A process design method for preventing the nap of corduroy from lying down and corduroy fabric

Abstract

The present invention belongs to the technical field of textiles, and in particular, relates to a corduroy anti-hair lodging process design method and corduroy fabric, the design method comprising: establishing a corduroy process library, assigning a corresponding stripe density range to each corduroy production process in the process library; determining the stripe density of the corduroy to be produced, and comparing it with the stripe density range corresponding to each production process in the corduroy process library, and preliminarily determining a matching alternative production process; judging the number of alternative production processes, sorting the minimum lengths of corduroy hair that can be obtained by each alternative production process, selecting at least one minimum length with a smaller value, and selecting an alternative production process corresponding to the minimum length. The present invention can obtain a corduroy fabric with the shortest hair if the process allows, and the hair includes different situations such as hair obtained by brushing after cutting and hair obtained by pulling with a needle, etc. By shortening the hair length, the hair lodging situation can be effectively solved.

Description

Technical Field

[0001] The present invention belongs to the technical field of textiles, and particularly relates to a process design method for preventing the nap of corduroy from lodging and a corduroy fabric. Background Art

[0002] Traditional corduroy fabrics often have the phenomenon of nap directionality. This is mainly because the surface of corduroy is composed of dense nap, and the nap forms a certain direction of lodging after brushing and dyeing and finishing water flow in one direction. Under daily use or the action of external friction, the nap is more likely to lodge, that is, to fall in one direction, thus forming the phenomenon of "nap directionality". In this case, the following problems will occur:

[0003] Due to the difference in light reflection, the nap directionality will cause the fabric to present different hues at different angles. This phenomenon is particularly obvious during use. For example, after the surface of the clothing is rubbed or indented, the lodged area will appear brighter and show a whitening phenomenon, affecting the overall aesthetics of the clothing; once the nap of the corduroy lodges, it will form an "imprint" and is difficult to automatically recover. The common recovery methods require manual combing or steam ironing, but in actual use, this method is time-consuming and laborious, and the indentation cannot be completely eliminated.

[0004] The nap directionality of corduroy not only affects the aesthetics, but also reduces the service life of the fabric to a certain extent. Frequent lodging and recovery treatments are likely to cause the nap to break or wear, affecting the durability of the fabric. Summary of the Invention

[0005] The present invention provides a process design method for preventing the nap of corduroy from lodging and a corduroy fabric, which can effectively solve the problems in the background art.

[0006] To achieve the above object, the technical solution of the present invention is as follows:

[0007] A process design method for preventing the nap of corduroy from lodging includes:

[0008] Establish a corduroy process library, and assign a corresponding stripe density range to each corduroy production process in the process library;

[0009] Determine the stripe density of the corduroy to be produced, and compare it with the stripe density ranges corresponding to the production processes in the corduroy process library to preliminarily determine the matching alternative production processes;

[0010] Judge the number of the alternative production processes. If the number is 0, interrupt the process design; if the number is equal to 1, determine to adopt the alternative production process; if the number is greater than 1, perform the following steps:

[0011] Rank the minimum lengths of the corduroy pile that can be obtained by each of the alternative production processes, select at least one of the smaller minimum lengths, and select the alternative production process corresponding to the minimum length.

[0012] Further, the processes in the corduroy process library include the following pile obtaining steps:

[0013] After one weft of the corduroy is woven in, at least one pile weft is woven in parallel in sequence. The floating length of the pile weft spans at least three warp threads, and multiple wefts and pile wefts are intertwined with the warp threads to form cloth together.

[0014] Remove a partial length of the floating length of the pile weft. After removal, the end of the remaining part of the pile weft stands upright relative to the pile root, and the pile roots of adjacent pile wefts are arranged in a staggered manner.

[0015] Further, during the pile obtaining process, the following cutting tool is adopted, including:

[0016] A fly needle having a connection part and two steel wires led out at intervals to one side relative to the connection part;

[0017] A core strip fixedly connected to the connection part and located between the two steel wires, dividing the interval between the two steel wires into two regions;

[0018] Two parallel pile cutting blades corresponding to the fly needle, the pile cutting blades are rotationally arranged through a shaft body and are inserted into the two regions one by one, and the core strip and the steel wires limit the pile cutting blades on both sides of the axis direction of the shaft body;

[0019] The fly needle is inserted into the bottom of the floating length of the pile weft and is arranged parallel to the corduroy width direction, and the removed part length is adjusted by the width of the core strip.

[0020] Further, the design of the cutting tool includes the following steps:

[0021] According to the parameters of the corduroy to be produced, determine the outer width and the core strip width of the cutting tool;

[0022] At least based on the outer width, the core strip width, the thickness of the pile cutting blade, and the material of the fly needle, comprehensively determine the width range of the steel wire, and select the steel wire width within the width range;

[0023] Conduct trial processing with the cutting tool adopting the outer width, the core strip width, and the steel wire width, and record the magnitude of the force exerted on the fly needle by the corduroy;

[0024] The outer width is adjusted according to the magnitude of the applied force, and after the adjustment, the steel wire width is secondary selected within the width range to obtain an updated steel wire width;

[0025] The trial machining is performed at least once until the force is within a set range.

[0026] Furthermore, the end of the steel wire is a round head structure.

[0027] Furthermore, the connection points are provided at two locations, respectively connecting the two ends of the two steel wires.

[0028] Furthermore, the process in the corduroy process library includes the following steps of obtaining the fluff:

[0029] Weaving warp and weft into fabric;

[0030] On one side of the fabric, part of the fibers on the surface of the weft yarns are pulled up to form a pile.

[0031] Furthermore, during the process of obtaining the fluff, densely packed needles or thorns are used to pull up the fibers.

[0032] Furthermore, the design of the thorn needle or thorn fruit includes the following steps:

[0033] Determining the insertion depth, density and insertion angle of the pricking needle or pricking fruit according to the parameters of the corduroy to be produced;

[0034] Conducting trial processing by using the needles or thorns with the insertion depth, density and insertion angle, and collecting the surface image of the processed corduroy;

[0035] Identifying and analyzing at least one of the height consistency, density uniformity, directionality, fullness and color of the villi through the surface image;

[0036] Adjusting the insertion depth, density and insertion angle according to the identification and analysis results;

[0037] The trial processing is performed at least once until the identification and analysis results meet the requirements.

[0038] A corduroy fabric, wherein the process method of the corduroy fabric is obtained by the process design method for preventing the corduroy from falling over as described above.

[0039] The technical solution of the present invention can achieve the following technical effects:

[0040] In the present invention, under the condition permitted by the process, a corduroy fabric with shorter pile can be obtained. By shortening the pile length, the problem of pile lodging can be effectively solved. Even when subjected to external friction or extrusion, the surface can remain flat, avoiding the visual effect of reverse pile. This method fundamentally reduces the probability of pile lodging and improves the appearance and durability of the fabric. This process design method has good applicability. Whether it is different stripe densities such as 12W, 14W or 18W, the appropriate process can be quickly found through stripe density matching. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the drawings in the following description are only some embodiments recorded in the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0042] Figure 1 It is a flowchart of the process design method for anti-pile lodging of corduroy;

[0043] Figure 2 It is a distribution diagram of ground weft, pile weft and warp and weft;

[0044] Figure 3 It is a design flowchart of the cutting tool;

[0045] Figure 4 It is a comparison diagram of the pile surfaces obtained by the cutting tool using a single pile-cutting blade and the cutting tool using a double pile-cutting blade;

[0046] Figure 5 It is a schematic diagram of forming pile by pulling up part of the fibers of the weft;

[0047] Figure 6 It is a flowchart of forming pile by pulling up part of the fibers of the weft;

[0048] Figure 7 It is a comparison diagram of the pile surfaces obtained by cutting the pile and the non-cutting method of raising the pile;

[0049] Reference numerals: 1, warp; 2, pile weft; 3, ground weft; 4, weft; 41, pulled-out part; 42, remaining part. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0050] The following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments.

[0051] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the technical field to which this invention belongs. The terms used in the description of this invention are for the purpose of describing specific embodiments only and are not intended to limit the invention. The term "and / or" used herein includes any and all combinations of one or more of the related listed items.

[0052] Example 1

[0053] As Figure 1 shown, a process design method for preventing the nap of corduroy from lying down includes:

[0054] A1: Establish a corduroy process library and assign a corresponding stripe density range to each corduroy production process in the process library; when the number of corresponding production processes gradually increases, there will often be an overlap in the stripe density ranges that can be produced by different processes. Through this step, different production processes and stripe density ranges can be classified and managed, forming a set of standardized process data systems;

[0055] A2: Determine the stripe density of the corduroy to be produced and compare it with the stripe density ranges corresponding to each production process in the corduroy process library to preliminarily determine the matching alternative production processes; in this step, the stripe density is used as the basis for the preliminary screening of the process, and an accurate preliminary screening result can be obtained based on the process library;

[0056] A3: Judge the number of alternative production processes. If the number is 0, interrupt the process design. Through this interruption mechanism, subsequent errors can be reduced and the trial - and - error cost can be lowered; if the number is equal to 1, determine to adopt the alternative production process. On the basis of subsequent implementation, it is often necessary to make detailed adjustments to the determined alternative production process. The adjustments referred to here include, but are not limited to, fine - tuning of the nap length, adjustment of the weaving tension, optimization of the post - finishing process, and adjustment of environmental factors, etc. And the optimized process after adjustment can also be incorporated into the process library as the data basis for subsequent process design; if the number is greater than 1, then execute the following steps:

[0057] A4: Sort the minimum lengths of corduroy fluff that can be obtained by each alternative production process, select at least one minimum length with a smaller value, and select the alternative production process corresponding to the minimum length; this step includes the case where only one alternative production process is selected, in which case the value of the minimum length corresponding to the alternative production process is the smallest; or, it also includes the case where several alternative production processes are selected, in which case the alternative production process corresponding to the minimum length ranked from large to small is selected. In order to comprehensively consider other aspects of the process and obtain a better final process path, the selection of multiple alternative production processes is better, which facilitates further detailed screening and adjustment based on other screening conditions; in this step, a second screening result is provided based on the minimum length of the fluff, and multi-layer screening makes the decision more scientific, accurate, and adaptable, and can meet the production needs of corduroy of different densities.

[0058] In the above method, if the process allows, a corduroy fabric with shorter pile can be obtained. By shortening the pile length, the pile lodging problem can be effectively solved. Even if it is rubbed or squeezed by the outside world, the surface can remain flat, avoiding the visual effect of the pile being inverted and straight. This method fundamentally reduces the probability of the pile lodging and improves the appearance and durability of the fabric. This process design method has good applicability. Whether it is different stripe densities such as 12W, 14W or 18W, the appropriate process can be quickly found through stripe density matching.

[0059] As an optimization method for the process library in the above process design method, Figure 2 As shown, the process in the corduroy process library includes the following steps for obtaining the fluff:

[0060] After a weft thread of the corduroy is woven in, at least one pile weft 2 is woven in parallel, the floating length of the pile weft 2 at least spans three warp threads 1, and the multiple weft threads and the pile weft 2 are interwoven with the warp threads 1 to form a cloth;

[0061] The floating length of the pile weft 2 is partially removed, and the end of the remaining part of the pile weft 2 after the removal stands upright relative to the pile roots, and the pile roots of adjacent pile wefts 2 are staggered.

[0062] By incorporating this method of obtaining fluff into the corduroy process library, the length of the fluff can be further reduced for some alternative processes. Through the rational use of the process library, the anti-lodging ability of the fluff of the obtained corduroy products can be effectively improved.

[0063] In this method, the weft threads serve as ground wefts 3 and are interwoven with the warp threads 1 in a plain weave to form the ground cloth. To ensure the stability of the ground cloth and thus enable the corduroy fabric to achieve the desired usage effect, the number of pile wefts 2 corresponding to each ground weft 3 should not be excessive. A preferable implementation is to have two corresponding pile wefts 2. Moreover, in this case, it is a more appropriate implementation that the floating length of the pile weft 2 spans five warp threads 1. Of course, this is only a preferable implementation and does not limit the protection scope of the present invention.

[0064] The intersection of the pile weft 2 and the warp thread 1 serves as the pile root to ensure the effective fixation of the pile. During the corduroy weaving process, the cutting position of the pile weft 2 needs to be between two warp threads 1. The floating length of the pile weft 2 spanning at least five warp threads 1 can ensure that the pile-forming parts at both ends of the pile root retain sufficient length and can achieve the cutting of different pile wefts 2 along the same straight-line trajectory; as Figure 2 shown, the cutting distance D1 is the length of the removed part. After cutting along the dotted-line trajectory on both sides of this distance, it can be ensured that the length of the pile weft 2 on the right side of the pile root in the lower right corner of the figure spans two warp threads 1, while the length of the pile weft 2 on the right side of the nearest pile root retains the length spanning one warp thread 1 due to dislocation. This length can ensure the effective fixation of the pile root within a certain stripe density range; the final removed part can be discharged through a pile suction device.

[0065] It should be noted that in this preferred solution, since it is necessary to ensure sufficient floating length of the pile weft, the stripe density range should not be too large. During implementation, it is more suitable for medium-thick corduroy with less than 12W. The pile stands upright, and the wale is clear and three-dimensional like a relief. Of course, this stripe density threshold is only a preferable value, and according to different process differences, the 12W threshold can also be adjusted within an appropriate range, all within the protection scope of the present invention. After implementation, through methods such as local floating length removal and pile dislocation setting, the independent support and elasticity of the pile are enhanced, thereby reducing the lodging phenomenon caused by friction or extrusion, significantly improving the anti-lodging ability of the fabric. The upright pile ends bring a soft and comfortable touch, and at the same time, the dislocated pile root structure reduces the mutual friction between the piles and improves the durability of the fabric.

[0066] As a preference of the above embodiment, in order to further improve the corduroy process in the process library, in the above step of obtaining the pile, the form of the tools used is further improved. During the process of obtaining the pile, the following cutting tools are adopted, including:

[0067] It has a connection part, and a flyer needle that extends two steel wires spaced apart to one side relative to the connection part; a core strip that is fixedly connected to the connection part and is located between the two steel wires, dividing the space between the two steel wires into two regions; two parallel cutting blades corresponding to the flyer needle, the cutting blades are rotationally arranged through a shaft body, and are respectively inserted into the two regions, and the core strip and the steel wires limit the cutting blades on both sides in the axial direction of the shaft body, and the axial direction is perpendicular to the length direction of the core strip; wherein, preferably, there are two connection parts, which are respectively connected to the two ends of the two steel wires, so that the flyer needle structure is more stable. The flyer needle is inserted into the bottom of the floating length of the weft pile, and is arranged parallel to the wale corduroy width direction, and part of the length is removed by adjusting the width of the core strip. During use, the cutting blades rotate and intermittently avoid the ground weft 3 to cut the weft pile 2, and the flyer needle squeezes the two warp threads 1 on both sides through the friction surfaces on both sides, so that the floating length of the weft pile to be cut correspondingly is tightened. Appropriate tension helps the weft pile 2 to be cut smoothly. This tension should not be too small to prevent the fabric surface from being too loose, and the flyer needle cannot pass straight, and it is easy to wander in the channel, resulting in uneven lengths of the fluff; the space between the two steel wires forms a total space that restricts the two cutting blades, and the setting of the core strip in the total space forms an independent limiting area corresponding to each cutting blade, so that each cutting blade can perform cutting along a stable straight-line trajectory, thus effectively ensuring the final quality of the product.

[0068] The cutting blades perform cutting actions between the two warp threads 1 restricted by the steel wires and the core strip, and the specific position between the two warp threads 1 is adjusted by the width of the core strip, and the width of the core strip is approximately equal to the length of the removed part.

[0069] When designing the dimensions, the wider the core strip, the shorter the fluff. However, because the width of the corduroy is fixed, the steel wires fixing the cutting blades at both ends will be thinner, and it is impossible to ensure that the cutting blades can be fixed. In addition, when the width of the core strip exceeds a certain range, the fluff is too short, and the wale surface is difficult to be saturated, forming grooves; in order to solve the above problems more comprehensively, preferably, as Figure 3 shown, the design of the cutting tool includes the following steps:

[0070] S1: According to the parameters of the wale corduroy to be produced, determine the outer width of the cutting tool and the width of the core strip;

[0071] S2: At least based on the outer width, the width of the core strip, the thickness of the cutting blade, and the material of the flyer needle, comprehensively determine the width range of the steel wire. This range needs to effectively ensure that the steel wire's limitation of the cutting blade is stable, and select the steel wire width within the width range;

[0072] S3: Conduct trial processing using a cutting tool with the outer width, core strip width, and wire width, and record the magnitude of the force exerted on the flying needle by the corduroy. This force value can be collected through the use of a pressure sensor. Specifically, a structure such as an extrusion block can be fixedly installed relative to the connection of the flying needle to extrude a fixedly arranged pressure sensing sheet. Along with the change in the force on the flying needle, the change in the output data of the pressure sensing sheet can be realized, and the required force magnitude can be obtained through conversion. Of course, other methods can be used to obtain this force in the prior art, all within the protection scope of the present invention;

[0073] S4: Adjust the outer width according to the magnitude of the force. This adjustment is based on the obtained force value and can obtain a clear basis. This adjustment can ensure that the flying needle obtains a straight and non-wandering usage state. After adjustment, the wire width is secondarily selected within the width range to obtain an updated wire width. During this secondary selection process, the wire width can be selected comprehensively considering the new outer width, the state of the fabric during trial processing, and the state of the cutting blade during trial processing;

[0074] Conduct at least one trial processing until the force is within the set range. Through gradual fine-tuning, finally, based on the process flow determined by the trial processing, the optimal state of the cutting tool is achieved.

[0075] In the above optimization method, the fabric state includes but is not limited to:

[0076] Fabric float length recovery state: The float length recovery state refers to whether the pile weft float length can maintain a standing state after cutting. A good float length recovery state helps to maintain the fullness and lodging resistance of the fluff. After trial processing, observe the height of the float length recovery through an optical measurement or image analysis system. Specifically, a laser rangefinder or a high-resolution camera can be used to measure the average height and uniformity of the fluff to judge the float length recovery effect;

[0077] Fabric surface uniformity: The surface uniformity can be detected using a surface roughness meter or a surface scanner to generate a three-dimensional surface contour map for analyzing the flatness and uniformity after cutting;

[0078] Fabric resilience: Simulate the frictional force by applying a slight pressure to detect the fluff resilience, and use a precision pressure sensor to record the fluff recovery height and time to analyze the resilience performance.

[0079] Correspondingly, the state of the cutting blade includes but is not limited to:

[0080] Cutting blade temperature: Install a temperature sensor on the cutting blade to monitor the temperature change during the cutting process in real time. The temperature data can help judge whether the cutting blade remains within the safe temperature range during long-term continuous cutting to avoid a decrease in cutting accuracy caused by high temperature;

[0081] Smoothing of the cut-pile blade: The shaking of the cut-pile blade during the cutting process can be monitored through an acceleration sensor or a vibration sensor, and the data can be fed back to the control system to ensure the smoothness of the cut-pile blade during the cutting process;

[0082] Position and angle of the cut-pile blade: A laser rangefinder or a position sensor can be used to monitor the position of the cut-pile blade in real time to ensure that the cutting depth meets the set value; at the same time, an angle sensor is used to monitor the angle of the cut-pile blade in real time to ensure the stability of the cutting angle.

[0083] As a preference of the above embodiment, in order to avoid the influence of the steel wire on the corduroy fabric, the end of the steel wire is a round head structure, making the movement of the corduroy relative to the flying needles smoother and not causing damage to the corduroy. Based on the same raw materials, compared with the corduroy processed by the above optimized cutting tool and the corduroy using a single cut-pile blade without removing the floating length of the weft pile, as Figure 4 shown, the pile surface is more upright and has a strong three-dimensional sense, like the fluff implanted on the surface of the twill fabric.

[0084] Also for the purpose of improving the corduroy process in the process library, as another optimized way for the process library in the above process design method, as Figure 5 and 6 shown, the process in the corduroy process library includes the following fluff acquisition steps:

[0085] Weave the warp 1 and the weft 4 into a fabric; on one side of the fabric, pull up some of the fibers on the surface of the weft 4 to form fluff, Figure 5 which respectively show the pulled part 41 and the reserved part 42 in, and the reserved part 42 and the warp 1 jointly maintain the stability of the corduroy fabric surface.

[0086] By this way, in addition to achieving the purpose of controlling the length of the fluff within a certain range, the minimum limit value of the fluff can be effectively reduced, and better product effects can be achieved. By supplementing this fluff acquisition method into the process library, a better data basis can be obtained in the process design process. When this preferred solution is specifically implemented, long warp floats and long weft floats can be used in combination for weaving to present longitudinal pile stripes, forming corduroy with clear stripe pits and arched pile stripes. To achieve the fluff feeling of traditional corduroy, reasonable yarn counts and reasonable fabric weaves should be selected. The warp float length and the weft float length should not be too long, otherwise the yarns are easily pulled out and arched. The width of the weft float line is 1.5 mm to 3.5 mm, and the raising effect is the best, with fine, short and clear fluff.

[0087] The corduroy achieved by this fluff acquisition method is applicable to corduroy with a wider range of stripe densities, such as 14W corduroy, compared with the corduroy obtained by the method of removing part of the length of the weft pile 2 in the above embodiment. As Figure 7As shown, the characteristics of the formed fabric include:

[0088] Visually, it has a strong three-dimensional sense and a warm velvet feeling similar to traditional cut-pile corduroy; the pile is not cut, the fiber rigidity is weak, the hand feeling is more skin-friendly and soft than traditional corduroy, and the strength in the direction of the pile stripe is 3 times that of traditional corduroy; the pile will not shed or fall off after being rubbed countless times, and there is no problem of pile direction, and the pile is not easily flattened and whitened.

[0089] As an optimization of the above embodiment, during the process of obtaining the pile, a dense needle roller or burr is used to pull up the fibers. The densely arranged needle roller or burr can uniformly perform the raising operation on the fabric surface, making the pile density of the entire fabric surface consistent, avoiding sparse and uneven pile distribution, and improving the visual aesthetics of the corduroy; the needle roller or burr can control the height and density of the pile when pulling up the fibers, suitable for generating short and dense pile. By adjusting the density and penetration depth of the needle roller, precise control of the pile height can be achieved, thereby enhancing the texture of the fabric.

[0090] As a further optimization to enrich the process library, the design of the needle roller or burr includes the following steps:

[0091] B1: According to the parameters of the corduroy to be produced, determine the insertion depth, density and penetration angle of the needle roller or burr; during implementation, the insertion depth, density and penetration angle of the needle roller or burr can use existing product design software or databases in the field, input the parameters of the corduroy, and the system calculates the initial values, or they can also be initially determined through human experience;

[0092] B2: Conduct trial processing using the needle roller or burr with the insertion depth, density and penetration angle, and collect the surface image of the processed corduroy; specifically, a high-definition camera or an industrial camera can be used to collect images on the fabric surface. The camera should be equipped with a high-resolution lens to ensure clear capture of the details of the pile. Specifically, it can be photographed under constant lighting conditions to avoid image analysis errors caused by lighting changes;

[0093] B3: Identify and analyze at least one of the height consistency, density uniformity, directionality, pile fullness and pile color of the pile through the surface image;

[0094] In the specific recognition and analysis process, for high consistency, edge detection algorithms such as the Canny algorithm can be used, or laser height scanning can be used to analyze the height distribution of the fluff, and calculate the average height and standard deviation of each area; for density uniformity, texture analysis methods such as gray-level co-occurrence matrix can be used, or object detection methods can be used to identify the number of fluff in a unit area and determine whether there is uneven density; for directional analysis, direction detection algorithms such as Sobel edge detection and Hough transform can be used to evaluate the inclination direction of each fluff, calculate the overall direction consistency, and if the direction deviates too much, the insertion angle needs to be adjusted; for fullness and color, texture analysis and photometric measurement techniques can be used to detect the surface smoothness and fluff fullness, and a brightness analysis algorithm can be used to analyze the uniformity of the reflected brightness in different areas to determine whether the ideal gloss effect is achieved.

[0095] For a more intelligent purpose, an image classification model based on deep learning can be used to train a fabric quality detection model. The image is input into this model to automatically identify the above results. The above image recognition and analysis technologies can all obtain solutions in the prior art, and the obtained solutions are all within the protection scope of the present invention;

[0096] B4: Adjust the insertion depth, density, and insertion angle according to the recognition and analysis results; specifically, the insertion depth of the needle can be adjusted through a pressure sensor and a displacement sensor; by adjusting the needle arrangement, the needle pitch can be changed to control the density. If uneven density is recognized, the number of needles can be appropriately increased or decreased; for the adjustment of the insertion angle, an angle regulator is used to adjust the angle between the needle and the fabric surface to ensure the upright effect of the fluff;

[0097] Perform at least one trial processing until the recognition and analysis results meet the requirements. After each trial processing, repeat the processes of B2 and B3 to analyze the surface image. If the analysis results do not meet the expectations, continue to adjust the parameters according to the steps of B4 and perform the next round of trial processing until the results meet the standard requirements.

[0098] The parameters and image analysis results of each trial processing should be recorded in detail. A data set can be established. By analyzing the results of each time, the influence of parameter changes on the fluff effect can be found, and the parameter settings can be gradually optimized. These final parameter optimization results can be used as reference data for future production and incorporated into the process library for quick call of subsequent products.

[0099] Embodiment 2

[0100] A corduroy fabric, and the processing method of the corduroy fabric is obtained through the processing design method for preventing the pile of the corduroy from toppling as described in Embodiment 1. The technical effects that can be achieved by such a corduroy fabric are as described in the above embodiments. By shortening the pile length, the situation of the pile toppling can be effectively solved. Even if it is subjected to external friction or extrusion, the surface can remain flat, avoiding the visual effect of reverse pile. This method fundamentally reduces the probability of the pile toppling and improves the appearance and durability of the fabric.

[0101] The foregoing has shown and described the basic principles, main features and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited by the above embodiments. The above embodiments and the descriptions in the specification are only used to illustrate the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention will have various changes and improvements, and all these changes and improvements fall within the scope of the present invention claimed. The scope of the present invention claimed is defined by the appended claims and their equivalents.

Claims

1. A process design method for preventing the nap of corduroy from lying down, characterized in that, Including: Establish a corduroy process library, and assign a corresponding stripe density range to each corduroy production process in the process library; Determine the stripe density of the corduroy to be produced, and compare it with the stripe density ranges corresponding to the production processes in the corduroy process library to preliminarily determine the matching alternative production processes; Judge the number of the alternative production processes. If the number is 0, interrupt the process design; If the number is equal to 1, determine to adopt the alternative production process. If the number is greater than 1, perform the following steps: Sort the minimum lengths of the corduroy pile hairs that can be obtained by each of the alternative production processes, select at least one of the smaller minimum lengths, and select the alternative production process corresponding to the minimum length; It also includes the following pile hair obtaining steps: After one weft of the corduroy is woven in, at least one pile weft is woven in parallel in sequence. The floating length of the pile weft spans at least three warp threads, and multiple wefts and pile wefts are woven together with the warp threads to form cloth; Remove a partial length of the floating length of the pile weft. After removal, the end of the remaining part of the pile weft stands up relative to the pile root, and the pile roots of adjacent pile wefts are arranged in a staggered manner; During the pile hair obtaining process, the following cutting tool is adopted, including: A flying hair needle having a connection part and two steel wires led out at intervals to one side relative to the connection part; A core strip fixedly connected to the connection part and located between the two steel wires, which divides the interval between the two steel wires into two regions; Two parallel cutting blades corresponding to the flying hair needle. The cutting blades are rotatably arranged through a shaft body and are respectively inserted into the two regions. The core strip and the steel wires limit the cutting blades on both sides of the axis direction of the shaft body; The flying hair needle is inserted into the bottom of the floating length of the pile weft and is arranged parallel to the corduroy width direction. The length of the removed part is adjusted by the width of the core strip; The design of the cutting tool includes the following steps: According to the parameters of the corduroy to be produced, determine the outer width and the width of the core strip of the cutting tool; Comprehensively determine the width range of the steel wire at least according to the outer width, the width of the core strip, the thickness of the cutting blade and the material of the flying hair needle, and select the steel wire width within the width range; Perform trial processing by using the cutting tool with the outer width, the width of the core strip and the steel wire width, and record the magnitude of the force exerted on the flying hair needle by the corduroy; Adjust the outer width according to the magnitude of the force. After adjustment, re-select the steel wire width within the width range to obtain the updated steel wire width; Perform at least one trial processing until the force is within the set range.

2. The process design method for preventing the pile of corduroy from toppling as claimed in claim 1, wherein, The end of the steel wire is a round head structure.

3. The process design method for preventing the pile of corduroy from lying down according to claim 1, characterized in that, There are two connection parts, which are respectively connected to the two ends of the two steel wires.

4. The process design method for preventing the pile of corduroy from lying down according to claim 1, characterized in that, The processes in the corduroy process library include the following pile hair obtaining steps: Interweave warp and weft to form a fabric; On one side of the fabric, pull up some fibers on the surface of the weft to form pile hairs.

5. The process design method for preventing the pile of corduroy from lying down according to claim 4, characterized in that, During the pile hair obtaining process, dense thorn needles or thorn fruits are used to pull up the fibers.

6. The process design method for preventing the pile of corduroy from toppling according to claim 5, characterized in that The design of the thorn needle or thorn fruit includes the following steps: Determining the insertion depth, density and insertion angle of the pricking needle or pricking fruit according to the parameters of the corduroy to be produced; Conducting trial processing by using the needles or thorns with the insertion depth, density and insertion angle, and collecting the surface image of the processed corduroy; Identifying and analyzing at least one of the height consistency, density uniformity, directionality, fullness and color of the villi through the surface image; Adjusting the insertion depth, density and insertion angle according to the identification and analysis results; The trial processing is performed at least once until the identification and analysis results meet the requirements.

7. A corduroy fabric, characterized in that, The process method of the corduroy fabric is obtained by the process design method for preventing the corduroy from falling over as described in any one of claims 1 to 6.

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