Method for dynamically generating and controlling dosage of auxiliary agent in textile dyeing

Abstract

The invention relates to the technical field of textile, and discloses a method for dynamically generating and controlling the dosage of an auxiliary agent in textile dyeing, which is characterized by comprising the following steps: step 1, planning and designing an experiment: establishing an expert group, and performing a basic experiment on each dye and applicable cloth; 2, carrying out an experiment: 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 calculation model: analyzing and interpreting experimental process data and result data to obtain an experimental conclusion; the function model is formed through test data, the standard reaction conditions of the physical and chemical reaction can be obtained in different scenes through the model, then the initial value is detected, the condition difference required from the initial value to the standard conditions is calculated, and the corresponding auxiliary dosage is calculated according to the difference. Therefore, each reaction can be carried out under a standard condition, the success rate and the efficiency are improved, and the consumption of raw materials and the energy consumption are reduced.

Description

Technical Field

[0001] The invention relates to the field of textiles, in particular to a method for dynamically generating and controlling the dosage of auxiliary agents for textile dyeing. Background Art

[0002] The essence of textile dyeing is the physical and chemical reaction between dye molecules and fiber molecules. Auxiliary agents mainly play the role of assistance, promotion and adjustment in the textile dyeing process, which can improve the dyeing effect, increase the adhesion of dyes, and enhance the physical properties of textiles; accurate dosage of auxiliary agents can significantly affect the dyeing effect and the final quality of textiles, such as improving dyeing uniformity, enhancing dyeing fastness, and improving physical properties. Accurate dosage of auxiliary agents not only has a positive effect on dyeing effects, but also reduces the impact on the environment and improves economic benefits. Specifically, it reduces the use of chemical substances (accurately controlling the dosage of auxiliary agents can reduce the waste of chemical substances and reduce production costs), reduces the burden of wastewater treatment (excessive auxiliary agents will increase the difficulty of wastewater treatment, and accurate dosage can reduce the burden of wastewater treatment), and improves product quality (appropriate amount of auxiliary agents can ensure that textiles achieve the expected physical and chemical properties, improve product quality and market competitiveness). Accurate dosage of auxiliary agents plays an important role in the textile dyeing process, which can not only optimize the dyeing effect, but also improve the physical properties and environmental benefits of textiles.

[0003] At present, the traditional practice of printing and dyeing enterprises is: (1) The dosage of auxiliary agents relies on empirical values: according to different dye concentration ranges (white, light, medium, dark, black), 5 to 8 intervals are divided, and a fixed auxiliary agent dosage value is used for each concentration interval; the problem with this approach is that if the auxiliary agent dosage is insufficient, more dyes are needed, or a longer reaction time is required, which wastes dyes and time; if the auxiliary agent dosage is too sufficient, it will affect the coloring process, resulting in uneven coloring and waste of auxiliary agents. (2) For orders of the same color, after the color of the first cylinder is OK, the formula and dosage used are used as the standard, and the subsequent cylinders are produced using the standard formula of the first cylinder; however, due to the large uncertainty of the water quality used in the dyeing process (for example, in order to save sewage treatment costs, more and more dyeing plants use recycled water for dyeing, and the pH / conductivity of the water used in each cylinder may be different), after adding the auxiliary agent of the standard formula, the dye liquid environment cannot reach the standard pH / conductivity and other dyeing conditions of the first cylinder, which will have a great impact on the printing and dyeing reaction process, resulting in color addition or rework, increasing production costs and reducing production efficiency.

[0004] In summary, this application mainly has the following technical problems:

[0005] 1. Existing technologies often cannot be carried out under standard reaction conditions, resulting in low success rate and unstable quality;

[0006] 2. The low success rate of existing technologies leads to low efficiency, high dye auxiliaries and energy costs;

[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 lagging improvement in employee quality are an irreconcilable contradiction. Summary of the invention

[0009] The invention provides a method for dynamically generating and controlling the dosage of auxiliary agents in textile dyeing, so as to solve the problems raised in the background technology.

[0010] The present invention provides the following technical solution: a method for dynamically generating and controlling the amount of auxiliary agents used in textile dyeing, comprising the following steps:

[0011] Step 1: Plan and design experiments: form an expert group to conduct basic experiments on each dye and applicable fabric;

[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 calculation model: analyze the experimental process data and result data, and after judging the experimental conclusion, establish a data calculation model for generating dyeing conditions according to the influence conditions and relationships between different fabrics, different dyes, different concentrations, different dye combinations and the optimal dyeing conditions;

[0014] Step 4: Data verification: The technician enters the workshop and verifies the actual dyeing effect according to the dyeing conditions deduced from the data calculation model based on the actual production order and dye formula, and checks the validity of the data and data model. If there is any deviation, additional experiments will be planned and various parameters of the data calculation model will be corrected;

[0015] Step 5: Enter production order information and formula: The salesperson enters the order requirement information, and the laboratory enters the dye formula;

[0016] Step 6: When the order is put into the dyeing machine for production, water and cloth are fed into the dyeing machine, and the machine is operated for a period of time to allow the cloth to be fully soaked and evenly distributed;

[0017] Step 7: The expert system calculates the target conditions required for the dyeing reaction based on the order requirements and the dye formula using the above mathematical model;

[0018] Step 8: Before injecting the auxiliaries, first detect the pH and conductivity starting values ​​of the water in the dyeing machine;

[0019] Step 9: The expert system calculates the amount of auxiliary agent required to achieve the target conditions based on the difference between the target conditions required for the dyeing reaction and the conditions obtained by the current test;

[0020] Step 10: The workshop is equipped with an auxiliary agent delivery system that matches the dyeing machine. The expert system directly sends the auxiliary agent dosage calculation result to the auxiliary agent delivery system to complete the automation of the entire process of detection, calculation, and delivery.

[0021] Step 11: After the auxiliaries are added to the dyeing machine, re-check whether the dyeing liquid environment meets the suitable dyeing conditions; if not, recalculate the difference between the current conditions and the target conditions, and add auxiliaries or water;

[0022] Step 12: After the detection reaches the suitable dyeing conditions, the dyeing machine continues to perform the subsequent dyeing process until the dyeing is completed.

[0023] Preferably, in step 1, the basic experiments include experiments on the dependence of each dye on dyeing conditions at different concentrations and experiments on different dye combinations; the dyeing conditions include pH and conductivity.

[0024] Preferably, in step 5, the order requirement information entered includes customer, fabric, quality requirements, color fastness requirements, and testing standard requirements.

[0025] Preferably, in the preferred step 8, an online dye liquid environment detector for detecting pH / conductivity is installed on the dyeing machine; when the process executes the detection step, the detection is turned on and the detection value is transmitted to the expert system; after the detection is completed, the detection can be turned off to protect the detector probe.

[0026] Preferably, the dye solution environment online detector is connected to the expert system through a first wireless communication module, and the expert system is connected to the plurality of mobile terminals through a second wireless communication module.

[0027] Preferably, step 5 is input through a mobile terminal when entering production order information and recipes, and the mobile terminal includes a data backup module, and the data backup module is used to back up the input data. The mobile terminal is provided with a data model library, and the data model library stores commonly used order information and recipe information.

[0028] Preferably, the mathematical calculation model includes a calculation module and a display module, the calculation module constructs a function of the influence of different fabrics, different dyes, different concentrations, different dye combinations and optimal dyeing conditions, and the display module constructs a function image of the influence of different fabrics, different dyes, different concentrations, different dye combinations and optimal dyeing conditions.

[0029] Preferably, the expert system is provided with an expert management port, and the expert management port is used to verify expert login and input and store expert evaluation data.

[0030] The present invention has the following beneficial effects:

[0031] The present invention conducts auxiliary agent dependency experiments for auxiliary agents suitable for different fabrics and dyes of different concentrations, and obtains a data relationship model between different fabrics, different dyes, different concentrations and the best dyeing conditions (PH value, conductivity, etc.); in view of the problem of unstable water quality in production water, by detecting the initial condition value (PH value, conductivity, etc.) of the water in the dyeing machine before injecting the auxiliary agent, combined with the target value of the dyeing condition required by this order, the required auxiliary agent dosage is directly calculated using the above model. In this way, it can be ensured that the fabric and the dye undergo a dyeing reaction under the best reaction conditions, thereby ensuring the stability and controllability of the printing and dyeing reaction process, improving the one-time success rate of color, reducing the cost of dye auxiliary agents and energy costs, and improving efficiency. The principle of this patent is to obtain the standard conditions (conductivity, pH value, reaction temperature, reaction time, etc.) of physical and chemical reactions under different sample data through a large number of experiments, and to form a function model through the experimental data. Through this model, the standard reaction conditions of physical and chemical reactions can be obtained under different scenarios. Then, the starting value is detected, and the condition difference from the starting value to the standard condition is calculated. The corresponding amount of additives is calculated based on the difference, so that each reaction can be carried out under standard conditions, which improves the success rate and efficiency and reduces energy consumption. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 This is the system block diagram of the traditional model;

[0033] Figure 2 It is a system block diagram of the present invention. DETAILED DESCRIPTION

[0034] 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.

[0035] For example, see Figure 1 and Figure 2 A method for dynamically generating and controlling the amount of auxiliary agents for dyeing textiles comprises the following steps:

[0036] Step 1: Plan and design experiments: form an expert group to conduct basic experiments on each dye and applicable fabric;

[0037] 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;

[0038] Step 3, establish a mathematical calculation model: analyze the experimental process data and result data, and after judging the experimental conclusion, establish a data calculation model for generating dyeing conditions according to the influence conditions and relationships between different fabrics, different dyes, different concentrations, different dye combinations and the optimal dyeing conditions;

[0039] Step 4: Data verification: The technician enters the workshop and verifies the actual dyeing effect according to the dyeing conditions deduced from the data calculation model based on the actual production order and dye formula, and checks the validity of the data and data model. If there is any deviation, additional experiments will be planned and various parameters of the data calculation model will be corrected;

[0040] Step 5: Enter production order information and formula: The salesperson enters the order requirement information, and the laboratory enters the dye formula;

[0041] Step 6: When the order is put into the dyeing machine for production, water and cloth are fed into the dyeing machine, and the machine is operated for a period of time to allow the cloth to be fully soaked and evenly distributed;

[0042] Step 7: The expert system calculates the target conditions required for the dyeing reaction based on the order requirements and the dye formula using the above mathematical model;

[0043] Step 8: Before injecting the auxiliaries, first detect the pH and conductivity starting values ​​of the water in the dyeing machine;

[0044] Step 9: The expert system calculates the amount of auxiliary agent required to achieve the target conditions based on the difference between the target conditions required for the dyeing reaction and the conditions obtained by the current test;

[0045] Step 10: The workshop is equipped with an auxiliary agent delivery system that matches the dyeing machine. The expert system directly sends the auxiliary agent dosage calculation result to the auxiliary agent delivery system to complete the automation of the entire process of detection, calculation, and delivery.

[0046] Step 11: After the auxiliaries are added to the dyeing machine, re-check whether the dyeing liquid environment meets the suitable dyeing conditions; if not, recalculate the difference between the current conditions and the target conditions, and add auxiliaries or water;

[0047] Step 12: After the detection reaches the suitable dyeing conditions, the dyeing machine continues to perform the subsequent dyeing process until the dyeing is completed.

[0048] Among them, in step 1, the basic experiments include experiments on the dependence of each dye on dyeing conditions at different concentrations and experiments on different dye combinations; the dyeing conditions include pH and conductivity.

[0049] Among them, in step 5, the order requirement information entered includes customer, fabric, quality requirements, color fastness requirements, and testing standard requirements.

[0050] Among them, in the preferred step 8, an online dye liquid environment detector for detecting pH / conductivity is installed on the dyeing machine; when the process executes to the detection step, the detection is turned on and the detection value is transmitted to the expert system; after the detection is completed, the detection can be turned off to protect the detector probe.

[0051] The dye solution environment online detector is connected to the expert system through a first wireless communication module, and the expert system is connected to the mobile terminals through a second wireless communication module.

[0052] Among them, step 5 is input through a mobile terminal when entering production order information and recipes. The mobile terminal includes a data backup module, which is used to back up the input data. A data model library is set in the mobile terminal, and the data model library stores commonly used order information and recipe information.

[0053] Among them, the mathematical calculation model includes a calculation module and a display module. The calculation module constructs a function of the influence between different fabrics, different dyes, different concentrations, different dye combinations and optimal dyeing conditions, and the display module constructs a function image of the influence between different fabrics, different dyes, different concentrations, different dye combinations and optimal dyeing conditions.

[0054] The expert system is provided with an expert management port, which is used to verify expert login and input and store expert evaluation data.

[0055] Among them, the present invention conducts auxiliary agent dependency experiments for auxiliary agents suitable for different fabrics and different concentrations of dyes, and obtains a data relationship model between different fabrics, different dyes, different concentrations and the best dyeing conditions (PH value, conductivity, etc.); for the problem of unstable water quality of production water, by detecting the initial condition value (PH value, conductivity, etc.) of the water in the dyeing machine before injecting the auxiliary agent, combined with the target value of the dyeing condition required by this order, the required auxiliary agent dosage is directly calculated using the above model. In this way, it can be ensured that the fabric and dye undergo dyeing reaction under the best reaction conditions, thereby ensuring the stability and controllability of the printing and dyeing reaction process, improving the one-time success rate of color, reducing the cost of dye auxiliary agents and energy costs, and improving efficiency. The principle of this patent is to obtain the standard conditions (conductivity, pH value, reaction temperature, reaction time, etc.) of physical and chemical reactions under different sample data through a large number of experiments, and to form a function model through the experimental data. Through this model, the standard reaction conditions of physical and chemical reactions can be obtained under different scenarios. Then, the starting value is detected, and the condition difference from the starting value to the standard condition is calculated. The corresponding amount of additives is calculated based on the difference, so that each reaction can be carried out under standard conditions, which improves the success rate and efficiency and reduces energy consumption.

[0056] The essence of textile dyeing is the physical and chemical reaction between dye molecules and fiber molecules. Auxiliary agents mainly play the role of assisting, promoting and adjusting in the textile dyeing process. The precise amount of auxiliary agents can not only improve the dyeing effect and product quality, but also optimize the cost and environmental benefits.

[0057] The existing technology is driven by experience. When receiving an order, the first cylinder sample is made first. After the first cylinder is successful, the process and formula are fixed. The subsequent cylinder processing is to copy the formula and process of the first cylinder. The formula and process are not the reaction conditions of physical and chemical reactions. The actual production conditions of printing and dyeing enterprises are due to different seasonal weather, which leads to different water indicators (such as conductivity, pH value). The existing technology copies the fixed formula dosage, which often leads to chemical reactions that cannot be carried out under standard conditions, resulting in deviations in reaction results, unstable quality, low efficiency, high energy consumption, and high pollution.

[0058] The principle of this patent is to obtain the standard conditions (conductivity, pH value, reaction temperature, reaction time, etc.) of physical and chemical reactions under different sample data through a large number of experiments, and form a function model through the experimental data. Through this model, the standard reaction conditions of physical and chemical reactions can be obtained under different scenarios, and then the starting value is detected, and the condition difference from the starting value to the standard condition is calculated. According to the difference, the corresponding amount of additives is calculated, so that each reaction can be carried out under standard conditions, which improves the success rate, efficiency and reduces energy consumption.

[0059] The key points of the present invention are: 1. obtaining standard reaction conditions under limited scenarios (sample data) through experiments; 2. forming a fitting function through limited sample data to calculate standard reaction conditions under various scenarios; 3. detecting the actual starting condition value of the dyeing reaction; 4. calculating the required amount of auxiliary agent from the difference between the starting condition and the target condition; 5. replicating the reaction conditions and then calculating the corresponding amount of auxiliary agent instead of a fixed amount of auxiliary agent;

[0060] The above are only preferred embodiments of the present invention. It should be pointed out that, for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the technical principles of the present invention. These improvements and modifications should also be regarded as within the scope of protection of the present invention.

Claims

1. A method for dynamically generating and controlling the amount of auxiliary agents for textile dyeing, characterized in that: The following steps are involved: Step 1: Plan and design experiments: form an expert group to conduct basic experiments on each dye and applicable fabric; 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 calculation model: analyze the experimental process data and result data, and after judging the experimental conclusion, establish a data calculation model for generating dyeing conditions according to the influence conditions and relationships between different fabrics, different dyes, different concentrations, different dye combinations and the optimal dyeing conditions; Step 4: Data verification: The technician enters the workshop and verifies the actual dyeing effect according to the dyeing conditions deduced from the data calculation model based on the actual production order and dye formula, and checks the validity of the data and data model. If there is any deviation, additional experiments will be planned and various parameters of the data calculation model will be corrected; Step 5: Enter production order information and formula: The salesperson enters the order requirement information, and the laboratory enters the dye formula; Step 6: When the order is put into the dyeing machine for production, water and cloth are fed into the dyeing machine, and the machine is operated for a period of time to allow the cloth to be fully soaked and evenly distributed; Step 7: The expert system calculates the target conditions required for the dyeing reaction based on the order requirements and the dye formula using the above mathematical model; Step 8: Before injecting the auxiliaries, first detect the pH and conductivity starting values ​​of the water in the dyeing machine; Step 9: The expert system calculates the amount of auxiliary agent required to achieve the target conditions based on the difference between the target conditions required for the dyeing reaction and the conditions obtained by the current test; Step 10: The workshop is equipped with an auxiliary agent delivery system that matches the dyeing machine. The expert system directly sends the auxiliary agent dosage calculation result to the auxiliary agent delivery system to complete the automation of the entire process of detection, calculation, and delivery. Step 11: After the auxiliaries are added to the dyeing machine, re-check whether the dyeing liquid environment meets the suitable dyeing conditions; if not, recalculate the difference between the current conditions and the target conditions, and add auxiliaries or water; Step 12: After the detection reaches the suitable dyeing conditions, the dyeing machine continues to perform the subsequent dyeing process until the dyeing is completed.

2. The method for dynamically generating and controlling the amount of auxiliary agents for textile dyeing according to claim 1, characterized in that: In step 1, the basic experiments include experiments on the dependence of each dye on dyeing conditions at different concentrations and experiments on different dye combinations; the dyeing conditions include pH and conductivity.

3. The method for dynamically generating and controlling the amount of auxiliary agents for textile dyeing according to claim 1, characterized in that: In step 5, the order requirement information entered includes customer, fabric, quality requirements, color fastness requirements, and testing standard requirements.

4. The method for dynamically generating and controlling the amount of auxiliary agents for textile dyeing according to claim 1, characterized in that: In the preferred step 8, an online dye liquid environment detector for detecting pH / conductivity is installed on the dyeing machine; when the process executes to the detection step, the detection is turned on and the detection value is transmitted to the expert system; after the detection is completed, the detection can be turned off to protect the detector probe.

5. The method for dynamically generating and controlling the amount of auxiliary agents for textile dyeing according to claim 4, characterized in that: The dye solution environment online detector is connected to the expert system through a first wireless communication module, and the expert system is connected to the plurality of mobile terminals through a second wireless communication module.

6. The method for dynamically generating and controlling the amount of auxiliary agents for textile dyeing according to claim 5, characterized in that: The step 5 is input through a mobile terminal when entering the production order information and recipe. The mobile terminal includes a data backup module, which is used to back up the input data. The mobile terminal is provided with a data model library, which stores commonly used order information and recipe information.

7. The method for dynamically generating and controlling the amount of auxiliary agents for textile dyeing according to claim 1, characterized in that: The mathematical calculation model includes a calculation module and a display module. The calculation module constructs a function of the influence between different fabrics, different dyes, different concentrations, different dye combinations and optimal dyeing conditions, and the display module constructs a function image of the influence between different fabrics, different dyes, different concentrations, different dye combinations and optimal dyeing conditions.

8. The method for dynamically generating and controlling the amount of auxiliary agents for textile dyeing according to claim 1, characterized in that: The expert system is provided with an expert management port, and the expert management port is used to verify expert login and input and store expert evaluation data.

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