Low-loss warp knitting cut pile production method of Raschel blanket
By increasing the warp feed and tension in Raschel blanket production, adjusting the parameters of the cutter, and introducing a laser alignment sensor and an electrostatic eliminator, the problem of precise control in the cutter process was solved, achieving low-loss and high-efficiency production, and improving product quality and economic benefits.
Patent Information
- Application Number
- CN202511200898.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-08-26
- Publication Date
- 2025-12-09
AI Technical Summary
In the current production of Raschel blankets, the warp knitting and cutting process results in high losses, making it difficult to achieve efficient and precise control and cutting of the warp, leading to unstable product quality and high raw material loss rate.
The base fabric is woven using GB1 and GB4 comb bars. The amount of warp feed is increased by 5-8%, the tension of the warp yarn is controlled at 3-5 cN, the angle of the circular blade of the cutter is adjusted to 87-88°, and the position of the warp cluster apex is dynamically adjusted in real time by combining a laser positioning sensor. An electrostatic eliminator is installed to eliminate electrostatic interference, and the speed of the cutter is increased to 2800-3200 rpm.
It effectively reduces warp yarn breakage and base fabric damage, ensuring a smooth and even nap, achieving near-100% precision cutting, significantly reducing production loss rate to below 1.2%, and improving product quality and first-grade yield.
Smart Images
Figure CN121087685A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to the technical field of textiles, in particular to a low-loss warp-knitting cut-pile production method for Raschel blankets, and more particularly to a low-loss warp-knitting cut-pile production method capable of significantly reducing fabric loss, improving product quality and economic benefits. BACKGROUND
[0002] Raschel blankets are favored by the market due to their full pile, soft hand feeling and good warmth retention. The core production process is warp-knitting double-layer cut-pile technology, that is, two base fabrics are knitted simultaneously on a double-needle bed Raschel warp-knitting machine, and the two layers of base fabrics are connected by pile warp to form a double-layer pile fabric, and then the pile warp connecting the two layers is cut off through a cut-pile process, thereby obtaining two independent pile blanket base fabrics. The level of this technology directly determines the quality, production cost and market competitiveness of the final product.
[0003] However, in existing large-scale industrial production, the warp-knitting cut-pile link still faces a series of technical problems to be solved, resulting in high production loss, which restricts the further improvement of product quality and optimization of cost. First, the warp feed amount control and tension stability of pile warp are the basis. If the warp feed amount is insufficient or the tension is too large, it will lead to insufficient pile height, sparse pile surface, and the pile warp will be easily pulled out due to tension during cutting, causing damage to the base fabric or incomplete cutting. If the warp feed amount is too large or the tension is too small, it is easy to form loose loops and uneven pile height, making it difficult to accurately position the cutting point during cutting, resulting in high and low piles or damage to the base fabric. Second, the precision of the cut-pile process is the key bottleneck. The traditional mechanical cut-pile machine relies on fixed guide rollers and mechanical alignment, which is difficult to cope with the inevitable slight tension fluctuations and base fabric deformation during weaving, resulting in micron-level deviation between the cutting trajectory of the round blade and the actual position of the pile warp cluster top. This deviation can easily lead to incomplete cutting, resulting in "broken silk" defects, or excessive cutting that damages the base fabric structure, and in severe cases, even causes the entire base fabric to be scrapped, significantly increasing the raw material loss rate. In addition, static electricity generated during high-speed cutting can attract fiber debris, interfering with sensor operation and affecting the smoothness of blade cutting; and the parameter settings of the cutting element, such as the inclination and speed of the round blade, if not matched with the current high production rhythm and the characteristics of new synthetic materials, will also directly affect the cutting smoothness and the amount of fluff.
[0004] Therefore, there is an urgent need in the industry for an innovative low-loss warp-knitting cut-pile production method that can systematically solve the technical problems throughout the entire process from warp-knitting to precise cutting at high production efficiency, effectively control the loss of raw materials, and accurately control the quality of the final product. SUMMARY
[0005] The present application aims to provide a printing method for warp-knitted plush single-layer blanket double-sided different patterns.
[0006] To achieve the above object, the present application provides the following technical solutions.
[0007] A low-loss warp cutting method for producing a Raschel blanket, comprising the following steps:
[0008] ① Double-layered pile fabric weaving step: on a double-needle bed Raschel warp knitting machine, GB1 guide bar and GB4 guide bar are used to weave the base fabric, and GB2 guide bar and GB3 guide bar are used to form pile warp; the pile warp feed amount is increased by 5%-8% compared with the standard feed amount, the standard feed amount refers to the feed amount used when a conventional quality Raschel blanket is woven by using the same machine type, the same raw material and the same organization; the pile warp yarn tension is controlled at 3-5 cN;
[0009] ② Blanket setting and drying step;
[0010] ③ Knitting cutting step: the blanket treated in step ② is fed into a high-speed cutting machine, the installation angle of the circular blade (1) of the cutting machine is adjusted to form an acute angle of 87°-88° with the horizontal plane;
[0011] ④ Dynamic fine adjustment and cutting step: the laser alignment sensor (2) is used to monitor the vertex position of the pile warp cluster in real time, and the blanket conveying system is dynamically fine adjusted according to the feedback signal of the sensor, so that the pile warp cluster vertex is accurately aligned with the cutting point, and the pile is cut;
[0012] ⑤ Winding and finishing step.
[0013] Further, in the step ①, the weaving workshop environment humidity is controlled at 65%-75%, preferably 70%.
[0014] Further, in the step ③, the rotating speed of the circular blade (1) is increased to 2800-3200 rpm, preferably 3000 rpm.
[0015] Further, in the step ①, the pile warp feed amount is increased by 6%-7% compared with the standard feed amount.
[0016] Further, in the step ③, the installation angle of the circular blade (1) is 87.5°.
[0017] Further, in the step ③, an electrostatic eliminator (3) is arranged in front of the monitoring point of the laser alignment sensor (2).
[0018] Further, in the step ①, the pile warp yarn is one or more of superfine denier polyester, acrylic or nylon blended yarn.
[0019] Further, the single filament fineness of the pile warp yarn is 0.5-1.5 denier.
[0020] The beneficial effects of the present application are:
[0021] 1、The present application ensures that the pile warp yarn has sufficient and uniform yarn length and relaxation state during the weaving process by increasing the pile warp let-off amount by 5% to 8%, preferably 6% to 7%, compared to the standard let-off amount, and stably controlling the pile warp yarn tension at 3 to 5 cN in a high humidity environment. This technical solution effectively avoids the damage and holes of the base fabric caused by accidental pulling or breaking of the yarn due to tightness, provides a base fabric with complete structure and consistent pile height for subsequent cutting, and reduces potential losses caused by weaving defects from the source.
[0022] 2、By precisely adjusting the installation angle of the cutter blade of the cutting machine to an acute angle of 87° to 88° with the horizontal plane, preferably 87.5°, and increasing its speed to 2800 to 3200 rpm, preferably 3000 rpm, high-speed and efficient cutting is achieved. This unique angle setting combined with high speed allows the blade to contact the pile warp cluster at the optimal cutting angle, making the cutting action more crisp and neat, greatly reducing fiber pulling and fluff caused by poor cutting, and making the pile surface cut exceptionally smooth and smooth, effectively improving the appearance quality and hand feel of the finished product, while reducing the subsequent cleaning process and invisible loss of raw materials caused by excessive fluff.
[0023] 3、The core of the present application is the introduction of a real-time dynamic fine-tuning system based on a laser alignment sensor. This system accurately monitors the actual position of the pile warp cluster vertex of the moving base fabric in real time through the laser alignment sensor, and immediately feeds back the position signal to the base fabric conveying control system. The system compensates and fine-tunes the conveying speed or position in real time to ensure that each pile warp cluster vertex can be accurately guided to the fixed cutting track of the cutter blade. This active closed-loop control completely overturns the traditional passive mechanical alignment mode, completely offsets the alignment deviation caused by uneven weaving tension, base fabric elastic deformation and equipment transmission error, and achieves almost 100% accurate alignment, fundamentally eliminating major quality defects such as incomplete cutting and base fabric damage caused by misalignment cutting, and reducing raw material loss in the cutting process to the limit.
[0024] 4、By installing an electrostatic eliminator in front of the laser alignment sensor monitoring point, the static electricity generated by the friction between the pile warp yarn and the equipment components during high-speed cutting is effectively neutralized. This design eliminates the interference of static adsorbed fiber debris on the monitoring accuracy of the laser sensor, ensuring the long-term stability and reliability of the dynamic fine-tuning system; at the same time, it also avoids the problems of fiber disorder and difficulty in dispersion caused by static electricity, further ensuring the neatness and consistency of the pile surface after cutting, and plays an important auxiliary role in reducing overall loss. BRIEF DESCRIPTION OF DRAWINGS
[0025] Figure 1 is a schematic view of the cutting device structure.
[0026] Figure 2 Process flow chart for production.
[0027] Figure (1), round blade, (2), laser alignment sensor, (3) static eliminator. DETAILED DESCRIPTION
[0028] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative work fall within the protection scope of the present application.
[0029] Embodiment 1
[0030] A low-loss warp-knitting cut-pile production method of a Raschel blanket is performed according to the following steps:
[0031] ① Double-layer pile fabric knitting step: on an RD7DPLM / 12-3 type double-needle bed Raschel warp knitting machine, GB1 guide bar and GB4 guide bar are used to knit base fabric tissue by inserting polyester filaments, GB2 guide bar and GB3 guide bar are used to insert ultra-fine denier polyester yarn (single filament fineness is 1.0 denier) as pile warp. The pile warp let-off amount is increased by 6% compared with the standard let-off amount of the machine type for knitting conventional quality blankets. The on-machine tension of the pile warp yarn is accurately controlled at 4 cN. At the same time, the environmental humidity of the knitting workshop is stably controlled at 70% through a humidification system.
[0032] ② Blanket setting and drying step: the three-dimensional connected blanket obtained in step ① is sent into a setting and drying machine for setting and drying at a temperature of 135℃, so as to stabilize the fabric structure.
[0033] ③ On-machine cut-pile step: the blanket treated in step ② is introduced into a M-CES type high-speed cutting machine. The installation angle of the round blade (1) of the cutting machine is adjusted to form an acute angle of 87.5° with the horizontal plane. The driving motor speed of the round blade (1) is 3000 rpm. About 10 cm in front of the monitoring point of the laser alignment sensor (2), an ion wind static eliminator (3) is installed.
[0034] ④ Dynamic fine adjustment and cutting step: the cutting machine is started, the laser alignment sensor (2) starts to monitor the vertex position of the pile warp cluster on the moving blanket in real time, and transmits the position signal to the PLC control system in real time. The PLC dynamically fine adjusts the speed of the blanket conveying roller driven by the servo motor according to the feedback signal, so that the vertex of each pile warp cluster is accurately aligned with the fixed cutting track of the round blade (1), and efficient and accurate cutting is completed.
[0035] ⑤winding and post-finishing step: winding the two pieces of fabric separately after cutting, and then performing the conventional post-finishing processes such as ironing, cutting, printing, and shaking, to obtain the finished product.
[0036] Example 2
[0037] A low-loss warp-knitting cutting production method for a Raschel blanket is performed in the following steps:
[0038] ① double-layered pile fabric knitting step: on a double-bed Raschel warp knitting machine, GB1 and GB4 guide bars knit the base fabric, and GB2 and GB3 guide bars use acrylic / nylon blended yarn (single filament fineness of 1.2 denier) as pile warp. The pile warp let-off amount is controlled to be increased by 7% compared to the standard let-off amount. The pile warp yarn tension is controlled at 3.5 cN. The knitting workshop environment humidity is controlled at 65%.
[0039] ② fabric setting and drying step: same as Example 1.
[0040] ③ cutting step: adjust the installation angle of the cutting machine round blade (1) to 87°. The round blade rotation speed is 2800 rpm. Install the static eliminator (3).
[0041] ④ dynamic fine-tuning and cutting step: same as Example 1.
[0042] ⑤ winding and post-finishing step: same as Example 1.
[0043] Example 3
[0044] A low-loss warp-knitting cutting production method for a Raschel blanket is performed in the following steps:
[0045] ① double-layered pile fabric knitting step: on a double-bed Raschel warp knitting machine, GB1 and GB4 guide bars knit the base fabric, and GB2 and GB3 guide bars use ultra-fine denier nylon yarn (single filament fineness of 0.8 denier) as pile warp. The pile warp let-off amount is controlled to be increased by 5.5% compared to the standard let-off amount. The pile warp yarn tension is controlled at 5 cN. The knitting workshop environment humidity is controlled at 75%.
[0046] ② fabric setting and drying step: same as Example 1.
[0047] ③ cutting step: adjust the installation angle of the cutting machine round blade (1) to 88°. The round blade rotation speed is 3200 rpm. Install the static eliminator (3).
[0048] ④ dynamic fine-tuning and cutting step: same as Example 1.
[0049] ⑤ winding and post-finishing step: same as Example 1.
[0050] Comparative Example 1
[0051] The difference between the present comparative example and Example 1 is that in Step ①, the warp feed is strictly given according to the standard feed without any increase, and the warp tension is controlled at 8 cN. The rest of the steps and parameters are exactly the same as those in Example 1.
[0052] Comparative Example 2
[0053] The difference between the present comparative example and Example 1 is that in Step ③, the laser alignment sensor and dynamic fine adjustment system are not used, but a traditional fixed guide roller is used for mechanical alignment and cutting. The installation angle of the circular blade is the conventional 90°. The rest of the steps and parameters are exactly the same as those in Example 1.
[0054] Comparative Example 3
[0055] The difference between the present comparative example and Example 1 is that in Step ③, the static electricity eliminator (3) is not installed. The rest of the steps and parameters are exactly the same as those in Example 1.
[0056] Comparative Example 4
[0057] The difference between the present comparative example and Example 1 is that in Step ①, the humidity of the weaving workshop environment is 45%. The rest of the steps and parameters are exactly the same as those in Example 1.
[0058] Effect verification
[0059] The key quality indicators of the blanket base cloth produced in Examples 1-3 and Comparative Examples 1-4 above are detected, the cutting loss rate (%) of the base cloth per 10,000 meters is counted, and the finished products are rated, and the results are shown in the following table:
[0060]
[0061] From the above data, it can be seen that by using the technical solution (Examples 1-3) provided by the present application, through improving the feed, tension, humidity, blade parameters and combining the laser sensing dynamic fine adjustment system and the static electricity elimination device, the cutting production loss can be systematically reduced to a very low level (below 1.2%), and the first-class product rate of the product can be greatly improved. In the comparative examples, the lack of any one key feature will lead to a significant increase in the loss rate and a decrease in product quality, which fully proves that the technical features of the present application are mutually coordinated and indispensable, and together constitute a complete and efficient low-loss production technical solution. The structure diagram of the cutting device is shown in Figure 1 The production process flow chart is shown in Figure 2 .
[0062] The remaining matters of the present application are known technologies.
[0063] The above merely provides the preferred embodiments of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art, according to the technical solution of the present application and the improved concept thereof, makes equivalent replacement or change within the technical range disclosed by the present application, and should be covered within the protection scope of the present application.
Claims
1. A low-loss warp-knitted cut pile production method for Raschel blankets, characterized in that, Includes the following steps: ① Double-layer pile fabric weaving steps: On a double-needle bed Raschel warp knitting machine, the base fabric is woven using GB1 and GB4 guide bars, and the pile warp is formed using GB2 and GB3 guide bars; the pile warp feed is controlled to be 5%-8% higher than the standard feed, where the standard feed refers to the feed used when weaving a regular quality Raschel blanket using the same machine model, the same raw materials, and the same weave; the pile warp tension is controlled at 3-5 cN; ② Fabric shaping and drying steps; ③ Steps for cutting the fabric: Feed the fabric processed in step ② into the high-speed cutting machine, and adjust the installation angle of the circular blade (1) of the cutting machine so that it forms an acute angle of 87°-88° with the horizontal plane; ④ Dynamic fine-tuning and cutting steps: The laser alignment sensor ② monitors the vertex position of the pile warp cluster in real time, and dynamically fine-tunes the fabric conveying system according to the feedback signal of the sensor, so that the vertex of the pile warp cluster is precisely aligned with the cutting point for cutting. ⑤ Rolling and post-processing steps.
2. The low-loss warp-knitted cut pile production method for Raschel blankets according to claim 1, characterized in that, In step ①, the humidity of the weaving workshop environment is controlled at 65%-75%, preferably 70%.
3. The low-loss warp-knitted cut pile production method for Raschel blankets according to claim 1, characterized in that, In step ③, the rotational speed of the circular blade (1) is increased to 2800-3200 rpm, preferably 3000 rpm.
4. The low-loss warp-knitted cut pile production method for Raschel blankets according to claim 1, characterized in that, In step ①, the amount of warp feed is increased by 6%-7% compared to the standard amount of warp feed.
5. The low-loss warp-knitted cut pile production method for Raschel blankets according to claim 1, characterized in that, In step ③, the installation angle of the circular blade (1) is 87.5°.
6. The low-loss warp-knitted cut pile production method for Raschel blankets according to claim 1, characterized in that, In step ③, an electrostatic eliminator (3) is installed in front of the monitoring point of the laser alignment sensor (2).
7. The low-loss warp-knitted cut pile production method for Raschel blankets according to claim 1, characterized in that, In step ①, the warp yarn is one or more blended yarns of ultra-fine denier polyester, acrylic, or nylon.
8. The low-loss warp-knitted cut pile production method for Raschel blankets according to claim 7, characterized in that, The single filament fineness of the warp yarn is 0.5-1.5 denier.