Method and system for automatically calculating hosiery materials

Abstract

The application discloses a method for calculating sock raw materials, and calculates the length of the sock raw materials according to the process stretching of the socks in the process of calculating the sock raw materials, then calculates the weight of the raw materials according to the length of the sock raw materials, and calculates the weight of the length left on the finished socks which cannot be cut off, and the sum of the weight of the raw materials and the weight of the length left is the final calculated total weight of the sock raw materials. The material data budgeted by the application is more accurate and reasonable, the budget efficiency is greatly improved, and the material cost is saved.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of sock raw material budgeting, and in particular to a method and system for automatically calculating sock raw materials. BACKGROUND

[0002] The amount of raw materials required for producing socks is huge, with different specifications and fast turnover. Raw materials need to be purchased or dyed by multiple parties. The closer the budgeted purchase quantity of raw materials by an enterprise to the actual production needs, the fewer the number of purchase or dyeing times, and the lower the purchase cost. The more accurate the purchase quantity of raw materials, the less the warehouse raw material inventory, and the less the manpower and time required for warehouse management. The more accurate the purchase quantity of raw materials, the shorter the production cycle, and the less the impact on the quality or delivery date of socks caused by different batches or colors of raw materials due to repeated purchase or dyeing of raw materials due to insufficient quantity. This effectively reduces or avoids the troubles and difficulties caused by insufficient or excessive purchase of raw materials. The quotation of an enterprise to a customer is calculated based on the weight of all raw materials consumed by the socks, that is, the more accurate the budgeted weight, the more accurate the quotation. There are currently several methods for an enterprise to budget the weight of socks:

[0003] A1: Proportional estimation method: only suitable for the weight budgeting of simple flat socks, not suitable for the weight budgeting of patterned socks or socks with elastic bands on the upper and lower parts,

[0004] A2: Cutting and weighing method: only suitable for socks with large pattern areas that are easy to cut. If the cut sock pieces are too small to weigh, they cannot be calculated. Only the amount of the cut sock pieces that are knitted into loops can be calculated, and the amount of the part that is cut off by the scissors and sucked away during knitting cannot be calculated. The calculation is incomplete and inaccurate,

[0005] A3: Disassembling and weighing method: for patterned socks, the amount of the part that is cut off by the scissors and sucked away during knitting cannot be calculated. The calculation is still incomplete, time-consuming, labor-intensive, low in efficiency, and inaccurate,

[0006] A4: Estimating weight by loop count method: suitable for special parts, such as the use of 0.04g / loop*double for 100# elastic bands at the cuff, and 0.06g / loop*double for 21S / 1C single elastic bands at the cuff. This estimation method does not change with stretching, and the error is large. SUMMARY

[0007] The main purpose of the present application is to provide a method and system for automatically calculating sock raw materials that can accurately budget the order materials.

[0008] The technical solution adopted by the present application is:

[0009] The application provides a method for calculating sock raw materials, in which the length of the sock raw materials is calculated according to the process stretching of the sock, the weight of the sock surface is calculated according to the length of the sock raw materials, the weight of the remaining length which cannot be cut off from the finished sock is calculated, and the total weight of the final sock raw materials is calculated according to the weight of the sock surface, the raw materials which need to be cut off and the weight of the remaining length.

[0010] The application also provides a method for calculating sock raw materials, which comprises the following steps:

[0011] S1, obtaining basic order information of the sock, including order number, order quantity, production model, confirmed sample weight, order surplus and raw material loss;

[0012] S2, if the sock has no pattern, obtaining relevant information corresponding to the inner yarn and surface yarn raw materials used by each part of the sock; if the sock has a pattern, obtaining information corresponding to the inner yarn and surface yarn raw materials used by each part without pattern, and obtaining the name of the pattern, automatically collecting the color numbers of all pixel points in the pattern according to the name of the pattern, obtaining the unique value of the corresponding color number and the raw material information corresponding to the color number;

[0013] S3, calculating the loop weight, float weight, remaining length weight and terry weight of each single raw material used by each part of the sock according to the part information of the sock, calculating the finished product weight of the sock, and correcting the finished product weight according to the preset ratio;

[0014] S4, automatically adjusting the ratio according to the ratio of the finished product weight and the sample weight until the corrected finished product weight is equal to the sample weight;

[0015] S5, calculating the consumption weight, corrected weight and budget weight of all the raw materials of the corresponding order according to the order quantity, order surplus, raw material loss, raw material weight used by each part of the sock and the ratio.

[0016] According to the above technical scheme, wherein:

[0017] The ratio is (the sample weight-all the accumulated remaining length weights of the raw materials of all parts) / (the accumulated loop weights of the raw materials of all parts corresponding to the sample+the accumulated terry weights of all parts);

[0018] The finished product weight is (the accumulated loop weights of the raw materials of all parts corresponding to the sample+the accumulated remaining length weights of the raw materials of all parts corresponding to the sample+the accumulated terry weights of all parts);

[0019] The corrected finished product weight is ((the accumulated loop weights of the raw materials of all parts corresponding to the sample+the accumulated terry weights of all parts)*the ratio+the accumulated remaining length weights of the raw materials of all parts corresponding to the sample);

[0020] Consumption weight = (the cumulative sum of each part of each raw material loop weight + the cumulative sum of each part of the loop weight) * the ratio * raw material loss) + the cumulative sum of each part of each raw material loop weight;

[0021] Budget weight = consumption weight * order quantity * order balance.

[0022] The preceding technical solution, wherein:

[0023] Inner yarn loop weight = (inner yarn coefficient * total fineness of the stretch part 1 / 2 + (straight pull length * 2) / straight pull loop number) * total number of inner yarn loops * inner yarn raw material fineness / weight conversion coefficient;

[0024] Face yarn loop weight = (face yarn coefficient * total fineness of the stretch part 1 / 2 + (straight pull length * 2) / straight pull loop number) * total number of face yarn loops * face yarn raw material fineness / weight conversion coefficient;

[0025] Loop weight = total length of raw material loops * raw material fineness / weight conversion coefficient;

[0026] Loop weight = loop height * total number of loops * loop raw material fineness / weight conversion coefficient;

[0027] Length weight = total length of raw material loops left on the sample after the front cutting * raw material fineness / weight conversion coefficient;

[0028] Correction weight = loop weight + length weight + loop weight.

[0029] The present application also provides a method for automatically calculating the raw materials of a sock, comprising the following steps:

[0030] Step A: a calculation table is newly created, and order information of the sock is input in the calculation table, including order number, order quantity, production model, confirmed sample weight, order balance, and raw material loss;

[0031] Step B: the sample and pattern of the sock are analyzed to generate a sample analysis table, if the sock sample has no pattern, the corresponding information of the inner yarn and face yarn raw materials used by each part of the sock is directly input in the sample analysis table; if the sock sample has a pattern, the corresponding information of the inner yarn and face yarn raw materials used by each part without pattern is first input in the sample analysis table, the name of the pattern is then input in the sample analysis table, all pixel point color numbers in the pattern are automatically collected and stored in a data collection table, the unique value of the color number is extracted and listed in the sample analysis table, and the information of the raw materials corresponding to the color number is finally input.

[0032] Step C: sequentially add the sock part table in the calculation table, and input the relevant information containing the sample knitting process in the sock part table, automatically calculate the loop weight, float weight, length weight, and terry weight of each single material used in each part, calculate the finished product weight of the sock, and correct the finished product weight according to the preset ratio calculation;

[0033] Step D: automatically adjust the ratio according to the ratio of the finished product weight and the sample weight until the corrected finished product weight and the sample weight are equal;

[0034] Step E: according to the order quantity, order remaining amount and material loss of step A, the material weight used in each sock part calculated in step C and the adjusted ratio in step D, automatically summarize the material consumption weight, corrected finished product weight and budget weight required for the order in the single product summary table.

[0035] According to the above technical solution, the calculation formula used in the automatic process includes:

[0036] Ratio = (sample weight - sum of length weights of all parts of the material) / sum of loop weights of all parts of the material corresponding to the sample;

[0037] Finished product weight = sum of loop weights of all parts of the material corresponding to the sample + sum of length weights of all parts of the material corresponding to the sample + sum of terry weights of all parts;

[0038] Corrected finished product weight = (sum of loop weights of all parts of the material corresponding to the sample + sum of terry weights) * ratio + sum of length weights of all parts of the material corresponding to the sample;

[0039] Material consumption weight = (sum of loop weights of each part of each material + sum of terry weights of each part) * ratio * material loss + sum of float weights of each part of each material;

[0040] Budget weight = material consumption weight * order quantity * order remaining amount.

[0041] The present application also provides an automatic calculation of sock material system based on the above-mentioned automatic calculation of sock material method, comprising:

[0042] The basic data table includes a machine type data table, a material yarn specification table, a sock part name table and a list of corresponding values of the height of the loop piece;

[0043] The pattern analysis module is used to first extract the machine type data list corresponding to the order from the machine type data table, then extract the corresponding values of the pixel point color number of the specified part of the sock, then analyze each color number value, and classify and count according to the machine type data list;

[0044] The raw material calculation module is configured to calculate the weight of raw materials used in the non-patterned parts of the socks, and to calculate the weight of raw materials used in the patterned parts of the socks after the pattern analysis module is used to classify and count the patterned parts, so as to obtain the loop weight, float weight, length weight and terry weight of each single raw material used in each part of the socks, calculate the finished product weight of the socks, and correct the finished product weight according to the preset ratio calculation.

[0045] The raw material correction module is configured to compare the finished product weight with the sample weight, calculate the ratio, and make the calculated terry weight equal to the sample weight, so that the ratio is used to correct the calculation result and reduce the calculation error.

[0046] The single product raw material budget sheet generation module is configured to automatically generate a single product raw material budget sheet after the calculation result is adjusted and summarized.

[0047] The raw material summary sheet generation module is configured to select the single product raw material budget sheet to be summarized in the single product summary table, and automatically summarize the total weight of each raw material used in the selected single product sock.

[0048] According to the above technical solution, the pattern analysis module is specifically configured to:

[0049] A1: Extract the model data list corresponding to the order;

[0050] A2: Read the pattern, extract the color number of all pixel points of the specified part of the sock, and generate a data table;

[0051] A3: Count the total number of each color number in the specified area of the data table, and generate a summary list;

[0052] A4: Calculate the interval value between each color number in the specified area of the data table, count the number of each interval value, and automatically input the interval value into the corresponding position of the model data list, and then generate a new list.

[0053] According to the above technical solution, the raw material calculation module is specifically configured to:

[0054] B1: Analyze the stretch data and raw material composition of the stretch part, and automatically calculate the length value of each needle of the stretch part;

[0055] B2: According to the process chain data, if the calculated sock part is non-patterned, the total number of stitches of the sock part is directly calculated; if the calculated sock part is patterned, the pattern analysis module is used to analyze the pattern of the part, and the total number of stitches and the total length of the float of each raw material are counted respectively;

[0056] B3: Extracting the fineness value corresponding to each raw material from the basic data table, the raised pile height value corresponding to the raw material, and automatically calculating the loop weight, the float weight, the length weight and the terry weight consumed by each raw material at the corresponding position according to the data calculated by B1 and B2.

[0057] According to the above technical solution, the single product raw material summary module is specifically used for:

[0058] D1: Acquire data including order quantity, order balance and ratio adjustment;

[0059] D2: Automatically calculate the consumption weight of raw materials used for weaving a single sock according to the calculated raw material weight, raw material loss and ratio adjustment of each part of the sock;

[0060] D3: Automatically calculate the budget weight required by the order according to D1 and D2;

[0061] D4: Automatically generate a single product raw material summary table and save it in the single product summary table.

[0062] The present application has the advantages that: the present application not only calculates the raw material weight of the loop, but also calculates the raw material weight of the cut-off (not on the sock), so that the calculation is complete and accurate, and the actual consumption of raw material weight of the sock is very close, greatly saving the material cost of producing socks. BRIEF DESCRIPTION OF DRAWINGS

[0063] The present application will be further described below in combination with the drawings and examples, and the drawings are as follows:

[0064] Figure 1 is a flowchart of the method for calculating the raw material of the sock according to the embodiment of the present application;

[0065] Figure 2 is a flowchart of the method for automatically calculating the raw material of the sock according to the embodiment of the present application;

[0066] Figure 3 is Figure 2 a specific flowchart of step A in the method for calculating the raw material of the sock according to the embodiment of the present application;

[0067] Figure 4 is Figure 2 a specific flowchart of step B in the method for calculating the raw material of the sock according to the embodiment of the present application;

[0068] Figure 5 is Figure 2 a specific flowchart of step C in the method for calculating the raw material of the sock according to the embodiment of the present application;

[0069] Figure 6 is Figure 2 a specific flowchart of step D in the method for calculating the raw material of the sock according to the embodiment of the present application;

[0070] Figure 7 is Figure 2The specific flow chart of step E;

[0071] Figure 8 is a structural schematic diagram of a system for automatically calculating hosiery raw materials according to an embodiment of the present application. DETAILED DESCRIPTION

[0072] In order to make the purpose, technical solutions and advantages of the present application more clear and explicit, the present application is further described in detail below in combination with the drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present application and do not limit the present application.

[0073] For hosiery raw material budgeting, especially according to the confirmed sample weight per unit, pattern style and production process of the customer, the weight per unit of various raw materials required for knitting hosiery can be more accurately budgeted, and the weight of various raw materials required for completing the order can be accurately budgeted, which is beneficial to more accurately budgeting the cost and pricing of hosiery, reducing the procurement cost and effectively reducing the raw material inventory. The present application overcomes the traditional budgeting method, which not only calculates the weight per unit of the raw material knitted into a loop, but also calculates the weight per unit of the raw material cut off (not on the hosiery), so that the calculation is not missed and is calculated according to the process stretching of the hosiery, which greatly improves the accuracy and is very close to the actual consumption of the raw material weight per unit of the hosiery, which is an important basis for the enterprise to quote to the customer.

[0074] Hosiery mainly includes four parts of the top, the heel, the leg and the toe, and the most basic raw material for weaving hosiery is 3 kinds of raw materials, namely, rubber, cotton yarn and elastic fiber. The cotton yarn is woven on the outside, which is called face yarn or outer yarn, and the elastic fiber is inside, which is called inner yarn or lining yarn.

[0075] According to the above budgeting idea, the method for calculating hosiery raw materials of the embodiment of the present application mainly calculates the length of the hosiery material according to the process stretching of the hosiery in the process of calculating the hosiery raw materials, then calculates the hosiery surface weight according to the length of the hosiery material, and calculates the length weight left on the finished hosiery which cannot be cut off, and finally calculates the total weight of the hosiery material according to the hosiery surface weight, the weight of the raw material which needs to be cut off and the length weight left.

[0076] Hosiery is knitted circle by circle in the weaving process, and the knitted circle is called loop (which can be considered as the hosiery surface is all loops), and the non-loop is called floating line (on the back of the hosiery). The floating line is divided into two parts, one part is the excess thread end which needs to be cut off, and the other part is the length left on the hosiery which cannot be cut off, which is called length left. If the length of the floating line exceeds a certain fixed value, it will be cut off, and the length of the thread end after cutting is the fixed length left, because it is related to the height of the cutter disc. Therefore, the length of the cut-off floating line is the fixed value of the floating line minus the length left. Generally, the floating line will be cut off when it exceeds a certain number of stitches.

[0077] In the process of calculating the total weight of the sock material, the key is to convert the length of the sock material used into the weight according to the amount of the length of the sock material used. In the process of knitting, the loop length of the knitted sock surface can be calculated by using the process stretching. The float length of the sock surface that is not knitted can be directly calculated according to the corresponding length column value of the sock manufacturing machine type, and the loop length plus the float length is the length of the sock material used, which is converted into the weight to calculate the weight of the sock material.

[0078] If the sock has a pattern, a plurality of colors of threads need to be used, and the total number of stitches of each color multiplied by the length of each stitch is the total length of the sock surface, which is converted into the weight.

[0079] However, since the length of the float does not change with stretching, the length of the sock material calculated according to the stretching process is not accurate enough, and the length of the material needs to be corrected. The correction coefficient can be calculated according to the length of all parts of the sock.

[0080] If the sock has no pattern, with the correction coefficient, the length of the sock can be calculated according to the stretching process and corrected, and then the total weight of the sock material can be calculated according to the corrected length.

[0081] If there is a pattern, the corresponding material data of the pattern part needs to be calculated separately.

[0082] Specifically, as shown in Figure 1 the method for calculating the sock material according to the embodiment of the present application specifically includes the following steps:

[0083] S1, obtaining the basic order information of the sock, including the order number, the order quantity, the production machine type, the confirmed sample weight, the order surplus and the material loss;

[0084] S2, if the sock has no pattern, obtaining the corresponding information of the inner yarn and the surface yarn material used by each part of the sock; if the sock has a pattern, obtaining the corresponding information of the inner yarn and the surface yarn material used by each part without a pattern, and obtaining the pattern name, automatically collecting all pixel point color numbers in the pattern according to the pattern name, obtaining the unique value of the corresponding color number and the material information corresponding to the color number;

[0085] S3, calculating the loop weight, the float weight, the length of the single material used by each part of the sock, calculating the finished product weight of the sock (the finished product weight is mainly the total weight calculated by all parts of the sock), and correcting the finished product weight according to the preset ratio;

[0086] S4, automatically adjusting the ratio according to the ratio of the finished product weight and the sample weight until the corrected finished product weight is equal to the sample weight;

[0087] S5, according to the order quantity, order balance and raw material loss, the weight of raw material used by each part of the sock and the ratio, calculate the consumption weight, corrected weight and budget weight of all the raw materials of the corresponding order.

[0088] As shown in Figure 2 Another embodiment of the method for automatically calculating the raw materials of socks of the present application comprises the following steps:

[0089] Step A: create a calculation table, input the order information of the socks in the calculation table, including order number, order quantity, production model, confirmed sample weight, order balance and raw material loss;

[0090] Step B: analyze the sample and pattern of the socks, generate a sample analysis table, if the sample of the socks has no pattern, directly input the corresponding information of the inner yarn and face yarn raw materials used by each part of the socks in the sample analysis table; if the sample of the socks has a pattern, first input the corresponding information of the inner yarn and face yarn raw materials used by each part without pattern in the sample analysis table, secondly input the pattern name in the sample analysis table, automatically collect all pixel point color numbers in the pattern and store them in a data collection table, then extract the unique values of the color numbers and list them in the sample analysis table, finally input the raw material information corresponding to the color numbers;

[0091] Step C: add the sock part table in the calculation table in sequence, and input the related information containing the sample knitting process in the sock part table, automatically calculate the loop weight, float weight, length weight and terry weight of each single raw material used by each part, calculate the finished product weight of the socks, and calculate the corrected finished product weight according to the preset ratio;

[0092] Step D: automatically adjust the ratio according to the ratio of the finished product weight and the sample weight, until the corrected finished product weight and the sample weight are equal;

[0093] Step E: according to the order quantity, order balance and raw material loss of step A, the weight of raw material used by each part of the socks calculated in step C and the adjusted ratio in step D, automatically summarize the consumption weight, corrected finished product weight and budget weight of the raw materials required by the order, and list them in the single product summary table.

[0094] In step C, a real calculation ratio can also be calculated, which is the ratio of the finished product weight and the sample weight, and can be used to correct whether the calculated finished product weight is greatly deviated, if so, first check whether some data is wrong when inputting, if so, correct it in time. According to the real calculation ratio, automatically adjust the ratio again, until the corrected finished product weight and the sample weight are infinitely close, or manually adjust the ratio according to the needs.

[0095] In the above embodiment, the specific calculation formula is as follows:

[0096] Ratio = (sample weight - the sum of the length of all parts of the raw material) / (the sum of the weight of all parts of the raw material corresponding to the sample + the sum of the weight of all parts of the raw material corresponding to the sample + the sum of the weight of all parts of the raw material corresponding to the sample) ;

[0097] That is, the ratio:

[0098]

[0099] Where i = 1, 2, …, k, j = 1, 2, …, k, m = 1, 2, …, k;

[0100] G0: sample weight; GD i The weight of the thread left after the front break or the weight of the thread left after cutting for each part inside the sock, that is, the length of the weight; GA j The weight of the yarn woven into the sock for each part, that is, the loop weight; GC m The weight of the yarn woven into the loop for each part, that is, the loop weight.

[0101] The weight of the finished product = the sum of the weight of the raw material corresponding to all parts of the sample + the sum of the weight of the raw material corresponding to all parts of the sample + the sum of the weight of all parts of the raw material corresponding to the sample) ;

[0102] That is, the weight of the finished product:

[0103] Where the weight of the finished product is the calculated weight of the finished product, wherein:

[0104]

[0105] n = 1, 2, …, k, h = 1, 2, …, k. GI n The weight of the yarn in each part, GJ h The weight of the yarn in each part.

[0106]

[0107] Where LI n = LIA·NI, LIA is the length of each needle, NI is the total number of stitches of the inner yarn, LIn is the total length of the inner yarn in each part, DIn is the yarn count of the inner yarn in each part (i.e. the fineness of the inner yarn raw material), and Cz is the coefficient for converting the length of the yarn into weight.

[0108]

[0109] Where PI is the inner yarn coefficient, D is the total fineness value of the yarn in the stretch part, L is the straight length of the stretch part, N is the number of stitches in the stretch part, and NI is the total number of stitches of the inner yarn.

[0110]

[0111] wherein is the equivalent diameter of the yarn, since is very small, thus may be equivalent to approximately

[0112]

[0113] wherein the total length of loops LJ n of the veil is = LJA·NJ, LJA is the length of each needle of the veil loops, NJ is the total number of veil loops, DJ n is the yarn count specification of each part of the veil (i.e. the veil raw material fineness),

[0114] wherein PJ is the veil coefficient, D is the total fineness value of the yarn of the stretch part, L is the straight length of the stretch part, N is the number of loops of the stretch part, NJ is the total number of veil loops.

[0115]

[0116] wherein is the equivalent diameter of the yarn, since is very small, thus may be equivalent to approximately

[0117] Corrected finished product gram weight = (the sum of the raw material loop weight of all parts corresponding to the sample + the sum of the terry loop weight) * the adjustment ratio + the sum of the raw material length weight of all parts corresponding to the sample;

[0118] i.e. the corrected finished product gram weight: Consumption gram weight = (the sum of the raw material loop weight of each part + the sum of the terry loop weight of each part) * the adjustment ratio * the raw material loss) + the sum of the float weight of each part of each raw material;

[0119] i.e. the consumption gram weight:

[0120] wherein S is the consumption of each part of each raw material, i.e. the raw material loss, GB i is the float weight of each part of each raw material, i.e. the float weight.

[0121] Budget weight = consumption gram weight * order quantity * order surplus.

[0122] i.e. GH = GT·NO·YO

[0123] wherein the budget weight is the total weight of each raw material needed to complete the order, NO is the order quantity, and YO is the order surplus (i.e. the number of spare parts that need to be increased due to the possibility of defective products).

[0124] According to the above technical solution, wherein:

[0125] The total length of the float of each part = the total length of the float of each part * the yarn count specification of each float / the length-to-weight conversion factor;

[0126] That is, the weight of the float of each part: GB = LB·DB / Cz

[0127] The total length of the float of each part wherein k represents that the part has k floats, and different parts can have different numbers of floats; LJ represents the length value corresponding to each float (which can be found in the machine type list), and NJ represents the number corresponding to the length of each float, for example: 2cm*5+3cm*11+4.5cm*75…

[0128] The weight of the float is always greater than or equal to the weight of the left length. If there is no pattern, the weight of the float is zero, and the weight of the left length is also zero. If there is a pattern, if the number of stitches is particularly small, the weight of the float and the weight of the left length are the same because there is no cutting during the knitting process. If there is a relatively large pattern, there will be cut ends, and the weight of the float will be greater than the weight of the left length.

[0129] The weight of the loop = the height of the loop * the total number of loops * the fineness of the loop material / the length-to-weight conversion factor;

[0130] That is, the weight of the loop of each part: GC = LC·DC / Cz, wherein wherein LKp is the height of the loop, i.e., the length of the loop yarn per needle, NK is the number of corresponding needles, and DC is the yarn count specification of the loop material.

[0131] The weight of the left length of each part GD = LD·DD / Cz, LD is the total length of the line segment or the end of the line left in the sock, and DD is the yarn count specification of the yarn.

[0132] The corrected weight = the weight of the loop + the weight of the left length + the weight of the loop.

[0133] Further, as shown in Figure 3 the input pattern in step A is analyzed, specifically as follows:

[0134] A1: Extract the machine type data list corresponding to the order production;

[0135] A2: Read the pattern, extract all pixel color numbers of the specified part of the sock, and generate a data table;

[0136] A3: Count the total number of each color number in the specified area of the data table, and generate a summary list;

[0137] A4: Calculate the interval value between each color number in the designated area of the data table, count the number of each interval value, and automatically input it to the corresponding position of the model data list, and then generate a new list.

[0138] Further, as shown in Figure 4 , in step B, the data in each form is analyzed and calculated, specifically as follows:

[0139] B1: Analyze the stretching data and raw material composition of the stretching part, and automatically calculate the length value of each needle of the part,

[0140] B2: According to the process chain data of the part form, if the calculated sock part has no pattern, directly calculate the total number of stitches of the part, if the calculated sock part has a pattern, first use the pattern analysis module to analyze the pattern of the part, and respectively count the total number of stitches and the total length of floats of each raw material;

[0141] B3: Extract the fineness value and the corresponding value of the raw material from the base data table, and automatically calculate the stitch weight, float weight, loop weight, terry weight and correction weight of each raw material in the part according to the data calculated by B1 and B2.

[0142] Specifically, in one embodiment of the present application, the total stitch count calculation formula of each action of the toe and the heel includes:

[0143] TB = TA - 2·BA

[0144] TB is the number of stitches in the horizontal row at the end of each pick action, TA is the number of stitches in the horizontal row at the beginning of each pick action, and BA is the chain number of each pick action.

[0145] The total number of stitches knitted by each pick action: T = (TA + TB)·BA;

[0146] The number of stitches in the horizontal row at the end of each tuck action: QB = QA + 2BB, wherein QA is the number of stitches in the horizontal row at the beginning of each tuck action, and BB is the chain number of each tuck action.

[0147] The total number of stitches knitted by each tuck action: Q = (QA + QB)·BB.

[0148] Further, as shown in Figure 5 , in step C, the calculated product weight and sample weight are automatically compared and adjusted, and the specific adjustment is as follows:

[0149] C1: Calculate the stitch weight and terry weight of the sample according to the sample weight;

[0150] C2: Calculate the stitch weight and terry weight of all parts corresponding to the sample in the raw material calculation table;

[0151] C3 According to C1, C2, the ratio is automatically calculated and the corrected weight is corrected. The corrected weight and the sample weight can also be referred to, and the ratio is manually adjusted as needed. The reason for correcting the ratio is that the length of the floating line does not change with stretching, so the length of all parts of the sock needs to be removed when calculating the ratio. The ratio is actually a correction of the length calculated according to the stretching process. After adjusting the value of the ratio, the length of the sock can be directly calculated according to the stretching process, and the total weight of the sock can be calculated according to the length.

[0152] Further, as shown in Figure 6 , in step D, the total weight of all raw materials used for weaving a single sock and the weight of raw materials required for an order are automatically calculated, as follows:

[0153] D1: Obtain order quantity, order balance, ratio and other data;

[0154] D2: According to the calculated value of each part, the loss of raw materials and the ratio, automatically calculate the total weight of all raw materials used for weaving a single sock, i.e. the consumption weight;

[0155] D3: According to D1, D2, automatically calculate the weight of raw materials required for an order, i.e. the budget weight;

[0156] D4: Automatically generate a single product raw material summary sheet and save it in the single product summary sheet.

[0157] Further, as shown in Figure 7 , in step E, all raw materials in the selected single product raw material summary sheet are automatically calculated and summarized, as follows:

[0158] E1: Select the single product raw material summary sheet to be summarized;

[0159] E2: Automatically calculate and summarize all raw materials and quantities in the selected sheet;

[0160] E3: Automatically generate a raw material summary sheet and save it in the summary sheet or selected summary sheet.

[0161] The above-mentioned method for automatically calculating the raw materials of the sock can be realized by various programming software or office software, and the present patent does not limit this. As long as the above-mentioned method can be realized, it belongs to the protection scope of the present patent.

[0162] As shown in Figure 8 , the raw material automatic calculation system of the sock based on the above-mentioned method for automatically calculating the raw materials of the sock comprises:

[0163] A basic data table containing a machine type data table, a raw material yarn specification table, a sock part name table and a list of corresponding values of the height of the raw material;

[0164] The pattern analysis module is used for extracting the model data list corresponding to the order from the model data table, extracting the corresponding values of the pixel point color numbers of the specified parts of the socks, then analyzing each color number value, and classifying and counting in correspondence with the model data list;

[0165] The raw material calculation module is used for calculating the weight of the raw material used in the part of the sock without pattern, and calculating the weight of the raw material used in the part of the sock with pattern after the classification and counting by using the pattern analysis module, so as to obtain the loop weight, float weight, length weight and terry weight of each single raw material used in each part of the sock, and simultaneously calculate the finished product weight, corrected finished product weight and actual calculation ratio of the sock;

[0166] The raw material correction module is used for comparing the finished product weight with the sample weight, calculating the ratio, so that the calculated terry weight is equal to the sample weight, and the ratio is used to correct the calculation result and reduce the calculation error;

[0167] The single product raw material budget sheet generation module is used for automatically generating the single product raw material budget sheet after the calculation result is adjusted and summarized;

[0168] The raw material summary sheet generation module is used for selecting the single product raw material budget sheet to be summarized in the single product summary table, and automatically summarizing the total weight of each raw material used in the selected single product sock.

[0169] Further, the pattern analysis module is specifically used for:

[0170] A1: extracting the model data list corresponding to the order;

[0171] A2: reading the pattern, extracting all pixel point color numbers of the specified parts of the sock, and generating a data table;

[0172] A3: counting the total number of each color number in the specified area of the data table, and generating a summary list;

[0173] A4: calculating the interval value between each color number in the specified area of the data table, counting the number of each interval value, and automatically inputting to the corresponding position of the model data list, and then generating a new list.

[0174] Further, the raw material calculation module is specifically used for:

[0175] B1: analyzing the stretch data and raw material composition of the stretch part, and automatically calculating the length value of each needle of the stretch part;

[0176] B2: according to the process chain data, if the calculated sock part has no pattern, the total number of stitches of the sock part is directly calculated; if the calculated sock part has a pattern, the pattern analysis module is used to analyze the pattern of the part, and the total number of stitches and the total length of the float of each raw material are counted respectively;

[0177] B3: Extracting the fineness value corresponding to each raw material from the basic data table, the raised pile height value corresponding to each raw material, and the data calculated according to B1 and B2, automatically calculating the loop weight, the float weight, the length weight and the pile weight consumed by each raw material at the corresponding position.

[0178] Further, the raw material correction module is specifically used for:

[0179] C1: Calculating the loop weight of the sample according to the sample weight;

[0180] C2: Calculating the loop weight of all positions corresponding to the sample in the raw material calculation table;

[0181] C3: Automatically calculating the ratio and the corrected weight according to C1 and C2, and manually adjusting the ratio according to the corrected weight and the sample weight as needed.

[0182] Further, the single-product raw material summary module is specifically used for:

[0183] D1: Obtaining data including order quantity, order balance and ratio;

[0184] D2: Automatically calculating the raw material weight required for weaving a single sock according to the raw material weight calculated for each position of the sock, the raw material loss and the ratio;

[0185] D3: Automatically calculating the budget weight required for the order according to D1 and D2;

[0186] D4: Automatically generating a single-product raw material summary table and saving it in the single-product summary table.

[0187] In summary, the present application automatically calculates all the raw material weights required for knitting socks according to the sock knitting process, especially for patterned and complex socks, which not only saves time and effort, but also provides more accurate and reasonable data than the current budgeting method, which has important reference value for enterprises to quote to customers and obtain profits.

[0188] Purchasing or dyeing raw materials according to the budget of the present application can reduce the frequency and quantity of purchasing or dyeing raw materials, and re-purchasing or dyeing raw materials can cause different batches and colors of raw materials, affecting the quality or delivery date of socks, effectively reducing or avoiding the annoyance and worry caused by insufficient raw material procurement quantity; and can effectively reduce raw material inventory; the single-product raw material summary table automatically generated by the present application clearly lists the usage of each raw material, and the raw material loss is clear and visual, and can withstand scrutiny.

[0189] It should be understood that those skilled in the art can make improvements or changes according to the above description, and all these improvements and changes shall fall within the protection scope of the appended claims of the present application.

Claims

1. A method of calculating a sock material, characterized by, In the process of calculating the raw material of the sock, the length of the sock material is calculated according to the process stretching of the sock, then the weight of the sock surface is calculated according to the length of the sock material, and the weight of the remaining length which is not cut off on the finished sock is calculated, the total weight of the final sock material is calculated according to the weight of the sock surface, the raw material which needs to be cut off and the weight of the remaining length, and the final product weight is corrected according to the preset ratio, wherein the ratio=(sample weight-all parts of the sample corresponding to the total weight of the raw material left length) / (all parts of the sample corresponding to the total weight of the raw material stitch+all parts of the sample corresponding to the total weight of the terry); wherein the weight of the leg portion is the sum of the weight of the inner yarn and the weight of the surface yarn, the weight of the inner yarn = (inner yarn coefficient x total denier of the stretch portion + straight length x 2 / number of straight stretch stitches) x total number of stitches of the inner yarn x denier of the inner yarn material / weight conversion coefficient 1 / 2 + straight length x 2 / number of straight stretch stitches) x total number of stitches of the inner yarn x denier of the inner yarn material / weight conversion coefficient Yarn loop weight = (yarn coefficient × total fineness of the stretched section) 1 / 2 + (straight pull length × 2 / number of straight pull loops) × total number of stitches in the yarn loops × yarn raw material fineness / weight conversion coefficient.

2. A method of calculating a sock material, characterized by, It comprises the following steps: S1, obtaining the basic order information of the sock, including order number, order quantity, production model, confirming sample weight, order balance and raw material loss; S2, if the sock has no pattern, the corresponding information of the inner yarn and surface yarn raw materials used by each part of the sock is obtained; if the sock has a pattern, the corresponding information of the inner yarn and surface yarn raw materials used by each part without pattern is obtained, and the pattern name is obtained, then all pixel point color numbers in the pattern are automatically collected according to the pattern name to obtain the corresponding unique value of the color number and the raw material information corresponding to the color number; S3, calculating the loop weight, float weight, stitch length weight and terry weight of each sock part according to the sock part information, calculating the finished product weight of the sock, and correcting the finished product weight according to the preset ratio; wherein, the loop length of the woven sock surface is calculated using process stretching when calculating the loop weight; wherein, the loop weight is the sum of the inner yarn loop weight and the surface yarn loop weight, the inner yarn loop weight = (inner yarn coefficient × total fineness of stretching part 1 / 2 + straight pulling length × 2 / straight pulling loop number) × total number of inner yarn loops × inner yarn material fineness / weight conversion coefficient; Yarn loop weight = (yarn coefficient × total fineness of the stretched section) 1 / 2 + (straight-pull length × 2 / number of straight-pull loops) × total number of stitches in the yarn loops × yarn raw material fineness / weight conversion factor; S4, according to the ratio of the finished product weight and the sample weight, the ratio is automatically adjusted until the corrected finished product weight and the sample weight are equal, wherein the ratio=(sample weight-all parts of the sample corresponding to the total weight of the raw material left length) / (all parts of the sample corresponding to the total weight of the raw material stitch+all parts of the sample corresponding to the total weight of the terry); S5, according to the order quantity, order balance and raw material loss, the weight of the raw material used by each part of the sock and the ratio, the consumption weight, the corrected weight and the budget weight of all the summarized raw materials of the corresponding order are calculated.

3. The method of claim 2, wherein, Wherein: The finished product weight=the total weight of the raw material stitch of all parts corresponding to the sample+the total weight of the raw material left length of all parts corresponding to the sample+the total weight of the terry of all parts corresponding to the sample; The corrected finished product weight=(the total weight of the raw material stitch of all parts corresponding to the sample+the total weight of the terry of all parts corresponding to the sample)×ratio+the total weight of the raw material left length of all parts corresponding to the sample; The consumption weight=(the total weight of the raw material stitch of all parts corresponding to the sample+the total weight of the terry of all parts corresponding to the sample)×ratio×the total weight of the raw material loss+the total weight of the raw material float of all parts corresponding to the sample; The budget weight=consumption weight×order quantity×order balance.

4. The method of claim 2, wherein, Wherein: The float weight=total length of raw material float×float raw material fineness / weight conversion coefficient; The terry weight=raising height×total number of raising needles×raising raw material fineness / weight conversion coefficient; The left length weight=total length of raw material float which is not cut off and left on the sample×left length raw material fineness / weight conversion coefficient; The corrected weight=stitch weight+left length weight+terry weight.

5. A method of automatically calculating a sock material, characterized by, It comprises the following steps: Step A: a calculation table is newly created, and the order information of the sock is input in the calculation table, including order number, order quantity, production model, confirming sample weight, order balance and raw material loss; Step B: Analyze the sample and pattern of the sock to generate a sample analysis table. If the sock sample has no pattern, directly input the corresponding information of the inner yarn and face yarn materials used in each part of the sock in the sample analysis table. If the sock sample has a pattern, first input the corresponding information of the inner yarn and face yarn materials used in each part without pattern in the sample analysis table, then input the pattern name in the sample analysis table, automatically collect all pixel point color numbers in the pattern and store them in a data collection table, extract the unique values of the color numbers and list them in the sample analysis table, and finally input the material information corresponding to the color numbers; Step C: sequentially add the sock part table in the calculation table, and input the relevant information containing the sample knitting process in the sock part table, automatically calculate the stitch weight, float weight, loop length weight, terry weight of each part of the single material, calculate the finished product weight of the sock, and according to the preset ratio, calculate the correction of the finished product weight, wherein the ratio=(sample weight-the sum of the loop length weights of all parts corresponding to the sample) / (the sum of the stitch weights of all parts corresponding to the sample+the sum of the terry weights of all parts corresponding to the sample); wherein the stitch weight is the sum of the inner yarn stitch weight and the face yarn stitch weight, the inner yarn stitch weight=(inner yarn coefficient×total fineness of the stretch part 1 / 2 + straight stretch length×2 / straight stretch number)×total number of inner yarn stitches×inner yarn fineness / weight conversion coefficient; Yarn loop weight = (yarn coefficient × total fineness of the stretched section) 1 / 2 + (straight-pull length × 2 / number of straight-pull loops) × total number of stitches in the yarn loops × yarn raw material fineness / weight conversion factor; Step D: Automatically adjust the ratio according to the ratio of the finished product weight to the sample weight until the corrected finished product weight and the sample weight are equal; Step E: According to the order quantity, order balance, and material loss in step A, and the weight of the material used in each part of the sock calculated in step C and the adjusted ratio in step D, automatically summarize the consumption weight of the summarized material required by the order, the corrected finished product weight, and the budget weight, and list them in the single product summary table.

6. The method of automatically calculating a sock material according to claim 5, wherein, The calculation formulas used in the automatic process include: Finished product weight = (sum of the weight of all parts of the sample corresponding to the material stitch) + (sum of the weight of all parts of the sample corresponding to the material length) + (sum of the weight of all parts of the sample corresponding to the terry); Corrected finished product weight = (sum of the weight of all parts of the sample corresponding to the material stitch) + (sum of the weight of all parts of the sample corresponding to the terry) x ratio + (sum of the weight of all parts of the sample corresponding to the material length); Consumption weight = (sum of the weight of all parts of the sample corresponding to the material stitch) + (sum of the weight of all parts of the sample corresponding to the terry) x ratio x (sum of the weight of all parts of the sample corresponding to the material loss) + (sum of the weight of all parts of the sample corresponding to the material loop); Budget weight = consumption weight x order quantity x order balance.

7. An automated system for calculating hosiery materials, characterized by, It includes: Basic data module for building various data tables, including machine type data table, material yarn count specification table, sock part name table, and loop height corresponding value list; Pattern analysis module for extracting the machine type data list corresponding to the order from the machine type data table, then extracting the corresponding values of the pixel point color numbers of the specified parts of the sock, then analyzing each color number value and classifying and counting it according to the machine type data list; The raw material calculation module is used to calculate the weight of raw material used in the part of the sock without pattern, and the weight of raw material used in the part of the sock with pattern is calculated after the part is classified and counted by the pattern analysis module, so as to obtain the loop weight, float weight, length weight and terry weight of single raw material used in each part of the sock, calculate the finished product weight of the sock, and correct the finished product weight according to the preset ratio calculation; wherein, when the loop weight is calculated, the loop length of the woven sock surface is calculated by using process stretching; wherein, the loop weight is the sum of the loop weight of the inner yarn and the loop weight of the surface yarn, the loop weight of the inner yarn = (inner yarn coefficient × total fineness of stretching part 1 / 2 + straight length × 2 / straight loop number) × total number of inner yarn loops × inner yarn raw material fineness / weight conversion coefficient; The yarn loop weight = (yarn coefficient × total fineness of the stretching part 1 / 2 + straight drawing length × 2 / straight drawing loop number) × total number of yarn loops × yarn raw material fineness / weight conversion coefficient; Material correction module for comparing the finished product weight with the sample weight, calculating the ratio, making the calculated terry weight equal to the sample weight, and using the ratio to correct the calculation result to reduce the calculation error; wherein the ratio = (sample weight - sum of the weight of all parts of the sample corresponding to the material length) / (sum of the weight of all parts of the sample corresponding to the material stitch + sum of the weight of all parts of the sample corresponding to the terry); Single product material budget single generation module for summarizing the adjusted calculation results and automatically generating single product material budget single; The raw material summary sheet generation module is used for selecting the single product raw material budget sheet to be summarized in the single product summary table, automatically summarizing the total weight of each raw material used by the selected single product socks, and calculating the consumption weight, corrected weight and budget weight of all summarized raw materials of the corresponding order according to the order quantity, order balance, raw material loss, raw material weight used by each part of the socks and ratio adjustment.

8. The automatic calculating hosiery material system according to claim 7, wherein, The pattern analysis module is specifically used for: A1: extracting the model data list corresponding to the order; A2: reading the pattern, extracting the color number of all pixel points of the specified part of the socks, and generating a data table; A3: counting the total number of each color number in the specified area of the data table, and generating a summary list; A4: calculating the interval value between each color number in the specified area of the data table, counting the number of each interval value, and automatically inputting to the corresponding position of the model data list, and generating a new list.

9. The automatic calculating hosiery material system according to claim 7, wherein, The raw material calculation module is specifically used for: B1: analyzing the stretch data and raw material composition of the stretch part, and automatically calculating the length value of each needle of the stretch part; B2: according to the process chain data, if the calculated sock part has no pattern, the total number of stitches of the sock part is directly calculated; if the calculated sock part has a pattern, the pattern analysis module is used to analyze the part, and the total number of stitches and the total length of floats of each raw material are counted respectively; B3: extracting the fineness value and the corresponding value of the raw material from the basic data table, and automatically calculating the loop weight, float weight, length weight and terry weight of each raw material consumed in the corresponding part according to the data calculated by B1 and B2.

10. The automatic calculating hosiery material system according to claim 7, wherein, The raw material summary sheet generation module is specifically used for: D1: obtaining data including order quantity, order balance and ratio adjustment; D2: automatically calculating the consumption weight of each raw material used for knitting a single sock according to the calculated raw material weight of each part of the sock, raw material loss and ratio adjustment; D3: automatically calculating the budget weight required by the order according to D1 and D2; D4: automatically generating a single product raw material summary table and saving it in the single product summary table.

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