Dyeing and weaving integrated warp knitting equipment and dyeing and weaving method thereof

Abstract

The invention relates to dyeing and weaving integrated warp knitting equipment and a dyeing and weaving method thereof, and relates to the technical field of textile equipment and weaving. The dyeing and weaving integrated warp knitting equipment comprises a let-off unit, a dyeing unit, a weaving unit, a post-processing unit, a drafting and reeling unit and an integrated control unit which are integrally arranged on an equipment frame body. The let-off unit divides warp yarns into single yarn layers and sends the single yarn layers to the dyeing unit; the dyeing unit is used for dyeing and fixing the single yarn layer through the coloring mechanism and the color fixing mechanism in sequence to form dyed yarn, and the weaving unit is used for weaving the dyed yarn into fabric and sending the fabric to the post-processing unit; the post-processing unit is used for cleaning, drying and shaping the fabric through the cleaning mechanism and the drying and shaping mechanism in sequence to form a finished fabric, and the integrated control unit is used for synchronously controlling the coloring / color fixing action and the weaving action. The dyeing unit, the weaving unit and the post-processing unit are integrated on the equipment frame body and are cooperatively controlled by the integrated control unit, dyeing and weaving integrated continuous production is achieved, the production cost is reduced, and the stability of the fabric quality is improved.

Description

Technical Field

[0001] This application relates to the field of textile equipment and weaving technology, and in particular to a warp knitting equipment integrating dyeing and weaving and its dyeing and weaving method. Background Technology

[0002] Warp-knitted textiles are widely used in many fields such as clothing, home textiles, and industrial textiles due to their stable structure, good elasticity, and high production efficiency. With the continuous changes in market demand, the textile industry is developing towards personalization, rapid response, and small-batch production.

[0003] Currently, in the traditional warp-knitted textile production process, yarn dyeing and weaving are usually carried out as two independent processes. The production of warp-knitted textiles mainly adopts two separate process routes: "dyeing before weaving" and "weaving followed by dyeing". Among them, the "dyeing before weaving" process is the more commonly used production mode in the industry. Its process flow is roughly as follows: First, the raw yarn (such as polyester, nylon, etc.) is pretreated, including yarn inspection, scouring to remove impurities, and hydrogen peroxide bleaching. The pretreated yarn is then immersed in a high-temperature and high-pressure dyeing vat. After the immersion and dyeing is completed, the yarn is stretched and set and dried with hot air. Finally, the treated yarn is wound into dyed warp beams and transported to the weaving workshop by AGV. The warp knitting machine (such as Trico or Raschel models) is then used to knit the fabric in loops to form the greige fabric. The "post-weaving dyeing" process is mostly used for the production of thin fabrics and products with complex patterns. The process is as follows: the raw yarn is directly woven into a greige fabric, and the greige fabric enters the dyeing process after pre-shaping. In the dyeing process, flatbed printing is suitable for large patterns, and digital printing can achieve rapid switching of more than 1,000 colors, but both require post-treatment processes such as steaming and fixing, and washing and soaping.

[0004] However, the two existing processes mentioned above have many problems. In the "dye-then-weave" process, the separation of dyeing and weaving processes leads to long production cycles and low efficiency. Moreover, the dyeing process requires the centralized processing of a large amount of raw yarn, which is then sent back to the weaving workshop after high-temperature color fixing, drying and other steps. This not only increases the waiting time of the process but also causes the overall manufacturing response speed to lag. Secondly, there is a serious problem of raw material and semi-finished product inventory backlog, which increases warehousing and management costs. In addition, multi-color pattern weaving has a serious lack of flexibility. In the traditional warp knitting process, if it is necessary to change the color or pattern structure, it is usually necessary to change the warp beam of different colored yarns. The operation is cumbersome, time-consuming and requires machine shutdown, which makes it difficult to meet the flexible production needs of small batch, multiple varieties and rapid switching. Furthermore, the secondary unwinding of the dyed yarn is also prone to tension fluctuations, resulting in uneven fabric loops and an increase in the defect rate of more than 15%. While the "post-weaving dyeing" process eliminates the pre-dyeing step, the dye penetration into the fabric is often uneven (especially for thick double-needle bed fabrics). In addition, the fabric needs to be repeatedly pulled and shaped during finishing, which can easily cause weft skew and curling, affecting the stability of product size and quality. Moreover, the processes are still separate, making it difficult to shorten the overall production cycle. Summary of the Invention

[0005] The purpose of this application is to provide a warp knitting equipment and dyeing and weaving method that integrate dyeing and weaving, so as to solve the problems existing in the prior art.

[0006] To achieve the above objectives, the technical solution adopted in this application is as follows: On one hand, this application provides an integrated warp knitting equipment for dyeing and weaving, including an equipment frame, and further including a warp feeding unit, a dyeing unit, a weaving unit, a post-processing unit, a drafting and take-up unit, and an integrated control unit integrated on the equipment frame; the warp feeding unit includes a yarn separating and conveying mechanism for separating the warp yarns into independent parallel single yarn layers and conveying the single yarn layers to the dyeing unit; the dyeing unit includes a dyeing mechanism and a color-fixing mechanism arranged sequentially along the yarn travel direction, the dyeing mechanism for dyeing the single yarn layers, and the color-fixing mechanism for immediately fixing the dyed yarn to form colored yarn, and the output end of the dyeing unit is connected to The weaving unit has an input end; the weaving unit is used to weave colored yarn into a fabric with a colored pattern and to transport the fabric to the post-processing unit; the post-processing unit includes a cleaning mechanism and a drying and setting mechanism arranged sequentially along the fabric travel direction. The cleaning mechanism is used to clean the fabric, and the drying and setting mechanism is used to dry and set the fabric to form a finished fabric. The output end of the post-processing unit is connected to the input end of the drafting and take-up unit; the drafting and take-up unit is used to take up the finished fabric; the integrated control unit is connected to at least the dyeing unit and the weaving unit, and synchronously controls the dyeing / fixing action of the dyeing unit and the weaving action of the weaving unit.

[0007] Furthermore, the integrated control unit and the weaving unit are arranged at intervals along the first direction, the weaving unit, the post-processing unit and the drafting and take-up unit are arranged at intervals along the second direction, and the warp feeding unit, the dyeing unit and the weaving unit are arranged at intervals along the third direction, with the first direction, the second direction and the third direction being perpendicular to each other.

[0008] Furthermore, the yarn feeding mechanism includes a yarn guide, a yarn divider, a tension bar, and an electronically controlled warp feed module. The yarn guide, yarn divider, and tension bar are arranged sequentially along the second direction, while the electronically controlled warp feed module and the yarn guide are arranged sequentially along the first direction. The electronically controlled warp feed module is connected to the yarn guide to drive the yarn guide to release the raw yarn. After being guided by the yarn guide, the yarn is divided into independent parallel single yarn layers by the yarn divider. The tension of the single yarn layers is then maintained by the tension bar and fed to the dyeing unit. The electronically controlled warp feed module is connected to the integrated control unit.

[0009] Furthermore, the tension bar maintains the tension fluctuation range of the single yarn layer to be ≤±1.5%.

[0010] Furthermore, the coloring mechanism and the color-fixing mechanism are arranged alternately along the second direction.

[0011] Furthermore, the coloring mechanism includes at least four independent coloring components. Each coloring component includes an ink cartridge, a micro hydraulic pump, a solenoid valve, an inkjet tube, and a printhead. The ink cartridge is used to hold ink. The micro hydraulic pump is located inside the ink cartridge and connected to the ink inlet of the solenoid valve to pressurize and output ink. The ink outlet of the solenoid valve is connected to the printhead through the inkjet tube. The nozzles of multiple printheads are arranged in an array to cover the width of a single yarn layer laterally. Each nozzle corresponds to a single yarn. The ink cartridges of each coloring component hold different colors of ink.

[0012] Furthermore, the ink colors of the four ink cartridges are cyan, yellow, magenta, and black, respectively.

[0013] Furthermore, the distance between the nozzle and the yarn is 5-10mm.

[0014] Furthermore, the color-fixing mechanism includes a drying chamber and a multimodal energy module. The drying chamber has a double-layer stainless steel insulation structure with a high-temperature resistant ceramic layer on its inner wall. The multimodal energy module is installed inside the drying chamber to release energy into the drying chamber to achieve instant color fixation.

[0015] Furthermore, the multimodal energy module includes a distributed electric heating wire array assembly and / or a UV-LED array assembly disposed on the inner wall of the drying oven.

[0016] Furthermore, the weaving unit includes a control mechanism and a tension adjustment mechanism, a weaving mechanism, and a drafting mechanism arranged sequentially along a third direction. The tension adjustment mechanism is used to maintain the tension of the input colored yarn, the control mechanism controls the delivery of the colored yarn to the weaving mechanism, the weaving mechanism is used to weave the colored yarn into a fabric with a color pattern, and the drafting mechanism is used to draft the fabric to the post-processing unit. The control mechanism is connected to an integrated control unit.

[0017] Furthermore, the knitting mechanism includes a yarn guide comb assembly, a sinker plate, and knitting needles. The yarn guide needles of the yarn guide comb assembly guide the colored yarn to the loop-forming area, and after the sinker plate maintains the tension of the colored yarn, it is fed to the needle plate, and the knitting needles complete the loop knitting of the colored yarn.

[0018] Furthermore, the yarn guide needles are made of low-friction ceramic.

[0019] Furthermore, the knitting needles are made of nitrided wear-resistant alloy steel and have a surface coating to prevent dye staining.

[0020] Furthermore, the yarn guide comb assembly is connected to the control mechanism, enabling the yarn guide comb assembly to move in real time with the dyeing unit along the transverse guide rail, so as to realize the immediate introduction of the yarn guide comb into the weaving process after dyeing in the dyeing unit.

[0021] Furthermore, the cleaning mechanism and the drying and shaping mechanism are arranged alternately along the second direction.

[0022] Furthermore, the cleaning mechanism includes a cleaning tank, a circulating filter box, and a mechanical dewatering assembly. The cleaning tank is equipped with multiple sets of guide rollers, and an ultrasonic cleaner is installed at the bottom of the cleaning tank. The circulating filter box includes a pre-positioned particle filter and a post-positioned activated carbon filter. The circulating filter box is connected to the cleaning tank through a conduit and a water pump. The mechanical dewatering assembly includes two pressure rollers, which are arranged opposite each other to squeeze and dewater the fabric.

[0023] Furthermore, the outer surface of the pressure roller is coated with a silicone layer.

[0024] Furthermore, at least one of the two pressure rollers is connected to a pneumatic pressure module to achieve linear pressure regulation of 0.2-0.8 MPa.

[0025] Furthermore, the drying and setting mechanism includes an insulation box, a heating component, and a tension adjustment component. The heating component includes heating wires arranged in an array along the circumference of the insulation box on the inner wall of the insulation box. A hot air circulation system is provided on the top of the insulation box. The tension adjustment component includes a drive motor and a tension roller connected to each other to provide real-time feedback and adjust the pressure of the tension roller to maintain a constant tension on the fabric.

[0026] Furthermore, the drafting and take-up unit includes a pressure roller assembly and a transmission mechanism arranged sequentially along a third direction. The pressure roller assembly includes two take-up pressure rollers arranged opposite each other. The transmission mechanism includes a take-up drum and a transmission component connected to each other. The transmission component is at least used to drive the take-up drum to rotate in order to control the take-up rate and drafting tension, so that the take-up drum collects the fabric.

[0027] Furthermore, the integrated control unit includes a main control system and an operation control panel. The main control system is used at least to receive pattern data and synchronously control the actions of the dyeing unit and the weaving unit.

[0028] Furthermore, the main control system includes an industrial PLC and a distributed I / O module. The industrial PLC has a built-in color-structure synchronization engine to decompose the pattern data into dyeing instructions and weaving instructions, and send the dyeing instructions to the dyeing unit and the weaving instructions to the weaving unit to achieve synchronous and coordinated control of the dyeing unit and the weaving unit.

[0029] On the other hand, this application also provides a dyeing and weaving method based on the above-mentioned integrated dyeing and weaving warp knitting equipment, comprising the following steps: S1. The original colored yarn is fed to the dyeing unit through the warp feeding unit for dyeing to form colored yarn; S2. The colored yarn is fed to the weaving unit to be woven into a fabric with a colored pattern; S3. The fabric is conveyed to the post-processing unit for post-processing to form the finished fabric. S4. The finished fabric is conveyed to the drafting and winding unit for collection; The integrated control unit synchronously controls the dyeing unit to perform dyeing actions and the weaving unit to perform weaving actions in real time.

[0030] Furthermore, S1 also includes the following steps: S11. According to the structure of the predetermined fabric, the yarn separating and conveying mechanism arranges the yarns in parallel at a certain interval, so that the yarn layers are evenly distributed in a single layer to meet the accuracy requirements of subsequent online dyeing. S12. Based on the pattern, structure, and color of the fabric, the dyeing mechanism performs online dyeing of the original color yarn; S13. The dyeing yarn fed by the dyeing mechanism is fixed in real time by the color fixing mechanism to form colored yarn.

[0031] Furthermore, S3 also includes the following steps: S31. The residual dyes and impurities on the fabric are cleaned by the cleaning unit; S32. The surface of the fabric that has passed through the washing mechanism is treated by the drying and setting mechanism to form the finished fabric.

[0032] The beneficial effects of the technical solution provided in this application include at least the following: (1) This application integrates dyeing unit, weaving unit and post-processing unit on equipment frame and controls them in coordination through integrated control unit to realize continuous production of dyeing and weaving. By integrating inkjet dynamic dyeing, warp knitting and post-processing synchronously, the waiting time of the process and the transfer links between workshops are reduced, the production cycle is effectively shortened, the inventory backlog is effectively reduced, the enterprise's inventory capital occupation is reduced, the storage area is reduced, the production cost is reduced, and the dyeing and weaving processes are linked.

[0033] (2) This application uses a post-processing unit to precisely control the cleaning and setting processes, effectively improving material utilization, reducing fabric waste, and saving energy and materials. At the same time, through the color-fixing mechanism, immediate color fixing is achieved after dyeing, making the dye and yarn fibers more firmly bonded, improving the rubbing fastness, and solving the problem of uneven dye penetration in double-needle bed fabrics in traditional processes.

[0034] (3) This application uses an integrated control unit to synchronously control the dyeing and weaving actions, thereby avoiding longitudinal stripe defects caused by tension fluctuations, reducing the defect rate, and improving the stability of fabric quality. Attached Figure Description

[0035] The accompanying drawings are provided to further illustrate the present application and form part of the specification. They are used together with the embodiments of the present application to explain the application and do not constitute a limitation thereof. In the drawings: Figure 1 This is a schematic diagram of the structure of the warp knitting equipment in one embodiment of the present invention; Figure 2 This is a front view structural schematic diagram of the warp knitting equipment in one embodiment of the present invention; Figure 3 This is a schematic diagram of the flow structure of the delivery unit and the dyeing unit in one embodiment of the present invention; Figure 4 This is a schematic diagram of the structure of a staining unit in one embodiment of the present invention; Figure 5 This is a schematic diagram of the coloring mechanism structure in one embodiment of the present invention; Figure 6 This is a schematic diagram of the post-processing unit structure in one embodiment of the present invention.

[0036] Explanation of key figure labels: 10. Equipment frame; 100. Warp feed unit; 110. Warp head; 120. Yarn guide rod; 130. Yarn separating reed; 140. Tension rod; 150. Electronic control warp feed module; 200. Dyeing unit; 210. Coloring mechanism; 211. Ink cartridge; 212. Miniature hydraulic pump; 213. Solenoid valve; 214. Inkjet tube; 215. Printhead; 220. Color fixing mechanism; 221. Drying oven; 222. Multimodal energy module; 300. Weaving unit; 310. Tension adjustment mechanism; 321. Yarn guide needle; 322. Sinking plate; 323. Knitting needles; 400, Post-processing unit; 410, Cleaning mechanism; 411, Cleaning tank; 412, Circulating filter box; 414, Ultrasonic cleaner; 415, Particulate filter; 416, Activated carbon filter; 420, Mechanical dewatering assembly; 430, Drying and setting mechanism; 431, Insulation box; 432, Heating assembly; 433, Tension adjustment assembly; 500, Drafting and take-up unit; 510, Pressure roller assembly; 520, Transmission mechanism; 600, Integrated control unit; 610, Main control system; 620, Operation control panel; 700, Warp yarn. Detailed Implementation

[0037] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0038] In this specification, identical components are represented by the same reference numerals. It should be noted that the terms "front," "rear," "left," "right," "upper," and "lower" used in the following description refer to directions in the accompanying drawings, while the terms "bottom surface," "top surface," "inner," and "outer" refer to directions towards or away from a specific component, respectively. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this specification, "multiple" means two or more.

[0039] The raw materials for the undyed yarn may include natural fibers and / or chemical fibers; natural fibers may include plant fibers such as cotton and linen; and / or animal fibers such as wool, rabbit hair, camel hair, cashmere, and silk; and / or mineral fibers such as silica, alumina, and magnesium oxide; chemical fibers may include man-made fibers such as viscose fiber, acetate fiber, and cuprammonium fiber; and / or synthetic fibers such as polyester fiber, polyamide fiber, polyacrylonitrile fiber, polypropylene fiber, polyurethane fiber, aramid, polyetherimide fiber, and ultra-high molecular weight polyethylene fiber; the undyed yarn may be various organic or inorganic filament fibers, or at least one of various organic or inorganic short fibers, with the diameter of the filament fiber ranging from 5D to 3000D, and may also be applicable to monofilament, multifilament, and ply yarn, without any particular limitation in this application.

[0040] Example 1 Please see Figures 1-6 A warp knitting equipment integrating dyeing and weaving includes an equipment frame 10, and further includes a warp feeding unit 100, a dyeing unit 200, a weaving unit 300, a post-processing unit 400, a drafting and take-up unit 500, and an integrated control unit 600, all integrated on the equipment frame 10. The warp feeding unit 100 includes a yarn separating and conveying mechanism for separating the warp yarns 700 into independently parallel single yarn layers and conveying the single yarn layers to the dyeing unit 200. The dyeing unit 200 includes a dyeing mechanism 210 and a color-fixing mechanism 220 arranged sequentially along the yarn travel direction. The dyeing mechanism 210 is used to dye the single yarn layers, and the color-fixing mechanism 220 is used to immediately fix the dyed yarn to form colored yarn. The output end of the dyeing unit 200 is connected to the weaving unit. The input end of the 300 unit; the weaving unit 300 is used to weave colored yarn into a fabric with a colored pattern and to transport the fabric to the post-processing unit 400; the post-processing unit 400 includes a cleaning mechanism 410 and a drying and setting mechanism 430 arranged sequentially along the fabric travel direction. The cleaning mechanism 410 is used to clean the fabric, and the drying and setting mechanism 430 is used to dry and set the fabric to form a finished fabric. The output end of the post-processing unit 400 is connected to the input end of the drafting and take-up unit 500; the drafting and take-up unit 500 is used to take up the finished fabric; the integrated control unit 600 is connected to at least the dyeing unit 200 and the weaving unit 300, and synchronously controls the dyeing / fixing action of the dyeing unit 200 and the weaving action of the weaving unit 300.

[0041] In this embodiment, as Figure 1 , Figure 2As shown, the equipment frame 10 is the main frame structure of the equipment. The equipment frame 10 can be fixed to the ground or work platform using adjustable anchor bolts, thereby adjusting the level of the equipment. Internally, the equipment frame 10 is divided into areas such as the warp feeding area, dyeing area, weaving area, post-processing area, take-up area, and control area by means of crossbeams and longitudinal beams. Each area can be separated by protective barriers to ensure that each process operates independently. The warp feeding unit 100, dyeing unit 200, weaving unit 300, post-processing unit 400, drafting and take-up unit 500, and integrated control unit 600 are integrated into the warp feeding area, dyeing area, weaving area, post-processing area, take-up area, and control area of ​​the equipment frame 10, respectively, thus forming an integrated equipment. The warp feeding unit 100 mainly transports the external warp yarns 700 that need to be dyed and woven to the equipment. It is the first process unit of the equipment to receive the external warp yarns 700. The warp feeding unit 100 includes a yarn separating and conveying mechanism, which can first separate the warp yarns 700 transported to the warp feeding unit 100. According to the predetermined fabric structure, the yarn separating and conveying mechanism separates the warp yarns 700 at a certain interval to arrange them in parallel, so that the warp yarns 700 are evenly distributed in a single layer to form a single yarn layer with multiple yarns evenly spaced. This allows the individual yarns to be dyed separately when passing through the dyeing unit 200, thereby meeting the accuracy requirements of the subsequent online dyeing. Afterwards, the yarn separating and conveying mechanism transports the separated single yarn layer to the dyeing unit 200. In the dyeing unit 200, the dyeing unit 200 includes a dyeing mechanism 210 and a fixing mechanism 220 arranged sequentially along the yarn's travel direction in the equipment. The single yarn layer conveyed from the feed unit 100 passes through the dyeing mechanism 210, which performs dyeing treatment on the yarn according to the fabric requirements, i.e., spraying the yarn with dye of the corresponding color. The dyed yarn is then conveyed to the fixing mechanism 220 for fixing treatment to form colored yarn. The colored yarn is then conveyed to the weaving unit 300, where the weaving unit 300 weaves the dyed yarn from the dyeing unit 200 into a fabric according to a preset weaving program. The fabric with colored patterns is then woven and conveyed to the post-processing unit 400. The post-processing unit 400 includes a cleaning mechanism 410 and a drying and setting mechanism 430 arranged sequentially along the yarn in the traveling direction of the equipment. The cleaning mechanism 410 cleans the fabric woven by the weaving unit 300 to remove residual dyes and impurities. After cleaning, the fabric is conveyed to the drying and setting mechanism 430 for drying and setting to obtain the finished fabric. The finished fabric is then conveyed to the drafting and take-up unit 500, which collects the finished fabric, thus completing the overall process.The integrated control unit 600 is connected to the dyeing unit 200 and the weaving unit 300. According to the preset color pattern instructions, the integrated control unit 600 controls the dye supply system of the dyeing unit 200. The metering pump sprays the dye onto the yarn in proportion to accurately dye the single yarn layer, thereby forming the yarn of the required color. After the yarn is dyed, the weaving unit 300 is started under the synchronous control of the integrated control unit 600 to weave the colored yarn into a fabric with a color pattern. The integrated control unit 600 adjusts the yarn feed amount in real time according to the weaving speed to ensure that the fabric loops are uniform.

[0042] In the aforementioned structure, by integrating the dyeing unit 200, weaving unit 300, and post-processing unit 400 onto the equipment frame 10, and coordinating their operation through the integrated control unit 600, integrated continuous dyeing and weaving production is achieved. By simultaneously integrating inkjet dynamic dyeing, warp knitting, and post-processing, integrated production of "online dyeing—synchronous loop forming—post-processing" is realized, significantly reducing process waiting time and inter-workshop transfer links, effectively shortening the production cycle, quickly responding to small-batch and personalized order demands, effectively reducing inventory backlog, lowering enterprise inventory capital occupation, reducing warehouse space, and reducing production costs. The linkage between dyeing and weaving processes avoids repeated heating and transportation, reducing energy consumption per unit product. Precise control of cleaning and setting parameters in the post-processing stage effectively improves material utilization, reduces fabric waste, and saves energy and materials. Simultaneously, the color-fixing mechanism 220 achieves immediate color fixation after dyeing, resulting in a stronger bond between the dye and yarn fibers, improving rubbing fastness, and solving the problem of uneven dye penetration in double-needle bed fabrics in traditional processes. The integrated control unit 600 synchronously controls the dyeing and weaving processes, avoiding longitudinal stripe defects caused by tension fluctuations, reducing the defect rate, and improving the stability of fabric quality. In the specific distribution structure, the integrated control unit 600 and the weaving unit 300 are arranged at intervals along the first direction, the weaving unit 300, the post-processing unit 400 and the drafting and take-up unit 500 are arranged at intervals along the second direction, and the warp feeding unit 100, the dyeing unit 200 and the weaving unit 300 are arranged at intervals along the third direction. The first direction, the second direction and the third direction are perpendicular to each other.

[0043] In this embodiment, as Figure 1 , Figure 2As shown, based on the directional arrangement requirements of each unit, the equipment frame 10 adopts a three-dimensional frame design, defining three mutually perpendicular directions using an XYZ rectangular coordinate system: the X-axis can be a horizontal direction, the Y-axis can be a vertical direction, and the Z-axis can be a vertical direction. The angle between any two of the first, second, and third directions is 90 degrees, meaning they are all perpendicular to each other. The first direction is the X-axis, the second direction is the Y-axis, and the third direction is the Z-axis. Specifically, the integrated control unit 600 and the weaving unit 300 are arranged at intervals along the X-axis (first direction). The main body of the control cabinet of the integrated control unit 600 is located on one side of the X-axis of the equipment frame 10. The integrated control unit 600 can be connected to the dyeing unit 200 or the weaving unit 300 through a sealed cable tray. Servo control lines and signal feedback lines are laid in the tray to ensure uninterrupted signal transmission. The bottom of the control cabinet is equipped with casters with brakes, allowing for fine-tuning of the position along the X-axis for easy operation by maintenance personnel. The weaving unit 300, the post-processing unit 400, and the drafting and take-up unit 500 are arranged alternately along the Y-axis (second direction). The warp feed unit 100, the dyeing unit 200, and the weaving unit 300 are arranged alternately along the Z-axis (third direction).

[0044] In the above structure, the three-dimensional vertical arrangement reduces the equipment footprint compared to traditional planar layouts. The layered design along the Z-axis separates pre-treatment processes such as warping and dyeing from the main processes such as weaving and post-treatment, avoiding intersections between yarn and fabric transport paths and reducing mutual interference. The integrated control unit 600 is laterally spaced from the weaving unit 300 along the X-axis, creating an independent workspace between the control cabinet and the weaving operation area. Operators can adjust control system parameters without affecting weaving production. The weaving, post-treatment, and take-up units arranged along the Y-axis form a linear production flow, facilitating visual management. A single worker can simultaneously monitor the operating status of three units, reducing labor costs. The vertical arrangement of the warping-dyeing-weaving processes along the Z-axis ensures a straight yarn transport path, resulting in more stable tension fluctuations, reduced turning points in the transport, and enhanced process stability. The units are spaced apart along a fixed direction to ensure that vibrations do not transmit between them during equipment operation. At the same time, it can further improve the flexibility and expansion capability. The spacing of the units arranged along the Y-axis can be quickly adjusted via guide rails to support seamless switching of fabrics with different widths. The integrated control unit 600 in the X-axis direction has reserved expansion interfaces, which can be used to add dye ratio control modules, pattern design workstations, etc., according to production needs without reconstructing the overall layout. In the specific structure of the warp feeding unit 100, the yarn separating and conveying mechanism includes a yarn head 110, a yarn guide rod 120, a yarn separating reed 130, a tension rod 140, and an electronically controlled warp feeding module 150. The yarn guide rod 120, the yarn separating reed 130, and the tension rod 140 are arranged sequentially along a second direction. The electronically controlled warp feeding module 150 is arranged sequentially with the yarn head 110 along a first direction and is connected to the yarn head 110 to drive the yarn head 110 to release the raw yarn. After being guided by the yarn guide rod 120, the yarn is separated into independent parallel single yarn layers by the yarn separating reed 130. The tension of the single yarn layers is then maintained by the tension rod 140 and conveyed to the dyeing unit 200. The electronically controlled warp feeding module 150 is connected to the integrated control unit 600. The tension rod 140 maintains the tension fluctuation range of the single yarn layer to ≤±1.5%.

[0045] In this embodiment, as Figure 2 , Figure 3 As shown, the warp head 110 is located at the top of the warp feeding unit 100. Along the Y-axis (second direction), the yarn guide rod 120, the yarn divider 130, and the tension rod 140 are arranged sequentially from top to bottom. Along the X-axis (first direction), the electronically controlled warp feeding system and the warp head 110 are arranged from left to right. The original color yarn is driven by the electronically controlled warp feeding system to rotate and release the warp head 110. The yarn guide rod 120 guides the path and controls the direction. The yarn divider 130 then precisely separates the yarn into independent parallel single yarn layers. The tension rod 140 ensures that the tension of each yarn is stable and consistent during operation. Finally, the original color yarn is smoothly introduced into the dyeing unit 200.

[0046] The warp head 110 can be a steel cylindrical structure, with its width matching the working width of the warp knitting machine, and its surface is coated with a polyurethane anti-slip coating. The warp head 110 is mounted on the X-axis guide rail of the equipment frame 10 at both ends via bearing seats and is equipped with an axial limiting device. It can passively rotate around its own axis to wind and store the original color warp yarn 700. The yarn guide rod 120 is horizontally installed downstream of the warp head 110 along the Y-axis direction. Its two ends are fixed by adjustable brackets, and its height can be finely adjusted along the Z-axis direction to change the conveying path of the original yarn and avoid friction with other components. Rectangular yarn separating grooves are evenly distributed on the yarn separating reed 130. The yarn separating reed 130 is fixed on the slide rail along the Y-axis direction via slots, and its position can be finely adjusted along the Y-axis to ensure that the yarn separating grooves correspond one-to-one with the subsequent dyeing nozzles 215. Tension sensors are installed at both ends of tension bar 140, and a spring-damped reset mechanism is connected in the middle. Mounted on the Y-axis guide rail, it can oscillate ±5° around the support axis in the YZ plane to monitor and feedback the tension changes of the single yarn layer in real time. The electronic control warp feed module 150 can adopt existing technology, including a servo motor, gearbox, and encoder, all encapsulated in a metal control cabinet and spaced apart from the warp head 110 along the X-axis. The servo motor is connected to the drive shaft of the warp head 110 via a coupling. The encoder rotates synchronously with the warp head 110 to collect warp feed data. A touchscreen is provided on the control cabinet surface to display real-time warp feed speed and cumulative warp feed. The electronic control warp feed module 150 can be connected to the integrated control unit 600 via a Profibus bus. The tension sensors of tension bar 140 are connected to the electronic control warp feed module 150 via analog signal lines, forming a closed-loop control circuit. In practical operation, the integrated control unit 600 sends a warp feed command to the electronic control warp feed module 150 based on the weaving speed of the weaving unit 300. After receiving the command, the servo motor drives the warp head 110 to rotate in the set direction through the gearbox, releasing the wound original color warp yarn 700. The encoder monitors the rotation speed of the warp head 110 in real time and feeds it back to the electronic control warp feed module 150 to ensure that the warp feed speed matches the weaving speed. The original yarn released from the warp head 110 smoothly transitions through the surface of the guide rod 120, changing the conveying direction. The height adjustment of the guide rod 120 keeps the original yarn at a certain angle to the surface of the warp head 110, avoiding plastic deformation of the original yarn due to excessive bending. The raw yarn bundle enters the yarn separating reed 130 and is physically separated into independent parallel single yarn layers by the rectangular yarn separating grooves. After the single yarn layers are drawn out from the yarn separating reed 130, they pass around the surface of the tension bar 140, causing the tension bar 140 to be subjected to an oblique resultant force. The tension sensor converts the tension signal into an electrical signal and transmits it to the electronic control warp feeding module 150. When the tension fluctuation exceeds the set threshold, the module immediately adjusts the speed of the servo motor. When the tension is too high, the warp feeding speed is increased; when the tension is too low, the warp feeding speed is decreased, forming a dynamic balance. After passing through the single yarn layers with stable tension, they continue to be fed into the dyeing mechanism 210 of the dyeing unit 200, completing the entire process of yarn separation and feeding. Through closed-loop control of the electronically controlled warp feed module 150 and tension bar 140, the tension fluctuation of a single yarn layer is effectively stabilized. Stable tension improves the uniformity of dye adsorption in subsequent dyeing processes, reduces fabric loop density deviation, and significantly reduces defects caused by tension fluctuations. Simultaneously, real-time communication between the electronically controlled warp feed module 150 and the integrated control unit 600 allows the warp feed speed to be dynamically adjusted based on the dye supply of the dyeing unit 200 and the weaving speed of the weaving unit 300, avoiding the problem of excessive or insufficient raw yarn supply and improving the overall operating efficiency of the equipment. In the specific structure of the dyeing unit 200, the coloring mechanism 210 and the color-fixing mechanism 220 are arranged sequentially at intervals along the second direction. The coloring mechanism 210 includes at least four independent coloring components. Each coloring component includes an ink cartridge 211, a micro hydraulic pump 212, a solenoid valve 213, an inkjet tube 214, and a printhead 215. The ink cartridge 211 is used to hold ink. The micro hydraulic pump 212 is located inside the ink cartridge 211 and is connected to the ink inlet of the solenoid valve 213 to pressurize and output ink. The ink outlet of the solenoid valve 213 is connected to the printhead 215 through the inkjet tube 214. The nozzles of the multiple printheads 215 are arranged in an array to cover the width of a single yarn layer laterally. Each nozzle corresponds to a single yarn. The ink cartridges 211 of each coloring component hold different colors of ink. The distance between the printhead 215 and the yarn is 5-10 mm. The color-fixing mechanism 220 includes a drying chamber 221 and a multimodal energy module 222. The drying chamber 221 has a double-layer stainless steel insulation structure, and its inner wall is lined with a high-temperature resistant ceramic layer. The multimodal energy module 222 is disposed inside the drying chamber 221 and is used to release energy into the drying chamber 221 to achieve instant color fixing. The multimodal energy module 222 includes a distributed electric heating wire array assembly and / or a UV-LED array assembly disposed on the inner wall of the drying chamber 221.

[0047] In this embodiment, as Figure 3 , Figure 4 , Figure 5 As shown, the dyeing mechanism 210 and the fixing mechanism 220 are distributed sequentially along the Y-axis (second direction), so that the dyed yarn can enter the fixing process in a timely manner. The dyeing mechanism 210 contains at least four independent dyeing components, which are arranged sequentially along the Y-axis. The dyeing mechanism 210 also has multiple evenly spaced components along the X-axis (first direction), which are consistent with the width of the input single yarn layer, so that each yarn corresponds to one dyeing mechanism 210. Each coloring component includes an ink cartridge 211, a micro hydraulic pump 212, a solenoid valve 213, an inkjet tube 214, and a printhead 215. The ink cartridge 211 holds dye ink. The micro hydraulic pump 212 is built into the bottom of the ink cartridge 211 and connected to the ink inlet of the solenoid valve 213 via a silicone tube. The valve body of the solenoid valve 213 can be made of stainless steel to withstand the chemical corrosion of the ink. It is connected to the integrated control unit 600 via a signal line to achieve precise control of ink flow. The length of the inkjet tube 214 is adjusted according to the component position and can be finely adjusted synchronously with the printhead 215. The inkjet head array of the printhead 215 laterally covers the width of the yarn layer, with each nozzle corresponding to a single yarn. The distance between the printhead 215 and the yarn is 5-10mm. The color-curing mechanism 220 includes a drying chamber 221 and a multimodal energy module 222. The drying chamber 221 has a rectangular structure, is made of double-layered 304 stainless steel plates, filled with insulation cotton, and has a high-temperature resistant ceramic layer on the inner wall. The surface is smooth and non-stick, reducing dye residue. Yarn inlets and outlets are located at both ends of the chamber, and soft silicone curtains are installed at the openings to reduce heat loss. The multimodal energy module 222 can be a distributed electric heating wire array assembly, fixed to the upper and lower inner walls of the drying chamber 221 to form a symmetrical heating structure, or it can be a UV-LED array assembly composed of UV-LED lamp beads arranged in 3-4 rows along the Y-axis, with the number of lamp beads in each row matching the number of yarns, suitable for dye systems requiring photocuring. The integrated control unit 600 sends commands to each coloring component according to the preset yarn color scheme. The micro hydraulic pump 212 starts in advance to pressurize the ink to the working pressure, and the solenoid valve 213 is closed, waiting for the ejection command. The single yarn layer enters the coloring mechanism 210 along the Y-axis. According to the yarn position signal, the integrated control unit 600 synchronously controls the solenoid valve 213 of the corresponding nozzle to open. The micro hydraulic pump 212 delivers the ink to the printhead 215 through the inkjet tube 214. The nozzle ejects ink droplets, which accurately land on a single yarn. For example, the ink colors in the ink cartridges 211 of the four coloring components are cyan (C), yellow (Y), magenta (M), and black (K), respectively. The coloring components of different colors work together in proportion (such as CMYK color mixing) to achieve the target color value. The printhead 215 maintains a distance of 5-10mm from the yarn to ensure the best ink droplet atomization effect and avoid ink splatter. After dyeing, the yarn continues to travel along the Y-axis into the drying chamber 221 of the color-fixing mechanism 220. At this point, the ink on the yarn surface is not completely dry, creating conditions for immediate color fixing. Depending on the dye type, an energy module is selected. For thermosetting dyes, the distributed electric heating wire array assembly is activated, heating the yarn according to a preset temperature curve to evaporate moisture and promote dye-fiber bonding. For photocurable dyes, the UV-LED array assembly is simultaneously activated, using specific wavelengths of ultraviolet light to cross-link and solidify the dye molecules. These two modules can work individually or in combination to ensure color fixing efficiency. The color-fixed yarn is then output from the other end of the drying chamber 221 and transported to the weaving unit 300 for weaving.

[0048] In the above structure, the design of a single nozzle corresponding to a single yarn improves dyeing accuracy and flexibility. At least four independent dyeing components support multi-color blending, meeting the weaving needs of personalized patterns. The multimodal energy module 222 can flexibly switch the color fixing method according to the dye type, with heat curing and light curing working together to improve color fixing efficiency. Relying on the four-color independent ink cartridge 211 (CMYK) system and the piezoelectric printhead 215 array, millisecond-level color switching can be achieved during high-speed yarn operation without stopping the machine to change the warp beam. Combined with the CNC-programmed dyeing path and the linkage of the knitting needle 323, a single machine can produce complex patterned fabrics with color combinations, greatly improving the flexible production capacity and finished product quality of multi-color and multi-variety products. It supports extremely small batch orders starting from 1 meter, reducing the traditional 3-hour changeover time to 5 minutes, perfectly adapting to personalized and fast-response production needs.

[0049] In the specific structure of the weaving unit 300, the weaving unit 300 includes a control mechanism and a tension adjustment mechanism 310, a knitting mechanism, and a drafting mechanism arranged sequentially along a third direction. The tension adjustment mechanism 310 is used to maintain the tension of the input colored yarn. The control mechanism controls the delivery of the colored yarn to the knitting mechanism, which is used to weave the colored yarn into a fabric with a color pattern. The drafting mechanism is used to draft the fabric to the post-processing unit 400. The control mechanism is connected to the integrated control unit 600. The knitting mechanism includes a yarn guide assembly, a sinker plate 322, and knitting needles 323. The yarn guide needles 321 of the yarn guide assembly guide the colored yarn to the loop-forming area and, after maintaining the tension of the colored yarn through the sinker plate 322, deliver it to the needle plate. The knitting needles 323 complete the loop knitting of the colored yarn. The yarn guide needles 321 are made of low-friction ceramic. The knitting needles 323 are made of nitrided wear-resistant alloy steel, and their surface is coated with an anti-dye staining coating. The yarn guide comb assembly is connected to the control mechanism, enabling the yarn guide comb assembly to move in real time with the dyeing unit 200 along the transverse guide rail, so as to realize the immediate introduction of the yarn guide comb into the weaving process after dyeing in the dyeing unit 200.

[0050] In this embodiment, as Figure 2 , Figure 3 As shown, the weaving unit 300 is arranged in sequence along the Z-axis (third direction) with a tension adjustment mechanism 310, a knitting mechanism, and a drafting mechanism. These three are fixed to the equipment frame 10. The control mechanism is connected to each actuator and the integrated control unit 600 via cable bundles, forming a closed-loop control system. The tension adjustment mechanism 310 consists of a tension sensor and a guide roller assembly. The axis of the guide rollers is parallel to the X-axis and is fixed to the Z-axis guide rail via bearing seats, allowing for fine-tuning of the height in the vertical direction. The tension sensor is installed between the guide rollers to collect the yarn tension signal in real time and feed it back to the control mechanism. The knitting mechanism includes a yarn guide comb assembly with evenly arranged yarn guide needles 321. The yarn guide needles 321 are made of zirconia ceramic with a mirror-polished surface. A slider is installed at the bottom of the yarn guide comb, which cooperates with a precision linear guide rail in the X-axis direction to achieve lateral movement. The sinker 322 can reciprocate along the Z-axis direction. The knitting needles 323 are made of nitrided wear-resistant alloy steel and are fixed to a needle plate, which can move up and down. The drafting mechanism consists of two pairs of drafting rollers, upper and lower. The driving roller is covered with nitrile rubber, and the driven roller is a smooth steel roller. Pressure is applied by a cylinder. The control mechanism is a PLC controller with a built-in warp knitting pattern control algorithm and communicates with the integrated control unit 600. The colored yarn output from the color-fixing mechanism 220 enters the weaving unit 300. It first passes through the guide roller group of the tension adjustment mechanism 310. A tension sensor monitors the yarn tension in real time. Based on the pattern instructions sent by the integrated control unit 600, the control mechanism drives the yarn guide comb assembly to reciprocate along the X-axis transverse guide rail. The yarn guide needle 321 precisely guides the colored yarn into the loop-forming area. Because the yarn guide comb assembly and the dyeing unit 200 are linked in real time, the colored yarn can immediately enter the weaving process after dyeing, avoiding tension decay during yarn storage. During the actual weaving process, the sinker 322 moves upward under the drive of the cam mechanism, holding the old loop while pressing the colored yarn onto the needle plate surface. The knitting needle 323 reciprocates up and down with the needle plate, the needle tip passing through the loop formed by the colored yarn, completing loop-forming actions such as padding, yarn carrying, closing, looping, and loop removal. The low-friction ceramic material of the yarn guide needle 321 reduces yarn wear, and the anti-staining coating of the knitting needle 323 prevents needle hole clogging caused by dye residue, ensuring continuous weaving stability. The woven fabric enters the drafting mechanism, where upper and lower drafting rollers apply uniform tension to the fabric, flattening it before conveying it to the post-processing unit 400. The control mechanism receives synchronization signals from the integrated control unit 600 in real time. When the dyeing unit 200 adjusts the yarn color or warp feed speed, the lateral movement frequency of the yarn guide comb and the movement speed of the knitting needles 323 in the weaving mechanism are adjusted accordingly to ensure the accuracy of the color pattern weaving. The real-time linkage between the yarn guide comb assembly and the dyeing unit 200 enables seamless integration of yarn dyeing and weaving, shortening the production cycle and meeting the personalized customization needs of complex patterns. Simultaneously, it can achieve the weaving of complex jacquard structures. Combined with the color synchronization control of the integrated control unit 600, it can directly weave fabrics with complex color patterns such as gradients and camouflage, expanding the application areas of warp-knitted products.

[0051] In the specific structure of the post-processing unit 400, the cleaning mechanism 410 and the drying and shaping mechanism 430 are arranged sequentially at intervals along the second direction. The cleaning mechanism 410 includes a cleaning tank 411, a circulating filter box 412, and a mechanical dewatering assembly 420. The cleaning tank 411 is equipped with multiple sets of guide rollers, and an ultrasonic cleaner 414 is installed at the bottom of the cleaning tank 411. The circulating filter box 412 includes a pre-positioned particle filter 415 and a post-positioned activated carbon filter 416. The circulating filter box 412 is connected to the cleaning tank 411 via a conduit and a water pump. The mechanical dewatering assembly 420 includes two pressure rollers arranged opposite each other to squeeze and dewater the fabric. The outer surface of the pressure rollers is covered with a silicone layer. At least one of the two pressure rollers is connected to a pneumatic pressure module to achieve linear pressure regulation of 0.2-0.8 MPa. The drying and setting mechanism 430 includes a heat preservation box 431, a heating component 432, and a tension adjustment component 433. The heating component 432 includes heating wires arranged in an array along the circumference of the heat preservation box 431 on the inner wall of the heat preservation box 431. A hot air circulation system is provided on the top of the heat preservation box 431. The tension adjustment component 433 includes a drive motor and a tension roller connected to each other to provide real-time feedback and adjust the pressure of the tension roller to maintain constant tension of the fabric.

[0052] In this embodiment, as Figure 6As shown, the cleaning mechanism 410 and the drying and setting mechanism 430 are arranged alternately along the Y-axis (second direction). The inlet of the cleaning mechanism 410 is aligned with the outlet of the drafting mechanism of the weaving unit 300, and the outlet of the drying and setting mechanism 430 is aligned with the inlet of the drafting and winding unit 500. The cleaning mechanism 410 includes a cleaning tank 411, a circulating filter box 412, and a mechanical dewatering assembly 420. The cleaning tank 411 has a rectangular structure, and its width matches the fabric width. Multiple sets of guide rollers are evenly arranged in the tank along the Y-axis, with their axes parallel to the X-axis. They are fixed to the supports on both sides of the tank by bearing seats and their height can be finely adjusted according to the fabric thickness. Multiple ultrasonic cleaners 414 are evenly distributed at the bottom of the tank, which can generate high-intensity ultrasonic waves to remove floating dye and small impurities from the fabric surface. A circulating filter box 412 is positioned above the washing tank 411 along the Z-axis. Inside, from front to back, are a particulate filter 415 and an activated carbon filter 416. The particulate filter 415 can be made of stainless steel mesh to filter larger diameter impurities. The activated carbon filter 416 is filled with activated carbon to remove dye residues and organic pollutants from the water. The circulating filter box 412 is connected to the washing tank 411 via an inlet pipe and an outlet pipe. A water pump is installed on the inlet pipe to achieve water recycling. A mechanical dewatering assembly 420 is located at the outlet end of the washing tank 411 and consists of two opposing pressure rollers. The outer surface of the pressure rollers is covered with a silicone layer, providing good elasticity and wear resistance. At least one pressure roller is connected to a pneumatic pressure module, which can achieve linear pressure adjustment from 0.2 to 0.8 MPa to meet the dewatering needs of fabrics of different thicknesses.

[0053] The drying and setting mechanism 430 includes an insulation box 431, a heating component 432, and a tension adjusting component 433. The insulation box 431 is made of double-layered stainless steel with an insulation layer in between. Its width matches the fabric width. The insulation box 431 has fabric inlets and outlets at both ends, with soft rubber curtains installed at the openings to reduce heat loss. The heating component 432 includes heating wires and a hot air circulation system. The heating wires are evenly distributed on the inner wall of the insulation box 431. The hot air circulation system is located at the top of the insulation box 431 and consists of a centrifugal fan and a guide plate, ensuring uniform circulation of hot air within the box and guaranteeing even heating of the fabric. The tension adjusting component 433 is located on the outside of the insulation box 431 near the outlet and includes a drive motor, a tension roller, and a tension sensor. The tension roller is covered with a rubber layer and connected to the output shaft of the drive motor via a bearing seat. It can oscillate slightly with changes in fabric tension. The drive motor can receive feedback signals from the tension sensor in real time and adjust the pressure of the tension roller to maintain constant tension on the fabric during the drying and setting process. The fabric output from the weaving unit 300 enters the cleaning tank 411 of the cleaning mechanism 410 and is immersed in the cleaning water under the guidance of the guide rollers. The ultrasonic cleaner 414 is activated, and the impact force generated by the ultrasonic waves can effectively remove the floating color and impurities on the surface of the fabric. At the same time, the water pump draws the water in the cleaning tank 411 into the circulating filter box 412. After impurities are removed by the particle filter 415, the water is then adsorbed by the activated carbon filter 416. The purified water flows back to the cleaning tank 411, realizing water recycling. After the fabric is cleaned, it is conveyed between two pressure rollers. The pneumatic pressure module automatically adjusts the pressure of the pressure rollers according to the fabric thickness. The moisture in the fabric is removed by squeezing. The silicone layer of the pressure rollers has good elasticity, which can ensure uniform squeezing and avoid damage to the fabric. After dehydration, the fabric enters the heat preservation box 431 of the drying and setting mechanism 430. Guided by the guide rollers, it passes through the heating area. The heating wire is energized and heats up. The hot air circulation system evenly transfers heat to the fabric surface. The moisture in the fabric is evaporated through heat conduction and convection. The tension sensor of the tension adjustment component 433 monitors the fabric tension in real time. When the tension deviates from the set value, the drive motor adjusts the pressure of the tension roller to keep the fabric under constant tension and prevent the fabric from wrinkling or stretching during the drying process. Then it is conveyed to the drafting and winding unit 500. In the above structure, the ultrasonic cleaner 414, combined with the circulating filtration system, not only effectively removes floating dye and impurities from the fabric surface but also reduces the amount of washing water used. The dual filtration effect of the particle filter 415 and the activated carbon filter 416 allows for the reuse of washing water, reducing wastewater treatment costs. The pneumatic pressure regulation function of the mechanical dewatering component 420 can adapt to fabrics of different thicknesses, resulting in uniform moisture content in the dewatered fabric. The heating wire array and hot air circulation system ensure uniform temperature within the insulation chamber 431, ensuring even heating of the fabric and good drying results. In the specific structure of the drafting and take-up unit 500, the drafting and take-up unit 500 includes a pressure roller assembly 510 and a transmission mechanism 520 arranged sequentially along a third direction. The pressure roller assembly 510 includes two take-up pressure rollers arranged opposite to each other. The transmission mechanism 520 includes a take-up drum and a transmission component connected to each other. The transmission component is at least used to drive the take-up drum to rotate in order to control the take-up rate and drafting tension, so that the take-up drum collects the fabric.

[0054] In this embodiment, as Figure 2 As shown, the drafting and winding unit 500 arranges the pressure roller assembly 510 and the transmission mechanism 520 sequentially along the Z-axis (third direction), and the whole unit is connected to the outlet of the drying and setting mechanism 430 of the post-processing unit 400 to form a complete finished product processing link. The drafting pressure roller assembly 510 consists of two pressure rollers driven by cylinders arranged opposite each other. Its surface is covered with a nitrile rubber layer, and the surface of the rubber layer is treated with a diamond pattern to enhance the friction with the fabric. The gap between the pressure rollers is adjustable, which can uniformly clamp fabrics of different thicknesses.

[0055] The transmission mechanism 520 includes a variable frequency motor, a gearbox, a torque sensor, and a magnetic powder brake. The variable frequency motor is connected to the input shaft of the gearbox via a synchronous belt, and the output shaft of the gearbox is connected to the drive end of the pressure roller via a coupling to achieve stepless speed regulation of the pressure roller. The torque sensor is installed in the transmission chain to monitor the winding torque in real time and feed it back to the integrated control unit 600. The magnetic powder brake is connected to the driven end of the pressure roller and is used to fine-tune the winding tension. In the specific structure of the integrated control unit 600, the integrated control unit 600 includes a main control system 610 and an operation control panel 620. The main control system 610 is at least used to receive pattern data and synchronously control the actions of the dyeing unit 200 and the weaving unit 300. The main control system 610 includes an industrial PLC and a distributed I / O module. The industrial PLC has a built-in color-structure synchronization engine to decompose the pattern data into dyeing instructions and weaving instructions, and sends the dyeing instructions to the dyeing unit 200 and the weaving instructions to the weaving unit 300, so as to realize the synchronous and coordinated control of the dyeing unit 200 and the weaving unit 300.

[0056] In this embodiment, as Figure 2 As shown, the integrated control unit 600 consists of a main control system 610 and an operation control panel 620. The two interact via industrial Ethernet and are mounted on one side of the X-axis of the equipment frame 10. The main control system 610 is an industrial PLC, which can utilize existing technologies, such as a Siemens S7-1200 series or equivalent programmable logic controller. It has a built-in color-structure synchronization engine, including a color decomposition algorithm, a weaving trajectory planning module, and a timing synchronization controller, enabling real-time analysis of pattern data and instruction distribution. The distributed I / O module adopts a PROFINET distributed structure, connecting to the industrial PLC via a bus connector. Millisecond-level coordinated control of the dyeing module, loop forming module, and post-processing module is achieved through the PROFINET bus. The operation control panel 620 can also utilize existing technologies, such as a high-definition touchscreen supporting multi-touch and glove operation mode. Its surface is covered with scratch-resistant and wear-resistant tempered glass. The panel integrates an emergency stop button, status indicator lights (power, running, fault), and a USB interface (supporting pattern data import). A shock-absorbing bracket is installed at the bottom to adapt to workshop vibration environments. Example 2 On the other hand, this application also provides a dyeing and weaving method based on the above-mentioned integrated dyeing and weaving warp knitting equipment, comprising the following steps: S1. The original colored yarn is fed to the dyeing unit 200 through the warp feeding unit 100 for dyeing to form colored yarn; S2. The colored yarn is fed to the weaving unit 300 to be woven into a fabric with a colored pattern; S3. The fabric is conveyed to the post-processing unit 400 for post-processing to form the finished fabric. S4. The finished fabric is conveyed to the drafting and winding unit 500 for collection; The integrated control unit 600 synchronously controls the dyeing unit 200 to perform dyeing operations and the weaving unit 300 to perform weaving operations in real time.

[0057] More specifically, S1 also includes the following steps: S11. According to the structure of the predetermined fabric, the yarn separating and conveying mechanism arranges the yarns in parallel at a certain interval, so that the yarn layers are evenly distributed in a single layer to meet the accuracy requirements of subsequent online dyeing. S12. According to the pattern, structure and color of the fabric, the dyeing mechanism 210 dyes the original color yarn online. S13. The dyeing yarn fed by the dyeing mechanism 210 is fixed in real time by the color fixing mechanism 220 to form colored yarn.

[0058] In addition, S3 includes the following steps: S31. The residual dye and impurities on the fabric are cleaned by the cleaning unit 410; S32. The drying and setting mechanism 430 performs surface setting treatment on the fabric that has passed through the washing mechanism 410 to form the finished fabric.

[0059] In the steps of this embodiment, according to the predetermined fabric structure, the warp feeding unit 100 arranges the yarns in parallel at a certain interval, so that the yarn layers are uniformly distributed in a single layer, which meets the accuracy requirements of subsequent online dyeing. The warp feeding unit 100 first monitors the yarn tension in real time through a tension sensor and uses a servo braking device to maintain the tension at a constant value to ensure the stability of the yarn operation. Then, the yarn is unfolded by the yarn separating reed 130 and enters the spacing adjustment mechanism driven by a precision stepper motor. The spacing between the comb teeth can be finely adjusted within the range of 1.0–2.0 mm, thereby forming a single layer of parallel distributed yarn layers. Then, these layers pass through the tension bar 140 in sequence, and the tension sensing information is fed back to the PLC main control system 610. The PLC then performs closed-loop adjustment of the stepper motor and servo brake based on these data to ensure the uniformity of the yarn layers and the consistency of tension, providing accurate yarn positioning guarantee for subsequent online inkjet dyeing.

[0060] Subsequently, based on the pattern, structure, and color of the fabric, the yarn dyeing mechanism 210 dyes the primary color yarn online. The yarn dyeing system consists of four independent components, each loaded with one of four inks: cyan (C), magenta (M), yellow (Y), and black (K). Each dyeing component is equipped with a miniature hydraulic pump 212, a high-frequency solenoid valve 213, and a nozzle 215, forming a precision spraying unit. The controller drives the corresponding spraying unit—one or more nozzles 215 from the first to the fourth yarn dyeing components—in real time to spray dye particles onto the primary color yarn according to the required CMYK ratio, thereby forming the predetermined color on the moving yarn. To adapt to the requirements of different knitting processes on the spacing of pattern color dots, the controller can flexibly adjust the spraying sequence and position through program parameters, so that the distance between dyed dots precisely matches the texture structure of various weaving methods. This programmable dot spacing control not only ensures color reproduction and pattern clarity but also meets the diverse customized production needs. The blower of the yarn fixing mechanism 220 blows the heat generated by heating the electric heating wire onto the dyed yarn being conveyed in the yarn drying box 221 to dry the dyed yarn.

[0061] The colored yarn is stably conveyed from the dyeing unit 200 to the yarn guiding assembly of the warp knitting machine via tension rollers, and then fed into the loop-forming mechanism, which includes a single needle bed and a multi-needle bed. The single needle bed weaving process includes the finished colored yarn being adjusted by the tension roller group and then conveyed to the position of the single needle bed knitting needle 323 via the yarn guiding needle 321. When the knitting needle 323 is lifted by the cylinder or the selvage plate, the needle bar opens its tongue to receive the guided yarn. As the needle bar descends, the tongue closes and wraps the yarn, forming an independent loop. Subsequently, the knitting needle 323 is lifted again, the tongue opens, and the formed loop is released to the needle transfer table or pick-and-place mechanism below. Under the action of the traction device, the fabric is pulled out at a uniform speed to maintain the loop density and tension stability. This process is continuously repeated, and a flat fabric with a color pattern is woven stitch by stitch and row by row on the single needle bed. The fabric with the color pattern is then collected by the transmission mechanism 520 and sent to the post-processing unit 400. Double-needle-bed weaving involves the colored yarn first passing through the guide groove of the front guide beam, then being introduced into the tooth profile of the front needle bed by the guide comb, and subsequently falling between the circular movable latch needle of the front needle bed and the fixed movable latch needle of the rear needle bed. With the coordinated vertical up-and-down movement of the front needle bed needle bar and the synchronous lateral movement of the rear needle bed needle bar, the movable latch needles open and close, releasing and taking in the yarn, thus completing the single loop storage and transfer to form the first loop. As the machine barrel or turntable rotates continuously, each needle bed repeats the above actions sequentially, with the front and rear needle beds alternately performing opening, closing, and shifting to achieve multi-directional interlaced loop formation, thereby weaving a warp-knitted fabric with a predetermined color pattern and density. The fabric with the color pattern is then collected by the drafting mechanism and sent to the post-processing unit 400.

[0062] Afterwards, the fabric undergoes post-treatment to form the finished fabric. After color fixing, the colored fabric passes through a cleaning tank 411. The bottom of the cleaning tank 411 is equipped with an ultrasonic cleaner 414. The ultrasonic cleaner 414 generates ultrasonic waves. The ultrasonic waves generate cavitation and acceleration effects in the cleaning solution to act on the cleaning solution and the color-fixed dyed fabric, removing residual dye and impurities from the dyed yarn to form the colored fabric. The cleaned colored fabric passes through a heat preservation box 431. The heat preservation box 431 is equipped with heating wires and pressure rollers. The heat generated by the heating wires and the tension provided by the pressure rollers are used to dry and shape the fabric to form the finished colored warp-knitted fabric.

[0063] Finally, the finished fabric is collected by the stretching and winding unit 500.

[0064] In the embodiments disclosed in this application, the terms "installation," "connection," "linking," and "fixing" should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; "linking" can be a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in the embodiments disclosed in this application according to the specific circumstances.

[0065] The above description is only a preferred embodiment of this application. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of this application, and these improvements and modifications should also be considered within the scope of protection of this application.

Claims

1. A warp knitting equipment integrating dyeing and weaving, comprising an equipment frame, characterized in that, It also includes a warp feeding unit, dyeing unit, weaving unit, post-processing unit, drafting and take-up unit, and integrated control unit integrated on the equipment frame; The warp feeding unit includes a yarn separating and conveying mechanism for separating the warp yarns into independent parallel single yarn layers and conveying the single yarn layers to the dyeing unit; The dyeing unit includes a dyeing mechanism and a fixing mechanism arranged sequentially along the yarn travel direction. The dyeing mechanism is used to dye a single yarn layer, and the fixing mechanism is used to fix the dyed yarn in real time to form colored yarn. The output end of the dyeing unit is connected to the input end of the weaving unit. The weaving unit is used to weave colored yarn into a fabric with a colored pattern and to transport the fabric to the post-processing unit. The post-processing unit includes a cleaning mechanism and a drying and setting mechanism arranged sequentially along the fabric travel direction. The cleaning mechanism is used to clean the fabric, and the drying and setting mechanism is used to dry and set the fabric to form a finished fabric. The output end of the post-processing unit is connected to the input end of the drafting and winding unit. The stretching and take-up unit is used to take up the finished fabric; The integrated control unit is connected to at least the dyeing unit and the weaving unit, and synchronously controls the dyeing / fixing action of the dyeing unit and the weaving action of the weaving unit.

2. The warp knitting equipment integrating dyeing and weaving according to claim 1, characterized in that, The integrated control unit and the weaving unit are arranged at intervals along a first direction. The weaving unit, the post-processing unit, and the drafting and take-up unit are arranged at intervals along a second direction. The warp feeding unit, the dyeing unit, and the weaving unit are arranged at intervals along a third direction. The first direction, the second direction, and the third direction are perpendicular to each other.

3. The warp knitting equipment integrating dyeing and weaving according to claim 2, characterized in that, The yarn feeding mechanism includes a warp head, a yarn guide rod, a yarn separating reed, a tension rod, and an electronically controlled warp feed module. The yarn guide rod, the yarn separating reed, and the tension rod are arranged sequentially along the second direction. The electronically controlled warp feed module and the warp head are arranged sequentially along the first direction, and the electronically controlled warp feed module is connected to the warp head to drive the warp head to release the raw yarn. After being guided by the yarn guide rod, the yarn is separated into independent parallel single yarn layers by the yarn separating reed. The tension of the single yarn layers is then maintained by the tension rod and fed to the dyeing unit. The electronically controlled warp feed module is connected to the integrated control unit. And / or, the tension bar maintains the tension fluctuation range of the single yarn layer within ≤±1.5%.

4. The warp knitting equipment integrating dyeing and weaving according to claim 2, characterized in that, The coloring mechanism and the color fixing mechanism are arranged at intervals along the second direction; And / or, the coloring mechanism includes at least four independent coloring components, each of which includes an ink cartridge, a micro hydraulic pump, a solenoid valve, an inkjet tube, and a printhead. The ink cartridge is used to hold ink. The micro hydraulic pump is disposed in the ink cartridge and connected to the ink inlet of the solenoid valve to pressurize and output ink. The ink outlet of the solenoid valve is connected to the printhead through the inkjet tube. The nozzles of the multiple printheads are arranged in an array to cover the width of the single yarn layer laterally. Each nozzle corresponds to a single yarn. The ink cartridges of each coloring component hold different colors of ink. And / or, the ink colors of the four ink cartridges are cyan, yellow, magenta and black, respectively; And / or, the distance between the nozzle and the yarn is 5-10 mm; And / or, the color-fixing mechanism includes a drying chamber and a multimodal energy module. The drying chamber is a double-layer stainless steel heat-insulating structure with a high-temperature resistant ceramic layer lining its inner wall. The multimodal energy module is installed inside the drying chamber to release energy into the drying chamber to achieve instant color fixation. And / or, the multimodal energy module includes a distributed electric heating wire array assembly and / or a UV-LED array assembly disposed on the inner wall of the drying oven.

5. The warp knitting equipment integrating dyeing and weaving according to claim 2, characterized in that, The weaving unit includes a control mechanism and a tension adjustment mechanism, a weaving mechanism, and a drafting mechanism arranged sequentially along the third direction. The tension adjustment mechanism is used to maintain the tension of the input colored yarn. The control mechanism controls the colored yarn to be fed to the weaving mechanism. The weaving mechanism is used to weave the colored yarn into a fabric with a color pattern. The drafting mechanism is used to draft the fabric to the post-processing unit. The control mechanism is connected to the integrated control unit. And / or, the knitting mechanism includes a yarn guide comb assembly, a sinker plate, and knitting needles. The yarn guide needles of the yarn guide comb assembly guide the colored yarn to the loop forming area, and the sinker plate maintains the tension of the colored yarn before feeding it to the needle plate. The knitting needles then complete the loop knitting of the colored yarn. And / or, the yarn guide needle is made of low-friction ceramic; And / or, the knitting needles are made of nitrided wear-resistant alloy steel and their surface is coated with an anti-dye staining coating; And / or, the yarn guide comb assembly is connected to the control mechanism, so that the yarn guide comb assembly is linked with the dyeing unit in real time along the transverse guide rail, so as to realize the immediate introduction of the yarn guide comb into the weaving process after dyeing in the dyeing unit.

6. The warp knitting equipment integrating dyeing and weaving according to claim 2, characterized in that, The cleaning mechanism and the drying and shaping mechanism are arranged at intervals along the second direction; And / or, the cleaning mechanism includes a cleaning tank, a circulating filter box, and a mechanical dewatering assembly. The cleaning tank is equipped with multiple sets of guide rollers, and an ultrasonic cleaner is provided at the bottom of the cleaning tank. The circulating filter box includes a pre-positioned particle filter and a post-positioned activated carbon filter. The circulating filter box is connected to the cleaning tank through a conduit and a water pump. The mechanical dewatering assembly includes two pressure rollers, which are arranged opposite to each other to squeeze and dewater the fabric. And / or, the outer surface of the pressure roller is coated with a silicone layer; And / or, at least one of the two pressure rollers is connected to a pneumatic pressure module to achieve linear pressure regulation of 0.2-0.8 MPa; And / or, the drying and setting mechanism includes an insulation box, a heating component, and a tension adjusting component. The heating component includes heating wires arranged in an array along the circumference of the insulation box on the inner wall of the insulation box. The top of the insulation box is provided with a hot air circulation system. The tension adjusting component includes a drive motor and a tension roller connected to each other to provide real-time feedback and adjust the pressure of the tension roller to maintain constant tension of the fabric.

7. The warp knitting equipment integrating dyeing and weaving according to claim 2, characterized in that, The drafting and take-up unit includes a pressure roller assembly and a transmission mechanism arranged sequentially along the third direction. The pressure roller assembly includes two take-up pressure rollers arranged opposite each other. The transmission mechanism includes a take-up drum and a transmission component connected to each other. The transmission component is at least used to drive the take-up drum to rotate in order to control the take-up rate and drafting tension, so that the take-up drum collects the fabric.

8. The warp knitting equipment integrating dyeing and weaving according to claim 1, characterized in that, The integrated control unit includes a main control system and an operation control panel. The main control system is at least used to receive pattern data and synchronously control the actions of the dyeing unit and the weaving unit. And / or, the main control system includes an industrial PLC and a distributed I / O module. The industrial PLC has a built-in color-structure synchronization engine to decompose the pattern data into dyeing instructions and weaving instructions, and to send the dyeing instructions to the dyeing unit and the weaving instructions to the weaving unit, so as to realize the synchronous and coordinated control of the dyeing unit and the weaving unit.

9. A dyeing and weaving method based on the warp knitting equipment integrating dyeing and weaving according to any one of claims 1-8, characterized in that, Includes the following steps: S1. The original colored yarn is fed through the warp feeding unit to the dyeing unit for dyeing to form colored yarn; S2. The colored yarn is fed to the weaving unit to be woven into a fabric with a colored pattern; S3. The fabric is conveyed to the post-processing unit for post-processing to form a finished fabric. S4. The finished fabric is conveyed to the drafting and winding unit for collection; The integrated control unit synchronously controls the dyeing unit to perform dyeing operations and the weaving unit to perform weaving operations in real time.

10. The dyeing and weaving method according to claim 9, characterized in that, The S1 also includes the following steps: S11. According to the structure of the predetermined fabric, the yarn separating and conveying mechanism arranges the yarns in parallel at a certain interval so that the yarn layers are evenly distributed in a single layer to meet the accuracy requirements of subsequent online dyeing. S12. According to the pattern, structure, and color of the fabric, the dyeing mechanism performs online dyeing of the original color yarn; S13. The dyeing yarn fed by the dyeing mechanism is fixed in real time to form colored yarn. And / or, in S3, the following steps are also included: S31. The residual dye and impurities on the fabric are cleaned by the cleaning mechanism. S32. The drying and shaping mechanism performs surface shaping treatment on the fabric that has passed through the cleaning mechanism to form a finished fabric.

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