A type of satin weaving technique

Abstract

This invention belongs to the field of weaving technology, specifically relating to a satin weaving process. By optimizing the shuttle weaving technique, it ensures that the colored weft threads are accurately exposed on the front side of the fabric in the patterned area, while maintaining a neat back side, significantly improving the clarity and aesthetics of the pattern. A special method is used to reinforce the warp and weft interlacing points, ensuring that these points remain discontinuous without affecting the overall structural stability, thus enhancing the fabric's durability and flexibility. Furthermore, meticulous manual adjustment of each long float thread ensures even distribution, increasing the fabric's surface luster. In summary, this invention significantly improves the quality consistency of satin fabrics, reduces the defect rate, and expands its application range in the high-end market, meeting the demand for high-quality fabrics.

Description

Technical Field

[0001] This invention belongs to the field of weaving technology, specifically relating to a satin weaving process. Background Art

[0002] Guangduan is a traditional fabric with rich textures and intricate patterns, widely used in high-end clothing, home décor, and other fields. Traditional Guangduan weaving relies on manual operation and experienced craftsmen, which is not only time-consuming and labor-intensive but also makes it difficult to guarantee the consistency and high quality of each finished product. While existing mechanized weaving technology has improved production efficiency to some extent, many challenges remain in handling the transition between patterned and non-patterned areas, controlling weft thread exposure, and reinforcing warp and weft interlacing points.

[0003] The main problems with existing technologies:

[0004] Inaccurate control of weft thread exposure: In patterned areas, the weft threads need to be precisely exposed on the front side of the fabric to form a clear pattern, while the back side needs to remain neat. However, traditional processes and existing equipment cannot ensure that this requirement is met every time, resulting in inconsistent product quality.

[0005] Insufficient reinforcement at warp and weft interlacing points: To ensure the overall structural stability of the fabric, the warp and weft interlacing points must be reinforced. However, existing reinforcement methods often affect the fabric's flexibility and aesthetics, failing to achieve the effect of reinforcement without compromising overall structural stability.

[0006] Uneven distribution of long floats: The presence of long floats can increase the gloss of the fabric surface, but if they are not distributed evenly, it will cause defects on the fabric surface and affect the quality of the final product.

[0007] To address the aforementioned issues, particularly in controlling weft thread exposure, existing technologies cannot maintain both clarity of the pattern in the visible area and neatness on the back side. This imprecise control not only increases the defect rate but also limits the application of satin fabrics in the high-end market. Summary of the Invention

[0008] The purpose of this invention is to provide a satin weaving process that significantly improves the quality and aesthetics of satin fabrics, reduces the defect rate, and is particularly suitable for application scenarios with high requirements for pattern clarity and overall texture, so as to solve the problems mentioned in the background art.

[0009] To achieve the above objectives, the present invention adopts the following technical solution: a satin weaving process, comprising the following steps:

[0010] Select cooked silk thread as raw material, and perform preliminary treatment to make the cooked silk thread achieve the best flexibility;

[0011] Based on the pre-treated molten silk thread, warp threads are arranged on a wooden loom to form a basic framework, which will be used throughout the entire weaving process;

[0012] Introduce the weft and use the through shuttle weaving technique. First, operate in the area where the pattern is to be displayed, adjust the position of the weft to ensure that the colored weft is exposed on the front of the fabric, while keeping the back neat. Then, turn to the non-patterned area and weave the colored weft into the back, gradually completing the weaving of the entire piece of fabric.

[0013] The warp and weft interlacing points are reinforced to ensure that these points remain discontinuous without affecting the overall structural stability. Then, each long floating thread is manually adjusted to ensure even distribution. Finally, the completed Guangduan satin is finished.

[0014] Preferably, the step of selecting spun yarn as raw material and performing preliminary treatment to achieve optimal flexibility of the spun yarn includes:

[0015] When selecting processed silk threads, measure the initial diameter of each bundle of threads to ensure that it meets the predetermined standard range;

[0016] Soak the selected molten silk thread in warm water to allow it to fully absorb water and swell.

[0017] After soaking, the silk thread is stretched to ensure that it achieves optimal flexibility without being damaged.

[0018] The stretched yarns are dried, the ambient humidity is controlled, and the drying time is recorded.

[0019] Preferably, the step of arranging warp threads on a wooden loom based on the pre-treated spun silk to form a basic framework includes:

[0020] Measure the diameter of each bundle of warp threads and record its length to ensure that all warp threads have the same diameter;

[0021] A tension adjustment device is installed on the wooden loom to adjust the tension applied to each bundle of molten silk as it passes through the tension adjustment device to the required level.

[0022] The tension-adjusted molten silk threads are fixed on the warp beams of the wooden loom and arranged at predetermined intervals;

[0023] Start the wooden loom and begin preliminary weaving, checking the tension uniformity of each warp thread; if the tension deviation of a certain warp thread exceeds the allowable range, make adjustments.

[0024] Preferably, the introduction of the weft thread, using the shuttle embellishment technique, is first performed in the area designated for displaying the pattern, including:

[0025] Determine the location and size of the flower-revealing areas, and record the width and length of each flower-revealing area;

[0026] Select the weft threads of the color and material of the patterned area, measure their diameter, and calculate the required number of weft threads based on the area of ​​the patterned area.

[0027] The selected weft yarn is introduced into the wooden loom through the shuttle device, and the tension of the weft yarn is adjusted to the preset standard value;

[0028] Begin weaving within the patterned area, controlling the weaving density of each weft row.

[0029] Preferably, adjusting the position of the weft threads to ensure that the colored weft threads are exposed on the front side of the fabric while maintaining the neatness of the back side includes:

[0030] Measure the exposed length of each weft thread on the front side of the fabric in the pattern display area, and determine the ideal exposed length of each weft thread according to the pattern display design requirements;

[0031] Based on the measurement results, the position of the weft thread in the shuttle device was adjusted so that the exposed length of the weft thread was close to the ideal value;

[0032] After adjusting the weft position, check the weft arrangement on the back of the fabric to ensure that the wefts are neatly arranged on the back.

[0033] Preferably, the step of turning to the non-patterned area and weaving the colored weft into the back side includes:

[0034] Determine the location and size of the non-flower-displaying areas, and record the width and length of each non-flower-displaying area;

[0035] Select the weft threads of the color and material of the non-patterned area, measure their diameter, and calculate the required number of weft threads based on the area of ​​the non-patterned area.

[0036] Adjust the angle of the shuttle so that the weft yarn can be woven on the back of the non-patterned area without showing the front;

[0037] Begin weaving in the non-patterned area, controlling the weaving density of each row of weft threads to ensure the back is neat and no weft threads are exposed on the front.

[0038] Preferably, the step-by-step weaving of the entire fabric includes:

[0039] Determine the total length and width of the entire fabric and divide it into multiple patterned and non-patterned areas;

[0040] Based on the division results, calculate the number of latitude lines required for each region;

[0041] Before weaving begins in each area, adjust the angle and tension of the shuttle device to suit the needs of different areas;

[0042] Perform the weaving operation on each area one by one, and check the weaving quality of the current area after each weaving is completed. If it does not meet the set threshold, make adjustments.

[0043] Preferably, the reinforcement of the warp and weft intersections, ensuring that these points remain discontinuous without affecting the overall structural stability, includes:

[0044] Measure the position coordinates of each latitude and longitude intersection point and record its deviation from the ideal position;

[0045] Based on the measurement results, select reinforcement materials to ensure that their dimensions match the warp and weft intersection points;

[0046] Fix the reinforcement material at each intersection of the latitude and longitude lines, and adjust the angle of the reinforcement material to align it with the direction of the latitude and longitude lines.

[0047] Check the strength of the reinforced warp and weft intersections and record the values. If the strength is lower than the set threshold, perform additional reinforcement.

[0048] Preferably, the step of manually adjusting each segment of the long float to ensure even distribution includes:

[0049] Measure the actual length of each long float and its position coordinates on the fabric, and record the initial length and position deviation of each long float;

[0050] Based on the measurement results, the amount of length change that needs to be adjusted for each long floating line is calculated to compensate for deviations in actual weaving;

[0051] Use hand tools to fine-tune each long floating line to achieve the ideal length. During the adjustment process, control the angle of each long floating line to make it consistent with the direction of the latitude and longitude lines.

[0052] Check the uniformity and gloss of each long floating line segment. If the gloss is below the set threshold, make manual adjustments.

[0053] Preferably, the finishing of the completed satin includes:

[0054] Measure the overall dimensions of the finished Guangduan (a type of satin), record its length and width, calculate the actual area of ​​the Guangduan, and record the flatness of each area.

[0055] Based on the measurement results, the satin was smoothed using ironing equipment, and the ironing temperature and pressure were adjusted.

[0056] After smoothing, the satin is cut according to the design requirements to determine the final size, ensuring that the cut satin meets the design specifications and maintains its flatness.

[0057] The cut satin is subjected to quality inspection to check its surface smoothness and overall uniformity. If the smoothness or uniformity is lower than the set threshold, it is reworked.

[0058] Technical effects and advantages of the present invention: The satin weaving process proposed in this invention has the following advantages compared with the prior art:

[0059] This invention optimizes the weft thread application technique, ensuring that the colored weft threads are accurately exposed on the front of the fabric in the patterned area while maintaining a neat back, significantly improving the clarity and aesthetics of the pattern. A special method is used to reinforce the warp and weft interlacing points, ensuring these points remain discontinuous without affecting the overall structural stability, thus enhancing the fabric's durability and flexibility. Furthermore, meticulous manual adjustment of each long float thread ensures even distribution, increasing the fabric's surface luster. In summary, this invention significantly improves the quality consistency of satin fabrics, reduces the defect rate, and expands its application in the high-end market, meeting the demand for high-quality fabrics. Attached Figure Description

[0060] Figure 1 This is a flowchart of a satin weaving process according to the present invention. Detailed Implementation

[0061] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The specific embodiments described herein are merely used to explain the present invention and are not intended to limit the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0062] This invention provides a satin weaving process that optimizes the through-shuttle coloring technique and performs meticulous operations in both the patterned and non-patterned areas to ensure that the colored weft is accurately exposed on the front of the fabric in the patterned areas, while remaining neat on the back. This not only improves the consistency of the finished product's quality but also enhances the clarity and aesthetics of the pattern.

[0063] A special technique is used to reinforce the warp and weft interlacing points, ensuring these points remain discontinuous without compromising the overall structural stability. This method not only enhances the fabric's durability but also maintains its original flexibility, preventing lumps or unevenness caused by reinforcement. Each long float is meticulously adjusted by hand to ensure even distribution, thereby increasing the fabric's surface luster and improving the overall visual appeal.

[0064] In summary, this invention, through a series of innovative steps, significantly improves the quality and aesthetics of satin fabrics, reduces the defect rate, and is particularly suitable for applications requiring high pattern clarity and overall texture. This improvement not only increases production efficiency but also expands the application range of satin fabrics, meeting market demand for high-quality fabrics. Specifically:

[0065] like Figure 1 As shown, the present invention proposes a satin weaving process, which includes the following steps:

[0066] Step 1: Select spun silk thread as raw material, and perform preliminary treatment to achieve optimal flexibility; the specific process includes the following steps:

[0067] When selecting the finished silk threads, measure the initial diameter D_s (in millimeters) of each bundle of threads to ensure that it meets the predetermined standard range R, that is, satisfy the formula D_s∈[D_min,D_max], where D_min and D_max are the minimum and maximum allowable diameters, respectively. By accurately measuring the diameter of the silk threads, we can ensure that the parameter adjustments in subsequent processing steps are more accurate, thereby ensuring the consistency of the final product quality.

[0068] Based on the measurement results, the selected molten silk thread was soaked in warm water at a temperature of T_temp for H hours to allow the thread to fully absorb water and expand. The calculation formula is H=(D_s-D_min) / K, where K is a constant coefficient used to adjust the soaking time to suit different diameters of silk thread. Through soaking treatment, the silk thread can fully absorb water and expand, increasing its flexibility and preparing it for subsequent stretching treatment.

[0069] After soaking, the yarn is stretched. The stretching ratio L_r is determined according to the formula L_r=(D_max-D_s) / D_max*100% to ensure that the yarn achieves optimal flexibility without damage. This step uses the yarn diameter D_s adjusted after soaking. Through stretching, the flexibility and strength of the yarn are further improved, ensuring that it is not easily broken during weaving.

[0070] The stretched yarn is dried while maintaining an ambient humidity of RH%. The drying time DT hours is recorded and calculated using the formula DT=H*F, where F is a correction factor. This ensures that the yarn is neither over-dried nor over-wetted, maintaining optimal flexibility. The soaking time H is used in this step, and the drying time and humidity are adjusted according to the actual situation. By precisely controlling the drying time and ambient humidity, the yarn is kept in optimal flexibility, avoiding performance issues caused by over-drying or over-wetting.

[0071] Suppose we have a batch of molten yarn with an initial diameter of 0.6 mm, a minimum allowable diameter D_min of 0.5 mm, and a maximum allowable diameter D_max of 0.8 mm. We wish to perform preliminary treatment to achieve optimal flexibility.

[0072] Selection and measurement: D_s = 0.6 mm, within the range [0.5, 0.8] mm.

[0073] Soaking treatment: Set T_temp=30 degrees Celsius, K=0.1, and soaking time is H=(0.6-0.5) / 0.1=1 hour.

[0074] Stretching treatment: Stretching ratio L_r = (0.8 - 0.6) / 0.8 * 100% = 25%.

[0075] Drying process: Set the ambient humidity RH=50%, the correction factor F=1.2, and the drying time DT=1*1.2=1.2 hours.

[0076] By following the above steps, it can be ensured that the molten silk thread achieves optimal flexibility without damage, providing high-quality raw materials for subsequent satin weaving processes.

[0077] Step Two: Based on the pre-treated spun silk thread, warp threads are arranged on a wooden loom to form a basic framework, which will be used throughout the entire weaving process; the specific process includes the following steps:

[0078] Measure the diameter D_s (in millimeters) of each bundle of molten silk thread and record its length L_len (in meters); ensure that the diameter of all warp threads is consistent, satisfying the formula D_s=D_0, where D_0 is the preset standard diameter value; by accurately measuring and controlling the diameter of each bundle of molten silk thread, ensure the consistency of all warp threads, thereby improving the overall quality and uniformity of the fabric.

[0079] A tension adjustment device is installed on the wooden loom to adjust the tension P_t (unit: Newtons) applied to each bundle of warp threads as it passes through the device to the required level. The relationship between tension P_t and diameter D_s is determined by the formula P_t=A*(D_s-D_min)+P_base, where A is the tension coefficient, D_min is the minimum allowable diameter, and P_base is the base tension value. This step uses diameter D_s as a reference. By adjusting the tension, it is ensured that each warp thread maintains appropriate tension during the weaving process, avoiding excessive looseness or tightness, thereby ensuring the smoothness and strength of the fabric.

[0080] The tension regulating device is a key component on a wood loom used for precise control of the tension of each bundle of yarns. It adjusts and maintains the tension of the yarns during the weaving process, either mechanically or electronically, to ensure the quality and consistency of the fabric. The following are the main components of a tension regulating device and their working principles:

[0081] I. Composition of the tension adjustment device

[0082] Tension sensor

[0083] Function: Real-time detection of tension in each bundle of threads.

[0084] type:

[0085] Mechanical sensors: These sensors detect changes in tension using springs or other elastic elements and convert them into displacement signals.

[0086] Electronic sensors: These use strain gauges or piezoelectric materials to convert tension changes into electrical signals.

[0087] Tension controller

[0088] Function: Based on the data fed back by the sensor, calculate and output control signals to adjust the action of the tension regulating device.

[0089] type:

[0090] Analog controller: Uses analog circuits to process signals.

[0091] Digital controllers: These use microprocessors for data processing and typically offer higher precision and flexibility.

[0092] Tension Adjustment Mechanism

[0093] Function: Adjusts the tension of the thread according to the instructions issued by the controller.

[0094] Common types:

[0095] Friction wheel system: Tension is adjusted by changing the pressure of the friction wheel.

[0096] Magnetic powder clutch / brake: It uses a magnetic field to control the friction between powder particles, thereby adjusting the tension.

[0097] Pneumatic / hydraulic system: The tension is adjusted by changing the force acting on the yarn through air or hydraulic pressure.

[0098] Guide wheel and wire guide

[0099] Function: Guides the yarn through the tension adjustment device and ensures the stability of the yarn's path within the equipment.

[0100] Features:

[0101] Low-friction design: Reduces additional friction on the yarn, preventing damage to the yarn.

[0102] Adjustable angle: The path of the yarn can be adjusted as needed to optimize tension distribution.

[0103] Display and alarm systems

[0104] Function: Displays the current tension value in real time and issues an alarm when the tension exceeds the set range.

[0105] composition:

[0106] Display screen: Used to display the current tension value.

[0107] Alarm: When the tension exceeds the preset range, an audible and visual alarm signal will be emitted.

[0108] II. Working Principle of Tension Adjustment Device

[0109] Testing phase

[0110] Sensor detection: The tension sensor monitors the tension changes of each bundle of yarn in real time and converts this information into electrical signals or mechanical displacement signals.

[0111] Signal transmission: The sensor transmits the detected signal to the tension controller.

[0112] Control phase

[0113] Signal processing: The tension controller receives signals from the sensor and compares them with a preset target tension value.

[0114] Deviation calculation: The controller calculates the deviation between the actual tension and the target tension.

[0115] Generate control signal: Based on the deviation value, the controller generates a corresponding control signal to instruct the tension adjustment mechanism to make adjustments.

[0116] Adjustment phase

[0117] Action performed: The tension adjusting mechanism adjusts the force acting on the yarn according to the controller's instructions. For example:

[0118] Friction wheel system: Increase or decrease the pressure of the friction wheel to change the resistance when the thread passes through.

[0119] Magnetic powder clutch / brake: Changes the magnetic field strength to adjust the friction between powder particles.

[0120] Pneumatic / hydraulic system: Adjusting air or hydraulic pressure changes the force acting on the wire.

[0121] Feedback and Adjustment

[0122] Closed-loop control: The entire process forms a closed-loop control system. The tension sensor continuously monitors the tension change, and the controller continuously adjusts the action of the tension adjustment mechanism until the actual tension reaches the set value.

[0123] Automatic correction: If the tension exceeds the set range, the system will automatically correct it and trigger the alarm system if necessary.

[0124] III. Specific Application Examples

[0125] Suppose we have a wood loom whose tension adjustment device uses a magnetic powder clutch as the main adjustment mechanism. The following is the specific working process of this device:

[0126] Initial settings:

[0127] Set the target tension P_0 = 20 Newtons.

[0128] The tension coefficient is set to A = 10 N / mm, the minimum allowable diameter D_min = 0.5 mm, and the base tension value P_base = 15 N.

[0129] Real-time monitoring:

[0130] According to the tension sensor, the actual tension of a certain bundle of silk is P_t = 18 Newtons.

[0131] The diameter measurement result is D_s = 0.6 mm.

[0132] Calculate the deviation:

[0133] According to the formula P_t=A*(D_s-D_min)+P_base, the ideal tension P_ideal=10*(0.6-0.5)+15=16 Newtons is calculated.

[0134] The actual tension P_t = 18 Newtons, which is higher than the ideal tension of 16 Newtons.

[0135] Adjust the tension:

[0136] The controller issues a command to reduce the magnetic field strength of the magnetic powder clutch, thereby reducing the friction between the powder particles and thus reducing the tension acting on the wire.

[0137] After several adjustments, the tension gradually approached the set value of 20 Newtons.

[0138] Closed-loop control:

[0139] The tension sensor continues to monitor tension changes, and the controller continuously fine-tunes the magnetic field strength of the magnetic powder clutch based on the feedback information, eventually stabilizing the tension at around 20 Newtons.

[0140] Through the above steps, the tension regulating device can precisely control the tension of each bundle of yarns, ensuring that the fabric maintains a consistent tension during the weaving process, thereby improving the overall quality and aesthetics of the fabric.

[0141] The tension-adjusted warp threads are fixed on the warp beams of the wooden loom and arranged at a predetermined spacing S (unit: cm) to ensure that the distance between each warp thread is consistent. The formula for calculating the spacing S is S=L_len / N, where N is the total number of warp threads. This step uses the length L_len and the tension adjustment result. By arranging each warp thread evenly, the structural stability and aesthetics of the fabric are ensured, and irregular patterns or defects are avoided.

[0142] Start the wooden loom and begin preliminary weaving, checking the tension uniformity of each warp thread. If the tension deviation of a warp thread exceeds the allowable range, adjust the tension of that warp thread according to the formula Delta_P_t=|P_ti-P_avg|, where P_ti is the actual tension of a single warp thread and P_avg is the average tension of all warp threads. This step uses the tension P_t and the warp thread arrangement. By monitoring and adjusting the tension of each warp thread in real time, ensure that the tension of all warp threads is consistent, thereby improving the smoothness and quality of the fabric.

[0143] Suppose we have a batch of pre-processed yarn, with a measured diameter of 0.6 mm, a length of 100 meters, and a total of 1000 warp threads. We want to arrange these yarns on a wooden loom to form a basic framework.

[0144] Measure the diameter and length: D_s = 0.6 mm, L_len = 100 m, conforming to the standard diameter D_0 = 0.6 mm.

[0145] Set the tension adjustment device: set the tension coefficient A = 10 N / mm, the minimum allowable diameter D_min = 0.5 mm, the basic tension value P_base = 20 N, and calculate the tension as P_t = 10 * (0.6 - 0.5) + 20 = 21 N.

[0146] Fixing and arranging the warp threads: Set the total number of warp threads N=1000, and calculate the spacing as S=100 / 1000=0.1 cm.

[0147] Checking tension uniformity: Assuming the actual tension of a certain meridian is P_ti = 22 Newtons, and the average tension of all meridians is P_avg = 21 Newtons, then the tension deviation is Delta_P_t = |22 - 21| = 1 Newton. If the allowable range is ±0.5 Newtons, then the tension of that meridian needs to be adjusted.

[0148] By following the steps above, we can ensure that the diameter, tension, and spacing of each warp thread are at their optimal levels, thus providing a high-quality foundation for subsequent satin weaving processes.

[0149] Step 3: Introduce the weft line and use the shuttle embellishment technique. First, operate on the area designated for displaying the pattern. The specific process includes the following steps:

[0150] Determine the location and size of the patterned area, and record the width W_w (unit: cm) and length L_len (unit: cm) of each patterned area; the area A_area of ​​the patterned area is calculated by the formula A_area=W_w*L_len; by accurately measuring the size of the patterned area, we can ensure that the number of weft threads and other parameters required for subsequent calculations are more accurate, thereby ensuring the clarity and aesthetics of the patterned design.

[0151] Select the weft threads of the color and material of the patterned area and measure their diameter D_w (unit: mm); calculate the required number of weft threads N based on the area A_area of ​​the patterned area and the diameter D_w of the weft thread, using the formula N=A_area / (D_w*D_w*π / 4); this step references the area A_area of ​​the patterned area; by calculating the required number of weft threads, ensure that the patterned area has sufficient weft thread coverage, thereby guaranteeing the integrity and clarity of the pattern.

[0152] The selected weft yarn is introduced into the wooden loom through the shuttle device, and the tension P_w (unit: Newton) of the weft yarn is adjusted to meet the preset standard value P_0. The relationship between the weft yarn tension P_w and the weft yarn diameter D_w is determined by the formula P_w=B*D_w+P_base, where B is the weft yarn tension coefficient and P_base is the base tension value. The weft yarn diameter D_w is used in this step. By adjusting the tension of the weft yarn, it is ensured that each weft yarn maintains appropriate tension during the weaving process, avoiding being too loose or too tight, thereby ensuring the flatness and strength of the fabric.

[0153] Begin weaving within the patterned area, controlling the weaving density P_d (unit: threads / cm) of each row of weft threads to ensure a clear pattern. The weaving density P_d is determined by the formula P_d=N / L_len, where N is the number of weft threads and L_len is the length of the patterned area. This step uses the number of weft threads N and the length of the patterned area L_len. By controlling the weaving density, ensure that there are enough weft threads per centimeter to make the pattern clearly visible and avoid blurry or uneven patterns.

[0154] Suppose there is a patterned area with a measured width of 20 cm, a length of 30 cm, and a weft diameter of 0.5 mm. We wish to weave this area using the open shuttle weaving technique.

[0155] Determine the location and size of the flower-revealing area: W_w = 20 cm, L_len = 30 cm, and calculate the area of ​​the flower-revealing area as A_area = 20 * 30 = 600 square centimeters.

[0156] Select the latitude line and calculate the quantity: Assuming the diameter of the latitude line D_w = 0.5 mm, the required number of latitude lines is N = 600 / (0.5 * 0.5 * π / 4) ≈ 3056.

[0157] Adjusting the weft tension: Set the weft tension coefficient B = 8 N / mm, and the base tension value P_base = 15 N, then the weft tension is P_w = 8 * 0.5 + 15 = 19 N.

[0158] Controlling the weave density: With the number of weft threads N=3056 and the length of the patterned area L_len=30 cm, the weave density is P_d=3056 / 30≈102 threads / cm.

[0159] By following the steps above, we can ensure that the number of weft threads, tension, and weaving density in the patterned area are at their optimal levels, thereby guaranteeing the clarity and aesthetics of the pattern and improving the overall quality of the satin fabric.

[0160] Step 4: Adjust the position of the weft threads to ensure that the colored weft threads are visible on the front side of the fabric, while keeping the back side neat. The specific process includes the following steps:

[0161] Measure the exposed length L_f (unit: mm) of each weft thread on the front side of the fabric in the pattern display area; determine the ideal exposed length L_ideal for each weft thread according to the pattern display design requirements; the calculation formula is L_f=L_ideal+Delta_L, where Delta_L is an adjustment value used to compensate for errors in actual operation; by accurately measuring and adjusting the exposed length of each weft thread, ensure that the pattern display is clear and meets the design requirements, and avoid blurry or uneven patterns.

[0162] Based on the measurement results, the position of the weft thread in the shuttle device is adjusted so that the exposed length of the weft thread is close to the ideal value. The adjustment amount is determined by the formula Delta_P=(L_f-L_ideal) / K_p, where K_p is the adjustment coefficient used to control the magnitude of each adjustment. This step uses the exposed length L_f and the ideal exposed length L_ideal. By adjusting the position of the weft thread in the shuttle device, the exposed length of each weft thread is ensured to be as close as possible to the ideal value, thereby ensuring the clarity and aesthetics of the pattern.

[0163] After adjusting the weft yarn position, check the weft yarn arrangement on the back of the fabric and record the uniformity Q_b (unit: dimensionless) of each weft yarn on the back. The value ranges from 0 to 1, with 1 indicating complete uniformity. By checking the weft yarn arrangement on the back of the fabric, we can ensure that the weft yarns are arranged neatly, avoiding irregularities or unevenness, thereby improving the overall quality of the fabric. The formula for calculating uniformity Q_b is Q_b = 1 - (Sum(|Delta_Y|) / Y_max), where Delta_Y is the actual deviation of each weft yarn, and Y_max is the maximum allowable deviation; the adjustment amount Delta_P used in this step is...

[0164] Suppose there is a patterned area, and the ideal exposed length of each weft thread is measured to be 5 mm, with an adjustment value of 0.2 mm. The goal is to adjust the weft thread positions to ensure their exposed length on the front side of the fabric meets the requirements and to check the neatness on the back side.

[0165] Measure the length of the weft thread exposed on the right side of the fabric:

[0166] Assuming L_ideal = 5 mm and Delta_L = 0.2 mm, the actual exposed length is L_f = 5 + 0.2 = 5.2 mm.

[0167] Adjust the position of the parallels of latitude:

[0168] Assuming L_f = 5.2 mm, L_ideal = 5 mm, and K_p = 2, the adjustment amount is Delta_P = (5.2 - 5) / 2 = 0.1 mm.

[0169] Check the weft arrangement on the back of the fabric:

[0170] Assuming the actual deviation of a certain latitude line Delta_Y = 0.3 mm and the maximum allowable deviation Y_max = 1 mm, then the uniformity is Q_b = 1 - (0.3 / 1) = 0.7.

[0171] By following the steps above, we can ensure that the exposed length of each weft thread on the front side of the fabric meets the design requirements, while maintaining the neat arrangement of the weft threads on the back side of the fabric, thereby improving the overall quality and aesthetics of the satin fabric.

[0172] Step 5: Next, turn to the non-patterned area and weave the colored weft into the back side. The specific process includes the following steps:

[0173] Determine the location and size of the non-patterned areas, and record the width W_w (unit: cm) and length L_len (unit: cm) of each non-patterned area; the area A_area of ​​the non-patterned area is calculated by the formula A_area=W_w*L_len; by accurately measuring the size of the non-patterned areas, we can ensure that the number of weft threads and other parameters required for subsequent calculations are more accurate, thereby ensuring the smooth progress of the weaving process and the consistency of fabric quality.

[0174] Select the weft thread of the color and material of the non-patterned area and measure its diameter D_w (unit: mm); calculate the required number of weft threads N based on the area A_area of ​​the non-patterned area and the diameter D_w of the weft thread, using the formula N=A_area / (D_w*D_w*π / 4); this step uses the area A_area of ​​the non-patterned area; by calculating the required number of weft threads, ensure that the non-patterned area has sufficient weft thread coverage, thereby ensuring that the back is neat and no weft threads are exposed on the front.

[0175] Adjust the angle θ (unit: degrees) of the shuttle device so that the weft yarn can be woven on the back side of the non-patterned area without showing the front side; the relationship between the angle θ and the weft diameter D_w is determined by the formula θ=C*D_w+θ_base, where C is the angle adjustment coefficient and θ_base is the base angle value; the weft diameter D_w is used in this step; by adjusting the angle of the shuttle device, it is ensured that the weft yarn is woven on the back side of the non-patterned area without showing the front side, thereby ensuring the overall aesthetics and structural stability of the fabric.

[0176] Begin weaving in the non-patterned area, controlling the weaving density P_d (unit: threads / cm) of each row of weft threads to ensure the back is neat and no weft threads are exposed on the front. The weaving density P_d is determined by the formula P_d=N / L_len, where N is the number of weft threads and L_len is the length of the non-patterned area. The number of weft threads N and the length of the non-patterned area L_len are used in this step. By controlling the weaving density, ensure that there are enough weft threads per centimeter, so that the back is neat and no weft threads are exposed on the front, avoiding irregularities or unevenness.

[0177] Suppose there is a non-patterned area with a measured width of 25 cm, a length of 40 cm, and a weft diameter of 0.6 mm. The goal is to weave the colored weft into the back of this area.

[0178] Determine the location and size of the non-flowering area:

[0179] Assuming W_w = 25 cm and L_len = 40 cm, the area of ​​the non-flowering region is A_area = 25 * 40 = 1000 square centimeters.

[0180] Select the latitude and calculate the quantity:

[0181] Assuming the diameter of the parallel is D_w = 0.6 mm, the required number of parallels is N = 1000 / (0.6 * 0.6 * π / 4) ≈ 3537.

[0182] Adjust the angle of the shuttle device:

[0183] Assuming the angle adjustment factor C = 5 degrees / mm and the base angle value θ_base = 10 degrees, then the angle is θ = 5 * 0.6 + 10 = 13 degrees.

[0184] Controlling weaving density:

[0185] Assuming the number of weft threads N = 3537 and the length of the non-patterned area L_len = 40 cm, the weaving density is P_d = 3537 / 40 ≈ 88 threads / cm.

[0186] By following the steps above, we can ensure that the number of weft threads, the angle of the shuttle device, and the weaving density in the non-patterned areas are all at their optimal levels, thereby ensuring that the back is neat and no weft threads are exposed on the front, thus improving the overall quality and aesthetics of the satin fabric.

[0187] Step Six: Gradually complete the weaving of the entire fabric; the specific process includes the following steps:

[0188] Determine the total length L_total (in centimeters) and width W_total (in centimeters) of the entire fabric, and divide the fabric into multiple patterned and non-patterned areas; the area A_area of ​​each area is calculated by the formula A_area=W_w*L_len, where W_w is the width and L_len is the length; by accurately measuring and dividing the fabric into different areas, ensure the accurate size of each area, which facilitates subsequent calculations of the required number of weft threads and other parameter adjustments, thereby ensuring the overall quality and consistency of the fabric.

[0189] Based on the division results, calculate the number of latitude lines N required for each region; for areas with visible patterns, use the formula N=A_area / (D_wf*D_wf*π / 4); for areas without visible patterns, use the formula N=A_area / (D_wb*D_wb*π / 4), where D_wf and D_wb are the diameters (in millimeters) of the latitude lines in the areas with visible patterns and those without, respectively; this step uses the area A_area; by calculating the number of latitude lines required for each region, ensure that both areas with visible patterns and those without are covered by sufficient latitude lines, thereby guaranteeing the integrity of the pattern and the neatness of the back side.

[0190] Before weaving begins in each area, adjust the angle θ and tension P_w of the shuttle device to suit the needs of different areas. The angle θ is adjusted using the formula θ=C*D_w+θ_base, and the tension P_w is adjusted using the formula P_w=B*D_w+P_base, where C is the angle adjustment coefficient, B is the tension coefficient, and θ_base and P_base are the base angle value and base tension value, respectively. The weft diameter D_w is used in this step. By adjusting the angle and tension of the shuttle device, ensure that the weaving conditions of each area meet the requirements, avoid the phenomenon of weft threads being exposed on the front or back unevenly, and thus ensure the overall quality of the fabric.

[0191] The weaving process is performed area by area, and the weaving quality Q_q (unit: dimensionless) of the current area is checked after each weaving. Its value is between 0 and 1, where 1 indicates that it fully meets the design requirements. The formula for calculating the weaving quality Q_q is Q_q=1-(Sum(|Delta_X|) / X_max), where Delta_X is the actual deviation of each weft thread, and X_max is the maximum allowable deviation. If Q_q is lower than the set threshold, necessary adjustments are made. This step references the angle θ and tension P_w. By monitoring and adjusting the weaving quality of each area in real time, it is ensured that all areas meet the design requirements, avoiding defects or irregularities, thereby improving the overall aesthetics and structural stability of the fabric.

[0192] Suppose there is a piece of fabric with a total length of 200 cm and a total width of 150 cm. Divide the fabric into multiple patterned and non-patterned areas, one of which has a patterned area with a width of 30 cm and a length of 40 cm.

[0193] Determine the total length and width of the entire fabric piece, and divide it into sections:

[0194] Assuming the width of the flower-revealing area is W_w = 30 cm and the length is L_len = 40 cm, then the area of ​​the flower-revealing area is A_area = 30 * 40 = 1200 square centimeters.

[0195] Calculate the number of latitudes required for each region:

[0196] Flowering area: Assuming D_wf=0.5 mm, the required number of weft threads is N=1200 / (0.5*0.5*π / 4)≈6111.

[0197] Non-flowering area: Assuming D_wb=0.6 mm, the required number of weft threads is N=1200 / (0.6*0.6*π / 4)≈4244.

[0198] Adjust the angle and tension of the shuttle mechanism:

[0199] For the area where the flower pattern appears: Assuming C = 5 degrees / mm, θ_base = 10 degrees, and D_wf = 0.5 mm, the angle is θ = 5 * 0.5 + 10 = 12.5 degrees. Assuming B = 8 Newtons / mm and P_base = 15 Newtons, the tension is P_w = 8 * 0.5 + 15 = 19 Newtons.

[0200] Perform the weaving operation in each area and check the weaving quality:

[0201] Assuming the actual deviation of a certain weft thread is Delta_X = 0.2 mm, and the maximum allowable deviation is X_max = 0.5 mm, then the weaving quality is Q_q = 1 - (0.2 / 0.5) = 0.6. If the threshold is set to 0.7, then necessary adjustments are required.

[0202] By following the steps above, it can be ensured that each area of ​​the fabric is woven to a high standard according to the design requirements, thereby improving the overall quality and aesthetics of the satin fabric.

[0203] Step 7: Reinforce the points where the warp and weft intersect, ensuring these points remain discontinuous without compromising the overall structural stability. The specific process includes the following steps:

[0204] Measure the position coordinates (X_x, Y_y) of each warp and weft interlacing point, where X_x is the coordinate of the weft line (unit: cm) and Y_y is the coordinate of the warp line (unit: cm); record the actual position of each interlacing point and calculate its deviation from the ideal position, Delta_X_x and Delta_Y_y; the deviation values ​​are calculated using the formulas Delta_X_x = X_x - X_ideal and Delta_Y_y = Y_y - Y_ideal, where X_ideal and Y_ideal are the coordinates of the ideal position, respectively; by accurately measuring the actual position of each warp and weft interlacing point and its deviation from the ideal position, the subsequent reinforcement treatment is ensured to be more accurate, thereby guaranteeing the overall structural stability and aesthetics of the fabric.

[0205] Based on the measurement results, select reinforcement materials, such as filaments or fiber bundles, ensuring that their diameter D_r (unit: mm) matches the size of the warp and weft interlacing points; the amount N of reinforcement material is determined by the formula N=(Delta_X_x^2+Delta_Y_y^2) / D_r^2 to compensate for deviations in actual weaving; this step references the deviation values ​​Delta_X_x and Delta_Y_y; by selecting appropriate reinforcement materials and determining the required quantity, ensure that each warp and weft interlacing point is effectively reinforced, thereby enhancing the overall structural stability of the fabric.

[0206] The reinforcing material is fixed to each warp and weft interlacing point manually or mechanically. The angle θ (unit: degrees) of the reinforcing material is adjusted to align with the direction of the warp and weft lines. The formula for adjusting the angle θ is θ=atan(Delta_Y_y / Delta_X_x), ensuring that the reinforcing material can effectively enhance the stability of the interlacing point without affecting its discontinuity. The amount N and diameter D_r of the reinforcing material are referenced in this step. By adjusting the angle of the reinforcing material, its direction is ensured to be consistent with the warp and weft lines, thereby effectively enhancing the stability of the interlacing point while maintaining its discontinuity and avoiding affecting the overall flexibility of the fabric.

[0207] Check the strength S_s (unit: Newtons) of the reinforced warp and weft interlacing points and record its value; the formula for calculating the strength S_s is S_s=K_s*(D_r*N), where K_s is the strength coefficient used to evaluate the reinforcement effect; if the strength S_s is lower than the set threshold, additional reinforcement is performed; this step takes into account the angle θ and the amount of reinforcement material N; by monitoring and evaluating the strength of each warp and weft interlacing point in real time, ensure that all interlacing points meet the design requirements, avoid structural instability, and thus improve the overall quality and durability of the fabric.

[0208] Suppose there is a latitude-longitude intersection point. The measured actual latitude position X_x = 5.2 cm, the ideal latitude position X_ideal = 5 cm, the actual longitude position Y_y = 3.1 cm, and the ideal longitude position Y_ideal = 3 cm. We want to reinforce this point.

[0209] Measure the coordinates of each latitude and longitude intersection point:

[0210] Assuming X_x = 5.2 cm and X_ideal = 5 cm, the deviation of the latitude line position is Delta_X_x = 5.2 - 5 = 0.2 cm. Assuming Y_y = 3.1 cm and Y_ideal = 3 cm, the deviation of the longitude line position is Delta_Y_y = 3.1 - 3 = 0.1 cm.

[0211] Choose reinforcement materials:

[0212] Assuming the diameter of the reinforcing material is D_r = 0.3 mm, the number of reinforcing materials is N = (0.2^2 + 0.1^2) / (0.3^2) ≈ 0.44 pieces, which is rounded down to 1 piece.

[0213] Fixed reinforcement materials:

[0214] Assuming the latitude deviation Delta_X_x = 0.2 cm and the longitude deviation Delta_Y_y = 0.1 cm, the angle of the reinforcing material is θ = atan(0.1 / 0.2) ≈ 26.57 degrees.

[0215] Check the strength of the reinforced warp and weft intersections:

[0216] Assuming a strength coefficient K_s = 10 N / mm, a reinforcing material diameter D_r = 0.3 mm, and a reinforcing material quantity N = 1 piece, the strength of the reinforced warp and weft interlacing point is S_s = 10 * (0.3 * 1) = 3 N. If the strength threshold is set to 5 N, additional reinforcement is required.

[0217] By following the steps above, each warp and weft interlacing point can be effectively reinforced, thereby improving the overall structural stability and durability of the satin fabric.

[0218] Step 8: Next, manually adjust each long float to ensure even distribution. The specific process includes the following steps:

[0219] Measure the actual length L_len (in centimeters) of each long float and its position coordinates (X_x, Y_y) on the fabric, where X_x is the weft position coordinate (in centimeters) and Y_y is the warp position coordinate (in centimeters). Record the initial length and position deviation Delta_X_x and Delta_Y_y of each long float. The deviation values ​​are calculated using the formulas Delta_X_x = X_x - X_ideal and Delta_Y_y = Y_y - Y_ideal, where X_ideal and Y_ideal are the ideal position coordinates, respectively. By accurately measuring the actual length and position deviation of each long float, subsequent adjustments are made more accurately, thereby ensuring the uniform distribution and overall aesthetics of the long floats.

[0220] Based on the measurement results, the required length change Delta_L_l for each long float is calculated. The adjustment amount is determined by the formula Delta_L_l=(Delta_X_x^2+Delta_Y_y^2) / L_len to compensate for deviations in actual weaving and ensure that the length of each long float is uniform. This step uses the length L_len and the deviation values ​​Delta_X_x and Delta_Y_y. By calculating and adjusting the length change of each long float, its length is ensured to be uniform, thereby improving the overall quality and aesthetics of the fabric.

[0221] Use hand tools to fine-tune each long float segment to achieve the ideal length. During adjustment, control the angle θ (in degrees) of each long float segment to align it with the direction of the warp and weft threads. The formula for adjusting the angle θ is θ=atan(Delta_Y_y / Delta_X_x), ensuring that the long floats are evenly distributed without affecting the overall structure. This step uses the length change Delta_L_l. By manually fine-tuning the length and angle of each long float segment, ensuring its even distribution without affecting the overall structure of the fabric, the fabric's aesthetics and luster are improved.

[0222] Check the uniformity and gloss G_g (unit: dimensionless) of each long float. The value is between 0 and 1, with 1 representing the optimal gloss. The formula for calculating gloss G_g is G_g=1-(Sum(|Delta_L_l|) / L_max), where Delta_L_l is the actual length deviation of each long float, and L_max is the maximum allowable length deviation. If the gloss G_g is lower than the set threshold, further manual fine-tuning is performed. This step uses the angle θ and the length change Delta_L_l. By monitoring and evaluating the uniformity and gloss of each long float in real time, ensure that all long floats meet the design requirements, avoid irregularities or unevenness, and thus improve the overall quality and aesthetics of the fabric.

[0223] Suppose there is a long floating line with measured actual latitude position X_x = 6.3 cm, ideal latitude position X_ideal = 6 cm, actual longitude position Y_y = 4.2 cm, and ideal longitude position Y_ideal = 4 cm. The goal is to manually adjust the line to make its distribution uniform.

[0224] Measure the actual length and position coordinates of each long floating line segment:

[0225] Assuming the actual latitude position X_x = 6.3 cm and the ideal latitude position X_ideal = 6 cm, then the deviation of the latitude position is Delta_X_x = 6.3 - 6 = 0.3 cm. Assuming the actual longitude position Y_y = 4.2 cm and the ideal longitude position Y_ideal = 4 cm, then the deviation of the longitude position is Delta_Y_y = 4.2 - 4 = 0.2 cm.

[0226] Calculate the amount of length change that needs to be adjusted for each segment of the float:

[0227] Assuming the actual length of the long float is L_len = 10 cm, the position deviation of the latitude line is Delta_X_x = 0.3 cm, and the position deviation of the longitude line is Delta_Y_y = 0.2 cm, then the change in length is Delta_L_l = (0.3^2 + 0.2^2) / 10 ≈ 0.013 cm.

[0228] Use hand tools to fine-tune each long floating line:

[0229] Assuming the latitude deviation Delta_X_x = 0.3 cm and the longitude deviation Delta_Y_y = 0.2 cm, the angle of the long float is θ = atan(0.2 / 0.3) ≈ 33.69 degrees.

[0230] Check the uniformity and gloss of each long floating line segment:

[0231] Assuming the actual length deviation of a certain long floating line is Delta_L_l = 0.013 cm, and the maximum allowable length deviation is L_max = 0.1 cm, then the gloss level is G_g = 1 - (0.013 / 0.1) = 0.87. If the gloss level threshold is set to 0.9, further manual fine-tuning is required.

[0232] By following the steps above, it can be ensured that each long float is evenly distributed without affecting the overall structure, thereby improving the overall quality and aesthetics of the satin fabric.

[0233] Step Nine: Finally, tidy up the completed Guangdu silk; the specific process includes the following steps:

[0234] Measure the overall dimensions of the finished Guangduan satin, recording its length L (in centimeters) and width W (in centimeters); calculate the actual area S_area of ​​the Guangduan satin using the formula S_area=L*W; simultaneously, record the flatness F (dimensionless) of each area, with a value between 0 and 1, where 1 indicates complete flatness; the formula for calculating flatness F is F=1-(Sum(|Delta_Z|) / Z_max), where Delta_Z is the actual flatness deviation of each section of fabric, and Z_max is the maximum allowable flatness deviation; by accurately measuring the dimensions and flatness of the finished Guangduan satin, subsequent ironing, cutting, and quality inspection are ensured to be more accurate, thereby guaranteeing the high quality and consistency of the final product.

[0235] Based on the measurement results, the satin was smoothed using ironing equipment, adjusting the ironing temperature T (unit: degrees Celsius) and pressure P (unit: Pascals). The ironing temperature T was determined by the formula T=T_base+C*F, and the ironing pressure P was determined by the formula P=P_base+D*(1-F), where T_base and P_base are the base temperature and base pressure, respectively, and C and D are adjustment coefficients. This step references the smoothness F. By adjusting the ironing temperature and pressure, the satin was ensured to achieve the best smoothness during ironing, while avoiding damage caused by overheating or overpressure, thus improving the surface quality and aesthetics of the fabric.

[0236] After smoothing, the satin is cut according to design requirements to determine the final size. The length L_trim (in centimeters) and width W_trim (in centimeters) after cutting are calculated using the formulas L_trim=L-Delta_L and W_trim=W-Delta_W, where Delta_L and Delta_W are the trimming amounts for length and width, respectively. This ensures that the cut satin conforms to design specifications and maintains its flatness. The ironing temperature T and pressure P used in this step are also considered. Precise cutting of the satin ensures that its dimensions meet design requirements while maintaining flatness, thereby guaranteeing the high quality and consistency of the final product.

[0237] The cut satin fabric undergoes quality inspection, checking its surface smoothness (S_smooth, dimensionless) and overall uniformity (U, dimensionless), both values ​​ranging from 0 to 1, with 1 representing the optimal state. The formulas for calculating S_smooth and U_max are S_smooth = 1 - (Sum(|Delta_S|) / S_max) and U = 1 - (Sum(|Delta_U|) / U_max), where Delta_S and Delta_U represent the deviations from the actual smoothness and uniformity, respectively, and S_max and U_max are the maximum allowable deviations. If the smoothness or uniformity falls below a set threshold, necessary rework is performed. This step references the cutting dimensions L_trim and W_trim. By real-time monitoring and evaluation of the surface smoothness and overall uniformity of the satin, all indicators are ensured to meet design requirements, avoiding defects or irregularities, thereby improving the overall quality and aesthetics of the fabric.

[0238] Suppose we have a piece of finished satin with a length L = 200 cm and a width W = 150 cm. We want to iron, cut, and inspect its quality.

[0239] Measure the overall dimensions of the finished satin product:

[0240] The finished Guangduan satin has a length L = 200 cm and a width W = 150 cm, so its actual area is S_area = 200 * 150 = 30000 square centimeters. Assuming the actual flatness deviation of a certain section of fabric is Delta_Z = 0.2 cm, and the maximum allowable flatness deviation is Z_max = 0.5 cm, then the flatness is F = 1 - (0.2 / 0.5) = 0.6.

[0241] Use ironing equipment to smooth the satin:

[0242] Assuming a base temperature T_base = 150 degrees Celsius, a temperature adjustment factor C = 20 degrees Celsius (dimensionless), and a flatness factor F = 0.6, the ironing temperature is T = 150 + 20 * 0.6 = 162 degrees Celsius. Assuming a base pressure P_base = 2000 Pascals and a pressure adjustment factor D = 500 Pascals (dimensionless), the ironing pressure is P = 2000 + 500 * (1 - 0.6) = 2200 Pascals.

[0243] Cut the satin according to the design requirements:

[0244] Assuming the finished Guangduan satin has a length L = 200 cm, a width W = 150 cm, a length trimming amount Delta_L = 5 cm, and a width trimming amount Delta_W = 3 cm, then the trimmed length is L_trim = 200 - 5 = 195 cm, and the trimmed width is W_trim = 150 - 3 = 147 cm.

[0245] Quality inspection of the cut satin:

[0246] Assuming the actual smoothness deviation of a certain section of satin is Delta_S = 0.1 cm, and the maximum allowable smoothness deviation is S_max = 0.3 cm, then the smoothness is S_smooth = 1 - (0.1 / 0.3) ≈ 0.67. Assuming the actual uniformity deviation is Delta_U = 0.2 cm, and the maximum allowable uniformity deviation is U_max = 0.4 cm, then the uniformity is U = 1 - (0.2 / 0.4) = 0.5. If the thresholds for both smoothness and uniformity are set to 0.7, then necessary rework is required.

[0247] By following the steps above, it can be ensured that the finished Guangduan satin products meet high-quality standards during ironing, cutting, and quality inspection, thereby improving the overall quality and aesthetics of Guangduan satin fabrics.

[0248] In summary, this invention optimizes the weft threading technique to ensure that the colored weft threads are accurately exposed on the front side of the fabric in the patterned area, while maintaining a neat back side, significantly improving the clarity and aesthetics of the pattern. A special method is used to reinforce the warp and weft interlacing points, ensuring that these points remain discontinuous without affecting the overall structural stability, thus enhancing the fabric's durability and flexibility. Furthermore, meticulous manual adjustment of each long float ensures even distribution, increasing the fabric's surface luster. In conclusion, this invention significantly improves the quality consistency of satin fabrics, reduces the defect rate, and expands its application range in the high-end market, meeting the demand for high-quality fabrics.

[0249] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A satin weaving process, characterized in that, Includes the following steps: Select cooked silk thread as raw material, and perform preliminary treatment to make the cooked silk thread achieve the best flexibility; Based on the pre-treated molten silk thread, warp threads are arranged on a wooden loom to form a basic framework, which will be used throughout the entire weaving process; The weaver sitting on the loom controls the lifting of the corresponding warp threads by pulling the warp threads up and down according to the weaving rules prepared in the pattern book; after the jacquard is completed, the weaver sitting below the loom first uses his foot to step on the foot pedal to control the raising and lowering of the heald frame connected to it, so that the warp surface formed by the warp threads separates up and down to form a shed; next, the weaver sitting below the loom holds the shuttle loaded with weft threads to insert the weft. Introduce the weft and use the through shuttle weaving technique. First, operate in the area where the pattern is to be displayed, adjust the position of the weft to ensure that the colored weft is exposed on the front of the fabric, while keeping the back neat. Then, turn to the non-patterned area and weave the colored weft into the back, gradually completing the weaving of the entire piece of fabric. After the warp and weft threads are interwoven, use a reed to firmly press the newly woven weft thread in. This step only completes the weaving of one weft thread. By continuously changing the foot pedal, the warp threads are alternately changed up and down to achieve the weaving of the entire pattern. The warp and weft interlacing points are reinforced to ensure that these points remain discontinuous without affecting the overall structural stability. Then, each long floating thread is manually adjusted to ensure even distribution. Finally, the completed satin is steamed and ironed. The step of adjusting the position of the weft threads to ensure that the colored weft threads are exposed on the front side of the fabric while maintaining the neatness of the back side includes: measuring the exposed length of each weft thread on the front side of the fabric in the pattern display area, and determining the ideal exposed length of each weft thread according to the pattern display design requirements; adjusting the position of the weft threads in the shuttle device based on the measurement results so that the exposed length of the weft threads is close to the ideal value; and after adjusting the position of the weft threads, checking the arrangement of the weft threads on the back side of the fabric to ensure that the weft threads are neatly arranged on the back side. The step of turning to the non-patterned area and weaving the colored weft into the back includes: determining the position and size of the non-patterned area, and recording the width and length of each non-patterned area; selecting the weft yarn of the corresponding color and material for the non-patterned area and measuring its diameter, and calculating the required number of weft yarns based on the area of ​​the non-patterned area; adjusting the angle of the shuttle device so that the weft yarn can be woven on the back of the non-patterned area without being exposed on the front; starting the weaving operation in the non-patterned area, controlling the weaving density of each row of weft yarns to ensure that the back is neat and no weft yarns are exposed on the front.

2. The satin weaving process according to claim 1, characterized in that, The selection of spun yarn as raw material and the preliminary treatment to achieve optimal flexibility of the spun yarn include: When selecting processed silk threads, measure the initial diameter of each bundle of threads to ensure that it meets the predetermined standard range; Soak the selected molten silk thread in warm water to allow it to fully absorb water and swell. After soaking, the silk thread is stretched to ensure that it achieves optimal flexibility without being damaged. The stretched yarns are dried, the ambient humidity is controlled, and the drying time is recorded.

3. The satin weaving process according to claim 2, characterized in that, The basic framework is formed by arranging warp threads on a wooden loom based on the pre-treated spun silk thread, including: Measure the diameter of each bundle of warp threads and record its length to ensure that all warp threads have the same diameter; A tension adjustment device is installed on the wooden loom to adjust the tension applied to each bundle of molten silk as it passes through the tension adjustment device to the required level. The tension-adjusted molten silk threads are fixed on the warp beams of the wooden loom and arranged at predetermined intervals; Start the wooden loom and begin preliminary weaving, checking the tension uniformity of each warp thread; if the tension deviation of a certain warp thread exceeds the allowable range, make adjustments.

4. The satin weaving process according to claim 3, characterized in that, The introduction of the weft line, using the shuttle embellishment technique, is first performed on the area designated for displaying the pattern, including: Determine the location and size of the flower-revealing areas, and record the width and length of each flower-revealing area; Select the weft thread corresponding to the color and material of the patterned area, measure its diameter, and calculate the required number of weft threads based on the area of ​​the patterned area. The selected weft yarn is introduced into the wooden loom through the shuttle device, and the tension of the weft yarn is adjusted to the preset standard value; Begin weaving within the patterned area, controlling the weaving density of each weft row.

5. The satin weaving process according to claim 4, characterized in that, The process of gradually completing the weaving of the entire fabric includes: Determine the total length and width of the entire fabric. Perform the weaving operation on each area one by one, and check the weaving quality of the current area after each weaving is completed. If it does not meet the set threshold, make adjustments.

6. The satin weaving process according to claim 5, characterized in that, The reinforcement of the warp and weft intersections, ensuring that these points remain discontinuous without affecting the overall structural stability, includes: Measure the position coordinates of each latitude and longitude intersection point and record its deviation from the ideal position; Based on the measurement results, select reinforcement materials to ensure that their dimensions match the warp and weft intersection points; Fix the reinforcement material at each intersection of the latitude and longitude lines, and adjust the angle of the reinforcement material to align it with the direction of the latitude and longitude lines. Check the strength of the reinforced warp and weft intersections and record the values. If the strength is lower than the set threshold, perform additional reinforcement.

7. The satin weaving process according to claim 6, characterized in that, The process of manually adjusting each long float segment to ensure even distribution includes: Measure the actual length of each long float and its position coordinates on the fabric, and record the initial length and position deviation of each long float; Based on the measurement results, the amount of length change that needs to be adjusted for each long floating line is calculated to compensate for deviations in actual weaving; Use hand tools to fine-tune each long floating line to achieve the ideal length. During the adjustment process, control the angle of each long floating line to make it consistent with the direction of the latitude and longitude lines. Check the uniformity and gloss of each long floating line segment. If the gloss is below the set threshold, make manual adjustments.

8. The satin weaving process according to claim 7, characterized in that, The steaming and ironing of the completed satin includes: Measure the overall dimensions of the finished Guangduan (a type of satin), record its length and width, calculate the actual area of ​​the Guangduan, and record the flatness of each area. Based on the measurement results, the satin was smoothed using ironing equipment, and the ironing temperature and pressure were adjusted. After smoothing, the satin is cut according to the design requirements to determine the final size, ensuring that the cut satin meets the design specifications and maintains its flatness. The cut satin is subjected to quality inspection to check its surface smoothness and overall uniformity. If the smoothness or uniformity is lower than the set threshold, it is reworked.

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