Method for automatically generating dyeing process in laboratory of dyeing and finishing plant

Abstract

The invention discloses a method for automatically generating a dyeing process in a laboratory of a dyeing and finishing plant. According to the technical scheme, the method is characterized by comprising the following steps: step 1, planning and designing an experiment: carrying out an analysis experiment on physical characteristics and chemical characteristics of cloth and dye reactants; 2, carrying out specific experiment operation in a laboratory by an experimenter according to an experiment scheme and steps designed by an expert group, and recording experiment process data and result data; step 3, establishing a mathematical model: establishing a data calculation model for generating a dyeing process; 4, data verification, wherein parameters of the data calculation model are corrected; 5, inputting proofing order information, and making a formula by means of a spectrometer or manually making the formula; step 6, generating a laboratory dyeing process by the expert system; 7, combining laboratory dyeing processes by the expert system; and step 8, sending the process to the proofing press and executing the process. The process generated by the invention can be directly issued to a proofing press to be executed, so that errors are reduced.

Description

Technical Field

[0001] The invention belongs to the field of textile dyeing, and in particular relates to a method for automatically generating a dyeing process in a laboratory of a dyeing and finishing plant. Background Art

[0002] The printing and dyeing industry is a typical non-standard product processing industry. The requirements of each proofing order (fabric type, color and quality requirements) are different, and the dyes and amounts used each time will be different.

[0003] At present, the traditional practice of laboratories in printing and dyeing enterprises is to manually formulate several or dozens of empirical processes based on experience and preset them in the proofing machine; after the laboratory issues the formula for the proofing order, it is manually selected based on experience or a new process is formulated for proofing. The process formulated in this way lacks scientific data support, and using a fixed process to cope with the changing dyes and dosages cannot maximize the performance of the dyes, and will also increase the number of proofing times and reduce proofing efficiency; if such a process is applied to mass production, it will also lead to a waste of time and cost.

[0004] In summary, the traditional practices of dyeing and finishing plant laboratories have the following defects:

[0005] 1. Since the essence of textile dyeing is the physical and chemical reaction between dye molecules and fiber molecules, the traditional approach has not found the property rules of reactants (dye auxiliaries, fibers) through basic research, but only manually formulates some proofing processes based on experience. When dyeing, the reaction often cannot be carried out under standard conditions, resulting in low efficiency and low accuracy;

[0006] 2. Artificially compiling some processes will result in one process being applied to different fibers and dyes. However, different fibers and dyes have different properties, and the formulated process is unscientific.

[0007] 3. Existing technologies cannot get rid of their dependence on people and require a large number of skilled workers;

[0008] 4. As the requirements for textiles become increasingly higher, refined management is needed. The increasing demand for employee quality and the decline in employee quality are an irreconcilable contradiction. Summary of the invention

[0009] The object of the present invention is to provide a method for automatically generating a dyeing process in a laboratory of a dyeing and finishing plant, so as to solve the problems raised in the above-mentioned background technology.

[0010] To achieve the above object, the present invention provides the following technical solution: a method for automatically generating a dyeing process in a laboratory of a dyeing and finishing plant, comprising the following steps:

[0011] Step 1: Plan and design the experiment: Conduct experimental analysis on the physical and chemical properties of the fabric and dye reactants;

[0012] Step 2: Conduct the experiment: The experimenter shall carry out specific experimental operations in the laboratory according to the experimental plan and steps designed by the expert group, and record the experimental process data and result data;

[0013] Step 3, establish a mathematical model: establish a data calculation model for generating dyeing process;

[0014] Step 4: Data verification: Correct the parameters of the data calculation model;

[0015] Step 5: Enter the sample order information and formulate the formula with the help of a spectrometer or manually;

[0016] Step 6: The expert system generates a dyeing process;

[0017] Step 7, expert system merges dyeing processes;

[0018] Step 8: Send the process to the proofing machine and execute it.

[0019] Preferably, in step 1, an expert group composed of senior experts in the industry conducts basic experiments on each dye and applicable fabric, specifically including experiments on the temperature dependence of each dye at different concentrations, experiments on the dependence on heat preservation time, stage dyeing experiments, stage shrinkage experiments, and experiments on different dye combinations.

[0020] Preferably, in step 3, the expert group analyzes the experimental process data and result data, and after interpreting the experimental conclusions, establishes a data calculation model for generating the dyeing process based on the fabric fiber characteristics, the physical and chemical properties of the dye, and the influencing conditions and relationships between them.

[0021] Preferably, in step 4, a technician enters the laboratory and verifies the actual dyeing effect according to the process deduced from the data calculation model based on the actual proofing order and dye formula to test the validity of the data and the data model; if there is any deviation, additional experiments are planned to correct the various parameters of the data calculation model.

[0022] Preferably, in step 5, the business or laboratory clerk enters the order requirement information, including the customer, fabric type, quality requirements, color fastness requirements, and testing standard requirements, and the laboratory color matching master uses a spectrometer or manually to make a proofing formula; the operation method is: before starting to match the color, prepare the following materials and tools: spectrophotometer, colorant, container, stirrer, and ensure that all tools and materials are clean, dry and pollution-free; before using the spectrophotometer, calibrate the spectrophotometer; then the spectrophotometer matches the color to form several dye combination formulas, the expert system selects an optimal formula based on the research data, and then the expert system calculates the required auxiliaries and the amount of auxiliaries, and finally forms a complete laboratory formula for the generation process color matching.

[0023] Preferably, in step 6, the expert system generates the dyeing process. The expert system calculates and generates the dyeing process based on the order information and the formula information in combination with the data calculation model, which includes: comprehensively calculating the heating rate of the process based on the shrinkage of the fabric stage and the dyeing of the dye stage; comprehensively calculating the heating rate, holding temperature, holding time, and cooling rate of the process based on the concentration of each material in the formula dye combination and the processing requirement information.

[0024] Preferably, in step 7, the expert system merges dyeing processes: each proofing machine can put multiple cups for proofing at one time. For proofing machines with overall temperature control, the expert system evaluates the merger of similar processes without affecting the dyeing effect based on the above data model.

[0025] Preferably, in step 8, the process is sent to the proofing machine for execution: if the proofing machine does not support receiving the process, it is necessary to manually compile the process generated in the previous step on the proofing machine; if the proofing machine supports receiving the process, the expert system can directly send the generated process to the proofing machine; for the proofing machine with separate temperature control set for each step, the expert system directly sends the dyeing process to the proofing machine, and the proofing machine receives the process and executes it. For the proofing machine with overall temperature control, the expert system will merge the proofing orders of the same process, schedule them to the same proofing machine, and send the merged dyeing process to the proofing machine for execution; for processes that cannot be merged, they need to be sent to the next round of execution in a new batch, or scheduled to other proofing machines for execution.

[0026] Compared with the prior art, the present invention has the following beneficial effects:

[0027] The present invention conducts basic analysis on fabric types and dyes, obtains the physical and chemical properties of fabrics and various dye reactants, and establishes a mathematical model; for non-standard product proofing order requirements and formulas, this model calculates the laboratory dyeing process to maximize the performance of the dye, achieve the best dyeing effect, and reduce the waste of time and cost. The process generated by the present invention can be directly sent to the proofing machine for execution, thereby reducing manual operation and errors. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is a flow chart of the present invention. DETAILED DESCRIPTION

[0029] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0030] Example 1

[0031] See also Figure 1 The present invention provides a technical solution: a method for automatically generating a dyeing process in a dyeing and finishing factory laboratory, comprising the following steps:

[0032] Step 1: Plan and design the experiment: Conduct experimental analysis on the physical and chemical properties of the fabric and dye reactants;

[0033] Step 2: Conduct the experiment: The experimenter shall carry out specific experimental operations in the laboratory according to the experimental plan and steps designed by the expert group, and record the experimental process data and result data;

[0034] Step 3, establish a mathematical model: establish a data calculation model for generating dyeing process;

[0035] Step 4: Data verification: Correct the parameters of the data calculation model;

[0036] Step 5: Enter the sample order information and formulate the formula with the help of a spectrometer or manually;

[0037] Step 6: The expert system generates a dyeing process;

[0038] Step 7, expert system merges dyeing processes;

[0039] Step 8: Send the process to the proofing machine and execute it.

[0040] Among them, in the step 1, an expert group composed of senior experts in the industry conducts basic experiments on each dye and applicable fabric, specifically including experiments on the temperature dependence of each dye at different concentrations, experiments on the dependence on heat preservation time, stage dyeing experiments, stage shrinkage experiments, and experiments on different dye combinations.

[0041] Among them, in the step 3, the expert group analyzes the experimental process data and result data, and after judging the experimental conclusions, establishes a data calculation model for generating the dyeing process based on the fabric fiber characteristics, the physical and chemical properties of the dye, and the influencing conditions and relationships between them.

[0042] Among them, in step 4, the process technician enters the laboratory and verifies the actual dyeing effect according to the process deduced from the data calculation model based on the actual proofing order and dye formula to test the validity of the data and the data model; if there is any deviation, additional experiments are planned to correct the various parameters of the data calculation model.

[0043] Among them, in the step 5, the business or laboratory clerk enters the order requirement information, which includes the customer, fabric type, quality requirements, color fastness requirements, and testing standard requirements. The laboratory color master uses a spectrometer or manually proofs the formula; the operation method is: before starting to adjust the color, prepare the following materials and tools: spectrophotometer, colorant, container, stirrer, and ensure that all tools and materials are clean, dry and pollution-free; before using the spectrophotometer, calibrate the spectrophotometer; then the spectrophotometer matches the color to form several dye combination formulas, the expert system selects an optimal formula based on the research data, and then the expert system calculates the required auxiliaries and the amount of auxiliaries, and finally forms a complete laboratory formula for the generation process color.

[0044] Among them, in the step 6, the expert system generates the dyeing process. The expert system calculates and generates the dyeing process based on the order information and formula information in combination with the data calculation model, which includes: comprehensively calculating the heating rate of the process based on the shrinkage of the fabric stage and the dyeing of the dye stage; comprehensively calculating the heating rate, insulation temperature, insulation time, and cooling rate of the process based on the concentration of each material in the formula dye combination and the processing requirement information.

[0045] Among them, in the step 7, the expert system merges the dyeing processes: each proofing machine can put multiple cups for proofing at one time. For the proofing machine with overall temperature control, the expert system evaluates the merger of similar processes without affecting the dyeing effect based on the above data model.

[0046] Among them, in the step 8, the process is sent to the proofing machine for execution: if the proofing machine does not support receiving the process, it is necessary to manually compile the process generated in the previous step on the proofing machine; if the proofing machine supports receiving the process, the expert system can directly send the generated process to the proofing machine; for the proofing machine with separate temperature control set for each step, the expert system directly sends the dyeing process to the proofing machine, and the proofing machine receives the process and executes it. For the proofing machine with overall temperature control, the expert system will merge the proofing orders of the same process, schedule them to the same proofing machine, and send the merged dyeing process to the proofing machine for execution; for processes that cannot be merged, they need to be sent to the next round of execution in a new batch, or scheduled to other proofing machines for execution.

[0047] Among them, the present invention obtains the physical and chemical properties of fabrics and various dye reactants through basic analysis of fabric types and dyes, and establishes a mathematical model; for non-standard product proofing order requirements and formulas, this model calculates the laboratory dyeing process to maximize the performance of the dye, achieve the best dyeing effect, and reduce the waste of time and cost. The process generated by the present invention can be directly sent to the proofing machine for execution, thereby reducing manual operation and errors.

[0048] Example 2

[0049] The technical solution adopted by the present invention comprises the following steps:

[0050] Step 1. Plan and design experiments: A team of experts composed of senior experts in the industry will conduct basic experiments on each dye and applicable fabric, including experiments on the temperature dependence of each dye at different concentrations, experiments on the dependence on heat preservation time, stage dyeing experiments, stage shrinkage experiments, experiments on different dye combinations, etc., to study the physical and chemical properties of various fabrics and various dye reactants.

[0051] Step 2: Conduct the experiment: The experimenter shall carry out specific experimental operations in the laboratory according to the experimental plan and steps designed by the expert group, and record the experimental process data and result data.

[0052] Step 3: Establish a mathematical model: The expert group analyzes the experimental process data and result data. After interpreting the experimental conclusions, they establish a data calculation model for the dyeing process based on the fabric fiber characteristics, the physical and chemical properties of the dye, and the influencing conditions and relationships between them.

[0053] Step 4: Data Verification: The technician enters the laboratory and verifies the actual dyeing effect according to the process deduced from the data calculation model based on the actual proofing order and dye formula to test the validity of the data and the data model. If there is any deviation, additional experiments are planned to correct the various parameters of the data calculation model.

[0054] Step 5, input the proofing order information, and use the spectrometer to make the formula or manually: the business or laboratory clerk enters the order requirement information (including customer, fabric type, quality requirements, color fastness requirements, testing standard requirements, etc.), and the laboratory color master uses the spectrometer / or manually to make the proofing formula (each formula is usually a group of dye combinations containing multiple dyes of different concentrations); the operation method is: before starting to adjust the color, prepare the following materials and tools: spectrophotometer, colorant, container, stirrer, ensure that all tools and materials are clean, dry and free of pollution; before using the spectrophotometer, calibrate the spectrophotometer; the spectrophotometer matches the color to form several dye combination formulas, the expert system selects an optimal formula based on the research data, and then the expert system calculates the required auxiliaries and the amount of auxiliaries, and finally forms a complete laboratory formula for the generation process color.

[0055] Step 6: The expert system generates dyeing process: The expert system calculates and generates the dyeing process based on the order information and formula information, combined with the data calculation model, including:

[0056] The heating rate of the process is calculated comprehensively based on the shrinkage of the fabric stage and the dyeing of the dye stage.

[0057] According to the dye and concentration of each material in the formula dye combination, as well as the processing requirements information, the holding temperature, holding time, cooling rate, etc. of the process are comprehensively calculated.

[0058] Step 7. The expert system merges dyeing processes: Each proofing machine can hold multiple cups for proofing at one time. Some brands of proofing machines can control the temperature of each cup individually, while some brands of proofing machines can only control the temperature as a whole. For proofing machines with overall temperature control, the expert system evaluates the merger of similar processes based on the above data model without affecting the dyeing effect.

[0059] Step 8. Preferably, send the process to the proofing machine and execute it: If the proofing machine does not support receiving the process, it is necessary to manually compile the process generated in the previous step on the proofing machine; if the proofing machine supports receiving the process, the expert system can directly send the generated process to the proofing machine, thereby reducing manual operation and avoiding human operation errors. For the proofing machine with separate temperature control for each step, the expert system directly sends the dyeing process to the proofing machine, and the proofing machine receives the process and executes it. For the proofing machine with overall temperature control, the expert system will merge the proofing orders of the same process and schedule them to the same proofing machine, and send the merged dyeing process to the proofing machine for execution; for processes that cannot be merged, they need to be sent to the next round of execution in a new batch, or scheduled to other proofing machines for execution.

[0060] The present invention conducts basic analysis on fabric types and dyes, obtains the physical and chemical properties of fabrics and various dye reactants, and establishes a mathematical model; for non-standard product proofing order requirements and formulas, this model calculates the laboratory dyeing process to maximize the performance of the dye, achieve the best dyeing effect, and reduce the waste of time and cost. The process generated by the present invention can be directly sent to the proofing machine for execution, thereby reducing manual operation and errors.

[0061] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for automatically generating dyeing process in a dyeing and finishing factory laboratory, characterized in that: The following steps are involved: Step 1: Plan and design the experiment: Conduct experimental analysis on the physical and chemical properties of the fabric and dye reactants; Step 2: Conduct the experiment. The experimenter shall carry out specific experimental operations in the laboratory according to the experimental plan and steps designed by the expert group, and record the experimental process data and result data; Step 3, establish a mathematical model: establish a data calculation model for generating dyeing process; Step 4: Data verification: Correct the parameters of the data calculation model; Step 5: Enter the sample order information and formulate the formula with the help of a spectrometer or manually; Step 6: The expert system generates a dyeing process; Step 7, expert system merges dyeing processes; Step 8: Send the process to the proofing machine and execute it.

2. The method for automatically generating dyeing process in a dyeing and finishing factory laboratory according to claim 1, characterized in that: In step 1, an expert group composed of senior experts in the industry conducts basic experiments on each dye and applicable fabric, specifically including experiments on the temperature dependence of each dye at different concentrations, experiments on the dependence on heat preservation time, stage dyeing experiments, stage shrinkage experiments, and experiments on different dye combinations.

3. The method for automatically generating dyeing process in a dyeing and finishing factory laboratory according to claim 1, characterized in that: In step 3, the expert group analyzes the experimental process data and result data, and after interpreting the experimental conclusions, establishes a data calculation model for generating the dyeing process based on the fabric fiber characteristics, the physical and chemical properties of the dye, and the influencing conditions and relationships between them.

4. The method for automatically generating dyeing process in a dyeing and finishing factory laboratory according to claim 1, characterized in that: In step 4, the technician enters the laboratory and verifies the actual dyeing effect according to the process deduced from the data calculation model based on the actual proofing order and dye formula, so as to check the validity of the data and the data model; If there are deviations, additional experiments are planned to correct various parameters of the data calculation model.

5. The method for automatically generating dyeing process in a dyeing and finishing factory laboratory according to claim 1, characterized in that: In step 5, the business or laboratory clerk enters the order requirement information, including the customer, fabric type, quality requirements, color fastness requirements, and testing standard requirements, and the laboratory color matching master uses a spectrophotometer or manual proofing formula; the operation method is: before starting to match the color, prepare the following materials and tools: spectrophotometer, colorant, container, stirrer, and ensure that all tools and materials are clean, dry and free of contamination; before using the spectrophotometer, calibrate the spectrophotometer; The spectrometer forms several dye combination formulas, and the expert system selects the best formula based on the research data. The expert system then calculates the required auxiliaries and the amount of auxiliaries, and finally forms a complete laboratory formula for the color generation process.

6. The method for automatically generating dyeing process in a dyeing and finishing factory laboratory according to claim 1, characterized in that: In step 6, the expert system generates a dyeing process. The expert system calculates and generates the dyeing process based on the order information and the formula information in combination with the data calculation model, which includes: comprehensively calculating the heating rate of the process based on the shrinkage of the fabric stage and the dyeing of the dye stage; comprehensively calculating the heating rate, holding temperature, holding time, and cooling rate of the process based on the concentration of each material in the formula dye combination and the processing requirement information.

7. The method for automatically generating dyeing process in a dyeing and finishing factory laboratory according to claim 1, characterized in that: In step 7, the expert system merges dyeing processes: each proofing machine can put multiple cups for proofing at one time. For the proofing machine with overall temperature control, the expert system evaluates the merger of similar processes without affecting the dyeing effect based on the above data model.

8. The method for automatically generating dyeing process in a dyeing and finishing factory laboratory according to claim 2, characterized in that: In step 8, the process is sent to the proofing machine for execution: if the proofing machine does not support receiving the process, it is necessary to manually compile the process generated in the previous step on the proofing machine; if the proofing machine supports receiving the process, the expert system can directly send the generated process to the proofing machine; for the proofing machine with separate temperature control set for each step, the expert system directly sends the dyeing process to the proofing machine, and the proofing machine receives the process and executes it. For the proofing machine with overall temperature control, the expert system will merge the proofing orders of the same process, schedule them to the same proofing machine, and send the merged dyeing process to the proofing machine for execution; for the processes that cannot be merged, they need to be sent to the next round of execution in a new batch, or be scheduled to other proofing machines for execution.

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