comfort is far less than that of natural fibers, and most chemical fibers are difficult to degrade, causing great pressure on the environment. Summary of the Invention

[0004] Aiming at the deficiencies of the prior art, the present invention provides a multi-layer composite weaving method for worsted woolen fabrics, which solves the problem of performance limitations of single fibers.

[0005] To achieve the above purposes, the present invention is realized through the following technical solutions: A multi-layer composite weaving method for worsted woolen fabrics, including the following steps: S1. Prepare plush warp yarns, composite weft yarns, and sizing warp yarns made of a blend of multiple fibers; S2. Dye and size the yarns in sequence; for the dyeing treatment, use dyes suitable for the fiber components of each yarn and operate according to the corresponding dyeing process parameters. The dyeing process parameters include the pH value of the dye bath, the bath ratio, the heating program, and the holding time. After dyeing, perform conventional post-treatment to ensure color fastness; for the sizing operation, select different mixed sizing materials for the plush warp yarns and the sizing warp yarns, and form a uniform sizing film on the surface of the warp yarns by adjusting the pressure of the squeezing roller, the temperature of the drying cylinder, and the sizing speed; S3. Modify the loom to adapt to the requirements of multi-layer composite weaving; the loom modification includes adding warp beams, adjusting the shedding mechanism, and optimizing the weft insertion system, and ensuring the coordinated operation of each component of the loom through corresponding adjustments; S4. Implement multi-layer composite weaving using the modified loom, including warping, threading through heddles and reeds, and weaving, and control the corresponding process parameters; adopt the sectional warping method, and divide the warp yarns into different areas for threading according to the design requirements of the fabric; S5. Conduct on-line detection during the weaving process and quality inspection of the grey cloth after weaving. Use a variety of detection devices to monitor key parameters in real time during the weaving process. When the parameters are abnormal, automatic adjustment measures can be taken or an alarm can be issued. Specifically: Install a tension sensor at the key parts of the warp yarn. The tension of the warp yarn deforms the strain gauge in the sensor, changes the resistance value, and is converted into an electrical signal through the circuit and transmitted to the control system. When it exceeds the preset tension range, the system automatically adjusts or triggers an alarm to avoid the impact of abnormal tension on weaving; Utilize the principle of photoelectric induction. When the weft yarn is normal, the light is unobstructed. When it breaks, the light is blocked. The sensor converts the change in the light signal into an electrical signal and transmits it to the control system, causing the loom to stop and display the position of the broken end for easy handling; Use a high-definition camera to collect fabric images and transmit them to a computer system with an image recognition algorithm. Based on deep learning technology, it analyzes and compares the real-time images according to the defect characteristics mastered through pre-training, and determines whether to stop the machine for processing according to the severity of the defects; Monitor parameters such as loom speed, motor current, and temperature through corresponding sensors. When it exceeds the normal range, the control system ensures the stable operation of the equipment and the weaving process according to the preset strategy; Use a fabric density mirror to measure the number of warp and weft yarns within a certain length at different parts of the grey cloth and calculate the average value, and compare it with the design value. If the error exceeds the range, trace back to the weaving link for adjustment; The electronic fabric strength testing machine stretches the specimen at a constant speed, and the force sensor measures the maximum tensile force at break. After testing in the warp and weft directions and comparing with the standard requirements, if it does not meet the requirements, check the reasons and make improvements; The pendulum type tearing strength tester tears the specimen with a pendulum, and the sensor measures the maximum tearing force value, and judges according to the standard. If it does not meet the standard, analyze the reasons and optimize; Use an electronic balance to weigh a sample of the grey cloth with a certain area, convert it into grams per square meter, and compare it with the designed gram weight. If the deviation is large, trace back to the weaving link to solve; Use professional instruments to measure indexes such as yarn fineness and twist respectively, and compare them with the design specifications. If they do not meet the requirements, check the spinning link for adjustment; Use a measuring tool to directly measure the width of the grey cloth and compare it with the designed width. If it does not meet the requirements, check the relevant weaving link for optimization; Simulate different scenarios for testing according to the standard with the corresponding instrument; Manually visually inspect the surface of the grey cloth in combination with lighting, classify and record according to the severity and distribution of the defects, and process defective products according to the rules to ensure the appearance quality.

[0006] By adopting the above technical solutions, first, prepare yarns blended with a variety of fibers to make up for the limitations of single fibers and improve the fabric quality; then, carry out dyeing and sizing treatments to ensure the color and fastness of the yarns and enhance the performance of the warp yarns; then, transform the loom to achieve multi-layer interweaving, break through the structural limitations, improve the weaving stability and expand the design space; then, use the transformed loom to carry out weaving, control the parameters of each link, and produce high-quality multi-layer composite fabrics; finally, conduct on-line detection and grey cloth quality inspection to ensure the weaving quality, trace problems and optimize the process, comprehensively improve the fabric quality, function, appearance, production stability and efficiency, enhance the market competitiveness of the products, and meet diverse needs.

[0007] Preferably, in S1, the raw materials of the plush warp yarn, the composite weft yarn, and the sizing warp yarn each contain at least two different types of fibers, which are blended into yarns through the spinning process. The spinning process includes conventional fiber pretreatment and yarn forming steps.

[0008] Preferably, in S4, a warping machine is used to wind the warp yarns onto a loom beam according to the preset warp yarn arrangement order and density, while controlling the warping tension and speed.

[0009] Preferably, S4 also includes selecting appropriate threading and reed denting methods according to the design requirements; during weaving, controlling the loom speed, the warp yarn and weft yarn tensions, and reasonably regulating the structural parameters of each layer of the composite fabric.

[0010] Preferably, S5 also includes detecting the warp and weft densities, strength, gram weight, width, color fastness, and appearance defects of the grey fabric, judging the quality of the grey fabric by comparing with the preset standards, and processing the non-conforming grey fabric according to the corresponding rules.

[0011] The present invention provides a multi-layer composite weaving method for worsted woolen fabrics. It has the following beneficial effects: 1. By preparing plush warp yarns, composite weft yarns, and sizing warp yarns blended from multiple fibers, the present invention enriches the yarn properties. The plush warp yarns have characteristics such as warmth retention, softness, and luster. The composite weft yarns have antibacterial and health care functions, can inhibit the growth of microorganisms, maintain the hygiene of the fabric, improve warmth retention, and promote microcirculation in the human body. The sizing warp yarns enhance the strength and stiffness. Ultimately, the overall quality of the worsted woolen fabric is improved, meeting the diverse market demands. It solves the problem of the performance limitations of single fibers.

[0012] 2. By sequentially dyeing and sizing the yarns, the dyeing treatment can endow the yarns with rich colors and ensure good color fastness, enhancing the appearance aesthetic and competitiveness of the worsted woolen fabric. The sizing treatment can enhance the performance of the warp yarns, improve the weaving stability and efficiency, and contribute to the production of high-quality products. It solves the problems of uneven dyeing and poor abrasion resistance of the warp yarns.

[0013] 3. By modifying the loom to adapt to the requirements of multi-layer composite weaving, the present invention realizes precise multi-layer structure weaving, can create worsted woolen fabrics with diverse functions and rich appearances, improves the weaving quality and efficiency, reduces various weaving problems, and also expands the fabric design space, providing more material choices for related application fields. It solves the limitation problem that traditional looms can only produce single-structure fabrics.

[0014] 4. By implementing multi-layer composite weaving with the modified loom, the present invention can achieve precise warp arrangement and winding, obtain appropriate fabric structures and densities, ensure a stable weaving process, and finally produce high-quality multi-layer composite wool worsted fabrics with good layering, functionality, and appearance. It solves the problems of uneven warp arrangement and tension, and poor fabric quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a flowchart of the multi-layer composite weaving method for wool worsted fabrics proposed by the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0016] Next, the technical solutions of the present invention will be clearly and completely described in conjunction with the drawings of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0017] Please refer to the attached Figure 1 , the embodiment of the present invention provides a multi-layer composite weaving method for wool worsted fabrics, including the following steps: S1. Prepare plush warps, composite wefts, and sizing warps made of a blend of multiple fibers.

[0018] In S1, the raw materials of the plush warps, composite wefts, and sizing warps each contain at least two different types of fibers, and they are blended into yarns through the spinning process, which includes conventional fiber pretreatment and yarn forming steps.

[0019] Specifically, by blending multiple fibers, the advantages of each fiber are fully utilized to achieve complementary advantages, so as to meet the requirements of different properties of the fabric for the multi-layer composite weaving of worsted woolen fabrics. Different fibers have different physical and chemical properties. For example, wool has good warmth retention and elasticity, cashmere is soft and delicate, silk is smooth and has a unique luster, and functional fibers such as jade fiber filaments can endow the fabric with health care functions. During the contact with the human body, trace elements beneficial to the human body, such as selenium, zinc, nickel, cobalt, manganese, etc., will be released. These trace elements can be absorbed by the human skin and help regulate the body's metabolism to a certain extent, such as promoting blood circulation and enhancing cell vitality, etc., playing a positive health care role for the long-term wearers. In the spinning process, fiber pretreatment is used to remove impurities and improve fiber properties, and then through the yarn forming step, different fibers are evenly mixed and tightly combined to form a yarn with good comprehensive performance, integrating the advantages of different fibers. For example, combining the warmth retention and elasticity of wool, the softness and delicacy of cashmere, and the smoothness and unique luster of silk, making the yarn not only have good warmth retention ability and elastic recovery ability, but also feel soft and smooth, with a natural luster in appearance, improving the overall texture and beauty of the yarn, laying a foundation for the subsequent weaving of high-quality and beautifully-appearing worsted woolen fabrics.

[0020] Furry warp yarn: Select Merino wool with a fineness of 15 - 20μm and a length of 75 - 80mm, cashmere with a fineness of 10 - 15μm and a length of 40 - 45mm, and mulberry silk with a length of about 1000 - 1200mm as raw materials. First, these fibers are pretreated, including operations such as opening and impurity removal, to remove impurities, defects, and short fibers in the fibers, and improve the looseness and uniformity of the fibers. Then, they are blended in the ratio of 60% Merino wool, 30% cashmere, and 10% mulberry silk, and successively go through yarn forming processes such as carding, drawing (usually three drawing processes), roving, and spinning. In the spinning process, the roving twist coefficient is controlled at 80 - 100, the spinning twist coefficient is between 300 - 350, and the spindle speed is set at 12000 - 15000r / min to ensure the quality and performance of the yarn.

[0021] The raw materials for the plush warp yarn include Merino wool with a fineness of 15-20μm and a length of 75-80mm, cashmere with a fineness of 10-15μm and a length of 40-45mm, and mulberry silk with a length of approximately 1000-1200mm. These fibers undergo pretreatment, including opening and cleaning, to remove impurities, defects, and short fibers, and improve fiber bulk and uniformity. The yarn is then blended in a ratio of 60% Merino wool, 30% cashmere, and 10% mulberry silk. The yarn is then formed through the following steps: carding, drawing (usually three times), roving, and spinning. During the spinning process, the twist coefficient of the roving is controlled at 80-100, and the twist coefficient of the spun yarn is between 300-350. The spindle speed is set at 12,000-15,000 r / min to ensure yarn quality and performance.

[0022] The composite weft yarn is made from the aforementioned Merino wool and jade fiber filaments with a linear density of 45-55 dtex, with a ratio of 70% wool to 30% jade fiber. The raw materials are similarly pretreated before being blended using compact spinning technology. During the compact spinning process, the negative pressure of the compact spinning device is set at 20-30 hPa, and the length of the compacting zone is set at 25-30 mm. This tightly aggregates the fibers, reduces hairiness, and improves yarn strength and uniformity. This, to a certain extent, helps regulate metabolism, promotes blood circulation, and enhances cell vitality.

[0023] The shaped warp yarn is a blend of cotton yarn with a fineness of 1.5-2.0 dtex and a length of 30-40 mm, and polyester fiber with a length of 35-40 mm and a linear density of 1.2-1.5 dtex, at a ratio of 55 parts cotton to 20 parts polyester. After cleaning, carding, drawing (with appropriate adjustments to the draw frame's draft distribution and roller grip), roving, and spinning, the yarn is produced. During the spinning process, the twist coefficient of the roving is controlled between 70-90, and the twist coefficient of the spun yarn is set at 250-300. The spindle speed is maintained at approximately 10,000-13,000 r / min, resulting in a shaped warp yarn with a certain strength and stiffness.

[0024] By preparing plush warp yarns, composite weft yarns, and shaped warp yarns blended from multiple fibers, yarn properties are enriched. The plush warp yarns are endowed with warmth, softness, and luster. The composite weft yarns have antibacterial and health-promoting properties, inhibiting microbial growth, maintaining fabric hygiene, improving warmth, and promoting microcirculation in the human body. The shaped warp yarns enhance strength and crispness, ultimately improving the overall quality of wool worsted fabrics and meeting diverse market demands. This addresses the performance limitations of single fibers.

[0025] S2. dyeing and sizing the yarn in sequence.

[0026] In S2, for the dyeing process, dyes suitable for the fiber components of each yarn are used and operated according to the corresponding dyeing process parameters. The dyeing process parameters include the pH value of the dye bath, the bath ratio, the heating program, and the holding time. After dyeing, conventional post-treatment is carried out to ensure color fastness.

[0027] S2 also includes: For sizing operation, different mixed sizes are selected for the plush warp yarns and the shaped warp yarns, and by adjusting the pressure of the squeezing roller, the temperature of the drying cylinder, and the sizing speed, a uniform size film is formed on the surface of the warp yarns.

[0028] Specifically, different fiber components have different chemical structures and physical properties, and also have different affinities for dyes. Therefore, it is necessary to select suitable dyes according to the fiber components of the yarn. In the dye bath, by controlling parameters such as the pH value of the dye bath, the bath ratio, the heating program, and the holding time, physical adsorption, chemical bonding, etc. occur between the dye molecules and the fiber molecules, so as to realize the diffusion and fixation of the dyes into the fiber interior. Post-treatment after dyeing, such as washing and soaping, can remove the unfixed dyes on the fiber surface and improve color fastness.

[0029] Dyeing of plush warp yarns: The plush warp yarns are made of a blend of wool, cashmere, and silk. First, pre-treatment is carried out, including scouring (treatment at 80 - 90 °C for 30 - 45 minutes in a solution containing an appropriate amount of soda ash and detergent), bleaching (using a hydrogen peroxide bleaching process, controlling the hydrogen peroxide concentration at 2 - 3 g / L, the stabilizer dosage at 1 - 2 g / L, adjusting the pH value to 10 - 11, and bleaching at 90 - 100 °C for 60 - 90 minutes). Environmentally friendly acid dyes are selected for dyeing, adjusting the pH value of the dye bath between 4 - 5, the bath ratio at 1:20 - 1:30, entering the dye bath at low temperature and then slowly heating to 95 - 100 °C, and holding for dyeing for 60 - 90 minutes. After dyeing, post-treatment such as washing (rinsing with running water at room temperature for 10 - 15 minutes) and soaping (treatment with a solution containing 1 - 2 g / L of soaping agent at 80 - 90 °C for 15 - 20 minutes) is carried out.

[0030] Dyeing of composite weft yarns: The composite weft yarns are made of a blend of wool and functional fibers. First, pre-treatment is carried out to ensure the purity and dyeing performance of the yarns. Reactive dyes and acid dyes are selected for compound dyeing. When preparing the dye solution, the dosage of the dyes is determined according to the fiber ratio and adsorption characteristics. Adjust the pH value of the dye bath to 6 - 7, set the bath ratio at 1:15 - 1:25, and adopt a segmented heating dyeing method (first dye with reactive dyes at 50 - 60 °C for 30 - 45 minutes, then heat up to 90 - 95 °C and add acid dyes to continue dyeing for 45 - 60 minutes). After dyeing, sufficient washing, soaping and other post-treatment are carried out.

[0031] Set - sizing warp yarn dyeing: The set - sizing warp yarn is a blend of cotton yarn and polyester fiber. Before dyeing, it is treated in a detergent - containing solution at 70 - 80 °C for 20 - 30 minutes to remove impurities, sizing agents, etc. Direct dyes are selected for dyeing. Weigh the dyes accurately as required, adjust the pH value of the dye bath to 7 - 8, with a bath ratio of 1:10 - 1:20. Heat - up for dyeing (starting from room temperature, heating up to 80 - 90 °C at a rate of 1 - 2 °C per minute, and maintaining the temperature for dyeing for 45 - 60 minutes), then carry out washing and fixing (treating with a solution containing 1 - 2 g / L of fixing agent at 60 - 70 °C for 15 - 20 minutes).

[0032] The sizing operation is to coat a layer of sizing agent on the surface of the warp yarn. By adjusting parameters such as the pressure of the squeezing roller, the temperature of the drying cylinder, and the sizing speed, the sizing agent can be evenly attached to the surface of the warp yarn and penetrate between the fibers inside the warp yarn. Under the action of the drying cylinder, the moisture in the sizing agent evaporates, forming a uniform sizing film, enhancing the abrasion resistance, smoothness, and strength of the warp yarn, and reducing the breakage rate of the warp yarn during weaving.

[0033] Fluffy warp yarn sizing: Select a mixed sizing agent formula with 60% starch - based sizing agent, 25% polyvinyl alcohol (PVA), and 15% acrylic - based sizing agent, and control the sizing agent concentration between 8% - 10%. On the slasher, adjust the pressure of the squeezing roller to 20 - 30 kN, set the temperature of the drying cylinder to 100 - 120 °C, and let the warp yarn pass through the sizing trough and the drying cylinder at a speed of 20 - 30 m / min for sizing.

[0034] Set - sizing warp yarn sizing: Prepare a mixed sizing agent with 40% polyester sizing agent, 30% starch - based sizing agent, and 30% acrylic - based sizing agent, and control the sizing agent concentration within the range of 10% - 12%. When sizing, set the pressure of the squeezing roller to 25 - 35 kN, adjust the temperature of the drying cylinder to 110 - 130 °C, and keep the sizing speed of the warp yarn at 15 - 25 m / min.

[0035] By sequentially dyeing and sizing the yarn, the dyeing process can endow the yarn with rich colors and ensure good color fastness, enhancing the aesthetic appearance and competitiveness of wool worsted fabrics. The sizing process can enhance the performance of the warp yarn, improve the weaving stability and efficiency, and contribute to the production of high - quality products. It solves the problems of uneven dyeing and poor abrasion resistance of the warp yarn.

[0036] S3. Modify the loom to adapt to the requirements of multi - layer composite weaving.

[0037] In S3, the loom modification includes adding a warp beam, adjusting the shedding mechanism, and optimizing the weft insertion system, and ensuring the coordinated operation of each component of the loom through corresponding adjustments.

[0038] Specifically, increasing the number of warp beams on the basis of traditional looms is based on the principle that different warp layers are required for multi-layer composite weaving to construct the fabric structure. Warps with different functions and materials are wound around each warp beam respectively, and the delivery amount and tension of the warps are controlled by their respective independent warp let-off devices. For example, warps used to embody the plush texture of the fabric, warps for shaping, etc. are placed in different warp beams in layers. In this way, during weaving, according to the design requirements, each layer of warp can be accurately introduced into the weaving area in sequence and at a specific density, realizing the orderly interweaving of multiple layers of warps and laying the foundation for the formation of a multi-layer composite structure. And the parallelism between each warp beam is strictly controlled to ensure uniform warp tension when the warps are led out, avoiding uneven warp tension caused by installation deviation, which will in turn affect the accurate interweaving of warps and wefts and the fabric quality during the subsequent weaving process.

[0039] If a three-layer composite fabric is designed, three warp beams need to be equipped, which are respectively used to install the warp layers where the plush warps, shaping warps, and composite wefts are located (in the case of multiple layers of wefts, they can be reasonably arranged through methods such as splitting axes or winding in layers). The installation structure of the warp beams of the modified loom should ensure that the parallelism error between each warp beam is controlled within ±0.5 mm, ensuring the uniformity of warp tension when the warps are led out, and avoiding uneven warp tension caused by the installation deviation of the warp beams, which affects the weaving quality.

[0040] An electronic dobby shedding device is adopted. According to the functions played by different warp layers in the fabric and the weaving requirements, it accurately controls the shedding time, shedding height, and shedding sequence of each warp layer through programming. Different warp layers have different requirements for shedding due to their different thicknesses and functions. For example, the warp layer that is finer and used to create a plush effect has a relatively earlier shedding time and an appropriately increased shedding height, facilitating the weft to pass through smoothly and forming a plump plush appearance; while the warp layer for shaping has a slightly delayed shedding time and a slightly smaller shedding height to ensure that it closely adheres to the upper layer of the fabric after interweaving with the weft to maintain the structural stability. At the same time, a tension compensation device is installed. The tension sensor is used to monitor the tension change of the warp during the shedding process in real time. When the warp tension exceeds the set normal range, the tension compensation device will automatically adjust the movement speed or position of the heald lifting lever, etc., to fine-tune the warp tension. This is because the shedding action will cause fluctuations in the warp tension. If it is not compensated and adjusted in time, problems such as friction, breakage, or unclear interweaving between the warps are likely to occur, affecting the weaving quality.

[0041] An electronic dobby shedding device is adopted. For the plush warp layer, according to its relatively fine requirement and the need to form a rich plush effect, the shedding time is advanced by 5° - 10° relatively (referring to the loom main shaft angle), and the shedding height is set to 8 - 10 mm to ensure that the weft yarn can pass through smoothly and form a plump plush appearance; for the setting warp layer, since it mainly plays a setting role, the shedding time can be appropriately delayed by 3° - 5°, and the shedding height is controlled within 6 - 8 mm to ensure that it can closely adhere to the upper layer of the fabric after interweaving with the weft yarn and maintain the structural stability. At the same time, a tension compensation device is installed in the shedding mechanism to monitor and compensate the tension changes of each warp yarn during the shedding process in real time. When it is detected that the warp yarn tension exceeds the set normal range (such as the tension fluctuation of the plush warp yarn exceeds ±2 cN, and the tension fluctuation of the setting warp yarn exceeds ±1.5 cN), the tension compensation device automatically fine-tunes the warp yarn tension by adjusting the movement speed or position of the heald lifting rod, etc., so that the interweaving between the warp yarns is clear, reducing the friction and breakage between the warp yarns, and improving the weaving efficiency and quality.

[0042] The rapier weft insertion method is selected, and the rapier head structure is improved according to the characteristics of the composite weft yarn (such as containing functional fibers, which may be relatively slippery and have different stiffness). The yarn clamping device of the rapier head adjusts the clamping pressure through the feedback of the pressure sensor. The principle is that the appropriate clamping pressure can not only ensure the firm clamping of the composite weft yarn to prevent the weft yarn from slipping during the weft insertion process, but also will not damage the weft yarn fibers due to excessive pressure. During the weft insertion process, according to the tension feedback of the weft yarn, the weft insertion speed and tension are dynamically adjusted by adjusting the speed of the weft insertion motor, the damping of the weft yarn tensioner, etc. Because the resistance, the required insertion speed and tension of the weft yarn are different in different weaving areas and at different times, only by dynamically and accurately controlling can we ensure that the weft yarn can be evenly and smoothly introduced into the fell of the cloth, realize the accurate distribution of the weft yarn in each layer of the fabric, and ensure the consistency of the fabric quality.

[0043] The rapier weft insertion method is selected. Based on the characteristics of the composite weft yarn (such as containing jade fiber filaments, being relatively slippery and having a certain stiffness), the rapier head structure is improved. A yarn clamping device for the rapier head is designed to enable it to clamp the composite weft yarn more firmly and avoid the phenomenon of weft yarn slippage during weft insertion. The yarn clamping pressure of the rapier head is monitored in real time by a pressure sensor and feedback adjusted to control the yarn clamping pressure between 5 - 8 N, ensuring both stable yarn clamping and no damage to the weft yarn due to excessive pressure. At the same time, parameters such as the weft insertion speed and tension are adjusted. The weft insertion speed is optimized according to the complexity of the fabric structure and the performance of the loom. For the multi - layer composite fabric of this design, the initial weft insertion speed is set within the range of 800 - 1000 m / min. At the same time, according to the weft yarn tension feedback (monitored in real time by a tension sensor installed on the weft insertion path, and requiring the composite weft yarn tension fluctuation to be controlled within ±3 cN), by adjusting the speed of the weft insertion motor, the damping of the weft yarn tensioner, etc., the weft insertion speed and tension are dynamically adjusted to ensure that the weft yarn can be smoothly introduced into the cloth fell and the distribution of the weft yarn is uniform and consistent across the entire weaving width, guaranteeing the stable quality of the fabric.

[0044] By modifying the loom to adapt to the requirements of multi - layer composite weaving, precise multi - layer structure weaving is achieved, which can create woolen worsted fabrics with diverse functions and rich appearances, improve the weaving quality and efficiency, reduce various weaving problems, expand the fabric design space, and provide more material selection for related application fields. It solves the limitation problem that traditional looms can only produce fabrics with a single structure.

[0045] S4. Implement multi - layer composite weaving using the modified loom, including warping, drawing through heddles and reeds, and weaving, and control the corresponding process parameters.

[0046] In S4, the warping equipment winds the warp yarns on the warp beam according to the preset warp yarn arrangement order and density, while controlling the warping tension and speed.

[0047] S4 also includes, for drawing through heddles and reeds, selecting appropriate heddle drawing and reed passing methods according to the design requirements; for weaving, controlling the loom speed, the tension of the warp yarns and weft yarns, and reasonably regulating the structural parameters of each layer of the composite fabric.

[0048] Specifically, the warping equipment winds the warp yarns on the warp beam according to the preset warp yarn arrangement order and density. This is based on the design requirements of the fabric. Different warp yarn arrangements and densities will affect the fabric structure and appearance. Through the automatic tension adjustment system, according to the characteristics of the warp yarns and the winding position, the tension of the warp yarns is adjusted in real time. For example, the plush warp yarns are relatively soft and require relatively small tension; while the setting warp yarns have higher strength and can withstand larger tension. Controlling the warping speed is to ensure the uniformity and stability of the warp yarn winding, and avoid excessive warp yarn tension fluctuations or uneven winding caused by too fast speed.

[0049] Using the automatic warping device of the warping machine, the warp yarns are wound onto the loom beam according to the designed warp yarn arrangement order and density. For plush warp yarns, the warping tension is controlled at 10 - 12 cN, and the warping speed is set at 300 - 500 m / min; for set warp yarns, the warping tension is controlled at 8 - 10 cN, and the warping speed is set at 350 - 550 m / min. Through the automatic tension adjustment system, the tension change of the warp yarns is monitored in real time and adjusted according to the set parameters to ensure the uniformity of the warp yarn tension.

[0050] According to the design requirements of the fabric, select the appropriate harnessing and reed denting methods. Harnessing is to pass the warp yarns through the heddle eyes according to a certain rule, and the shedding motion of the heddles forms the fell of the cloth, enabling the weft yarn to pass through smoothly. Reed denting is to arrange the warp yarns evenly in the reed dents. The reed not only plays a role in determining the warp yarn density but also can push the weft yarn towards the fell of the cloth during beating-up to form a tight fabric structure. Different harnessing and reed denting methods will affect the fabric texture and appearance effect.

[0051] Adopt the sectional harnessing method. According to the design requirements of the fabric, divide the warp yarns into different areas for harnessing. For example, the plush warp yarn layer and the set warp yarn layer are harnessed separately to ensure the independent movement and interlacing effect of each layer of warp yarns. According to the density requirements of each layer of warp yarns, select the appropriate reed count and pass the warp yarns evenly and neatly through the reed dents. The selection of the reed count should be reasonably adjusted according to the fineness and density of the warp yarns to ensure that the warp yarn density of the fabric meets the design requirements.

[0052] During the weaving process, controlling the loom speed can affect the weaving efficiency and fabric quality. If the loom speed is too fast, it may lead to unstable tensions of the warp and weft yarns and increase the breakage rate; if the loom speed is too slow, it will reduce the production efficiency. The tensions of the warp and weft yarns are monitored in real time through tension sensors and adjusted according to the preset parameters. Reasonable regulation of the structural parameters of each layer of the composite fabric is to adjust the interlacing method, density, etc. of the warp and weft yarns according to the functions and design requirements of different layers to achieve the effect of multi-layer composite.

[0053] During the weaving process, the initial loom speed is set at 300 - 400 revolutions per minute. After the weaving process stabilizes, the loom speed is gradually increased to 500 - 600 revolutions per minute. The tensions of the warp and weft yarns are monitored in real time through tension sensors. When the warp yarn tension exceeds the range of 10 - 15 cN, the warp yarn tension adjustment device is automatically adjusted; when the weft yarn tension exceeds the range of 3 - 6 cN, the weft yarn tensioner is automatically adjusted. Reasonable regulation of the structural parameters of each layer of the composite fabric, control the density of the upper plush warp yarns at 30 - 40 ends per centimeter, the density of the lower set warp yarns at 25 - 35 ends per centimeter, and the inclination angle of the composite weft yarns in each layer at 30° - 45° to achieve the effect of multi-layer composite.

[0054] By implementing multi-layer composite weaving with the modified loom, precise warp arrangement and winding can be achieved, appropriate fabric texture and density can be attained, a stable weaving process can be ensured, and ultimately, high-quality multi-layer composite wool worsted fabrics with good layering, functionality, and appearance can be produced. The problems of uneven warp arrangement and tension, and poor fabric quality are solved.

[0055] S5. Conduct on-line detection during the weaving process and quality inspection of the grey cloth after weaving.

[0056] In S5, various detection devices are used to real-time monitor the key parameters during the weaving process. When the parameters are abnormal, automatic adjustment measures can be taken or an alarm can be issued.

[0057] S5 also includes detecting the warp and weft density, strength, gram weight, width, color fastness, and appearance defects of the grey cloth. By comparing with the preset standards, the quality of the grey cloth is judged, and the non-conforming grey cloth is processed according to the corresponding rules.

[0058] Specifically, tension sensors are installed at the key positions of the warp. The warp tension deforms the strain gauge in the sensor, changing the resistance value. After being converted into an electrical signal by the circuit, it is transmitted to the control system. When the tension exceeds the preset range, the system automatically adjusts or triggers an alarm to avoid the influence of abnormal tension on weaving.

[0059] Using the principle of photoelectric induction, when the weft is normal, the light is unobstructed. When the weft breaks, the light is blocked. The sensor converts the change in the light signal into an electrical signal and transmits it to the control system, causing the loom to stop and display the position of the broken weft for easy handling.

[0060] The fabric image is collected by a high-definition camera and transmitted to a computer system with an image recognition algorithm. Based on deep learning technology, it analyzes and compares the real-time image according to the defect characteristics mastered through pre-training, and determines whether to stop the machine for processing according to the severity of the defect.

[0061] By monitoring parameters such as the loom speed, motor current, and temperature through corresponding sensors, when they exceed the normal range, the control system ensures the stable operation of the equipment and the weaving process according to the preset strategy.

[0062] Use a fabric density mirror to measure the number of warp and weft yarns within a certain length at different parts of the grey cloth and calculate the average value. Compare it with the design value. If the error exceeds the range, trace back to the weaving link for adjustment.

[0063] The electronic fabric strength testing machine uniformly stretches the specimen, and the force sensor measures the maximum tensile force at break. After testing in the warp and weft directions and comparing with the standard requirements, if it does not meet the requirements, check the reasons and make improvements.

[0064] The pendulum type tearing strength tester uses a pendulum to tear the specimen, and the sensor measures the maximum tearing force value. Judge according to the standard. If it does not meet the standard, analyze the reasons and optimize.

[0065] Weigh a certain area of grey fabric sample with an electronic balance, convert it into grams per square meter, compare it with the designed gram weight, and trace back to the weaving process to solve problems in case of large deviation.

[0066] Use professional instruments to measure yarn fineness, twist and other indicators respectively, compare them with the designed specifications, and check and adjust the spinning process in case of non - compliance.

[0067] Directly measure the width of grey fabric with a measuring tool, compare it with the designed width, and check and optimize the relevant weaving process in case of non - compliance.

[0068] According to the standard, use corresponding instruments to simulate different scenarios for testing, such as friction, washing, sunlight exposure, etc., compare with the color card to evaluate the grade, and find reasons for improvement from the dyeing and other links in case of non - compliance.

[0069] Visually inspect the surface of grey fabric by combining manual inspection with lighting, classify and record according to the severity and distribution of defects, and process defective products according to the rules to ensure the appearance quality.

[0070] Through the on - line detection during the weaving process and the quality inspection of grey fabric after weaving, it can ensure the weaving quality in real time, improve the operation stability of equipment, realize intelligent weaving management. It can also ensure that the products meet the quality standards, trace and improve the production process, and meet the diverse market demands, comprehensively improving the product quality and production management level. It solves the problems that it is difficult to detect sudden quality problems in weaving in time and the errors of manual monitoring.

[0071] Although the embodiments of the present invention have been shown and described, for those of ordinary skill in the art, it can be understood that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principle and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A multi-layer composite weaving method for worsted woolen fabrics, characterized in that, It includes the following steps: S1. Prepare plush warp yarns, composite weft yarns, and sizing warp yarns made of a blend of multiple fibers; S2. Dye and size the yarns in sequence; For the dyeing treatment, use dyes suitable for the fiber components of each yarn and operate according to the corresponding dyeing process parameters. The dyeing process parameters include the pH value of the dye bath, the bath ratio, the heating program, and the holding time. After dyeing, perform conventional after-treatment to ensure color fastness. For the sizing operation, select different mixed sizing materials for the plush warp yarns and the sizing warp yarns, and form a uniform sizing film on the surface of the warp yarns by adjusting the pressure of the squeezing roller, the temperature of the drying cylinder, and the sizing speed; S3. Modify the loom to adapt to the requirements of multi-layer composite weaving; the loom modification includes adding warp beams, adjusting the shedding mechanism, and optimizing the weft insertion system, and ensuring the coordinated operation of each component of the loom through corresponding adjustments; S4. Implement multi-layer composite weaving using the modified loom, including warping, drawing-in, and weaving, and control the corresponding process parameters; adopt the sectional drawing-in method, and divide the warp yarns into different areas for drawing-in according to the design requirements of the fabric; S5. Conduct on-line detection during the weaving process and quality inspection of the greige fabric after weaving. Use a variety of detection devices to monitor the key parameters during the weaving process in real time. When the parameters are abnormal, automatic adjustment measures can be taken or an alarm can be issued. Specifically: install tension sensors at key positions of the warp yarns. The warp yarn tension deforms the strain gauge in the sensor, changes the resistance value, and is converted into an electrical signal through the circuit and transmitted to the control system. When the tension exceeds the preset range, the system automatically adjusts or triggers an alarm to avoid abnormal tension affecting the weaving; Using the principle of photoelectric induction, when the weft yarn is normal, the light is unobstructed, and when the weft yarn is broken, the light is blocked. The sensor converts the change in the light signal into an electrical signal and transmits it to the control system, causing the loom to stop and display the position of the broken weft for easy handling; Collect fabric images with a high-definition camera and transmit them to a computer system with an image recognition algorithm. Based on deep learning technology, it analyzes and compares real-time images by pre-training to master the characteristics of defects, and determines whether to stop the machine for processing according to the severity of the defects. Monitor parameters such as the weaving machine speed, motor current, and temperature through corresponding sensors. When they exceed the normal range, the control system ensures the stable operation of the equipment and the weaving process according to the preset strategy. Use a fabric density mirror to measure the number of warp and weft yarns within a certain length at different parts of the grey fabric and calculate the average value, and compare it with the design value. If the error exceeds the range, trace back to the weaving process for adjustment. The electronic fabric strength tester uniformly stretches the specimen, and the force sensor measures the maximum tensile force at break. After testing in the warp and weft directions and comparing with the standard requirements, if it does not meet the requirements, check the reasons and make improvements. The pendulum type tearing strength tester tears the specimen with a pendulum, and the sensor measures the maximum tearing force value, and judges according to the standard. If it does not meet the standard, analyze the reasons and optimize. Use an electronic balance to weigh the weight of a certain area of the grey fabric sample, convert it into grams per square meter, and compare it with the designed gram weight. If the deviation is large, trace back to the weaving process to solve. Use professional instruments to measure indexes such as yarn fineness and twist respectively, and compare them with the design specifications. If they do not meet the requirements, check and adjust the spinning process. Use a measuring tool to directly measure the width of the grey fabric, and compare it with the designed width. If it does not meet the requirements, check and optimize the relevant weaving process. Simulate different scenarios for testing according to the standard with the corresponding instrument. Visually inspect the surface of the grey fabric combined with lighting, classify and record according to the severity and distribution of the defects, and process the defective products according to the rules to ensure the appearance quality.

2. The multi-layer composite weaving method of worsted woolen fabrics according to claim 1, characterized in that: In S1, the raw materials of the plush warp yarn, composite weft yarn, and sizing warp yarn each contain at least two different types of fibers, and they are blended into yarns through the spinning process, which includes conventional fiber pretreatment and yarn forming steps.

3. The multi-layer composite weaving method of worsted woolen fabrics according to claim 1, characterized in that: In S4, use a warping device to wind the warp yarns onto the warp beam according to the preset warp yarn arrangement order and density, and at the same time control the warping tension and speed.

4. The multi-layer composite weaving method of worsted woolen fabrics according to claim 1, characterized in that: S4 also includes selecting appropriate threading and reed denting methods according to the design requirements; controlling the weaving machine speed, warp and weft yarn tensions during weaving, and reasonably regulating the structural parameters of each layer of the composite fabric.

5. The multi-layer composite weaving method of worsted woolen fabrics according to claim 1, characterized in that: S5 also includes detecting multiple aspects of the grey fabric such as warp and weft density, strength, gram weight, width, color fastness, and appearance defects, judging the quality of the grey fabric by comparing with the preset standard, and processing the grey fabric that does not meet the requirements according to the corresponding rules.

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