Weaving process for wide yarns

Abstract

The invention discloses a wide yarn weaving process, which realizes accurate control of weft yarn density and tension by combining a layered manual weft insertion technology with zoning treatment and tension adjustment, and ensures that the weft yarn density and tension of each area are uniform and consistent, so that the flatness and texture uniformity of the surface of a fabric are remarkably improved. Meanwhile, the complicated manual drafting and shedding steps are simplified by optimizing operation parameters, and the definition and the detail reduction degree of the fabric are improved. In addition, the surface flatness of the finished fabric is detected, and the weft tension is adjusted according to the detection result, so that the surface of the whole fabric is further ensured to reach the preset flatness standard. The process effectively solves the problems of high pattern complexity and poor texture uniformity in traditional manual weaving, and finally realizes high-quality and high-precision fabric production.

Description

Technical Field

[0001] The invention belongs to the technical field of weaving, and in particular relates to a wide yarn weaving process. Background Art

[0002] In the traditional wide yarn weaving process, hand-weaving fabrics with complex patterns usually faces several major challenges. First, the control of weft density and tension often relies on the operator's experience and feel, which leads to inconsistencies in the surface flatness and texture uniformity of the fabric. Second, the manual drawing and lifting steps are cumbersome and complicated, especially when dealing with high-detail designs, which can easily lead to problems such as blurred patterns or lost details. Most existing solutions rely on experienced craftsmen to make manual adjustments, lacking a systematic and standardized operating process.

[0003] The existing yarn weaving process generally includes the following steps: Select the type and specification of yarn: Choose the appropriate yarn according to the design. Determine the density of the warp: Determine the density of the warp through the design or pattern. After determining the number of warp threads, manually draw the heddle. Manually lift the heddle and insert the weft: The heddle frame connected to it is controlled by the heddle worker pulling the flower or the weaver's hands and feet stepping on the rod, so that the "warp surface" formed by the warp threads is separated from top to bottom. The weaver holds the shuttle with the weft threads to "throw the shuttle and insert the weft". After the warp threads and the weft threads are interwoven together, the "reed" is used to compact the weft threads that have just been woven. This step only completes the weaving of one weft thread. The warp threads are alternately changed up and down by constantly changing the pedals to achieve the weaving of the entire design. Quality inspection: The final product is inspected for quality, and uneven areas are found and adjusted manually.

[0004] However, each of these steps is highly dependent on the operator's experience and feel, and it is difficult to ensure the consistency and accuracy of each operation. Especially for complex designs, it is more difficult to pull the heald, which can easily lead to problems such as unclear design details and uneven fabric surface. Summary of the invention

[0005] The purpose of the present invention is to provide a wide yarn weaving process, which realizes precise control of weft yarn density and tension through layered manual weft insertion technology, combined with zoning processing and tension adjustment, so as to solve the problems raised in the above background technology.

[0006] To achieve the above object, the present invention adopts the following technical scheme: a wide yarn weaving process, comprising the following steps: Confirm the warp density and quantity according to the design drawing or pattern book; select the type and specification of the yarn, determine the weft density according to the pattern book, mark the layering points on the pattern book, and perform zoning processing according to the density; based on the results of the zoning processing, adjust the predetermined tension of the weft yarn in each zone, and set the operation parameters of manual weft insertion according to the adjustment results of the predetermined tension; use the operation parameters to guide the manual heddle threading process; after completing the weaving of the broadcloth according to the lifting order, check the pattern details, perform surface flatness detection on the completed broadcloth weaving, and record the uneven areas; according to the position of the uneven areas, adjust the tension of the corresponding weft yarn until the entire surface of the broadcloth reaches the predetermined flatness standard.

[0007] Preferably, the steps of selecting the type and specification of the yarn and determining the weft density according to the pattern book include the following: Analyze the color and texture requirements of the design drawing to determine the basic yarn material, and select the yarn thickness standard according to the characteristics of the basic yarn material; Using the yarn thickness standard and combining with the detail complexity of the design drawing, divide the weft density levels of different regions; Based on the division of the weft density levels, observe whether the effect of the design drawing meets the expectations.

[0008] Preferably, the steps of marking the layering points on the pattern book and performing zoning processing according to the density include the following: Determine the optimal weft density of each region and record the density value; Use a marking tool to mark the starting and ending points of layering at the corresponding positions on the weft yarn according to the recorded density value; According to the positions of the starting and ending points of layering, divide the weft yarn into multiple continuous paragraphs, and each paragraph corresponds to a weft density level; Adjust the weft yarn within each paragraph to ensure that the spacing between the weft yarns is uniform and meets the requirements of the design drawing.

[0009] Preferably, the steps of adjusting the predetermined tension of the weft yarn in each zone based on the results of the zoning processing include the following: Determine the initial tension value required for each weft yarn paragraph according to the evenness of the weft yarn spacing within each paragraph; Set a tension adjusting device at one end of the weft yarn paragraph and input the initial tension value into the device; Use the tension adjusting device to gradually tighten the weft yarn until the set initial tension value is reached.

[0010] Preferably, the steps of setting the operation parameters of manual weft insertion according to the adjustment results of the predetermined tension include the following: According to the state of the weft yarn after the tension adjustment is completed, determine the actual tension value of each weft yarn paragraph and record the actual tension value.

[0011] Preferably, guiding the manual harness threading process using the operating parameters includes the following steps: Based on the adjusted manual strength and speed, formulate a harness threading order table and mark the manual harness threading points that require special attention; Using the marked harness threading points as a reference, gradually perform the manual harness threading operation according to the harness threading order table; After completing the preliminary harness threading, inspect the loom device and make adjustments to local areas based on the inspection results; Connect the large yarn and the dobby pattern, and check the harness lifting order according to the dobby pattern; Before starting the manual weft insertion operation, set the manual strength and speed for each weft insertion based on the actual tension value; Perform the initial weft insertion operation using the set manual strength and speed, observe whether the performance of the weft yarn in the wide yarn meets the expected effect, and adjust the manual strength and speed according to the results of the initial weft insertion operation.

[0012] Preferably, connecting the large yarn and the dobby pattern and checking the harness lifting order according to the dobby pattern includes the following steps: Based on the inspection results after the preliminary harness threading, determine the detailed areas of the drafting pattern that require special attention and record the specific positions of these areas; Based on the recorded detailed areas of the drafting pattern, formulate a harness lifting order plan, clarifying the harness lifting priority and operation order for each area; Using the harness lifting order plan, perform the harness lifting operation on each area in sequence, ensuring that the manual strength and speed during each harness lifting are consistent with those during the harness threading; After completing the harness lifting operation, check again whether the loom device fully meets the design requirements and make adjustments to local areas based on the inspection results.

[0013] Preferably, checking the detailed drafting pattern after completing the wide yarn weaving according to the harness lifting order includes the following steps: According to the priority and operation order determined in the harness lifting order plan, perform the harness lifting operation on each area in sequence. During the harness lifting operation, monitor the interweaving state of the weft yarn and warp yarn in real time, and record any abnormal situations and their positions; For the recorded abnormal situations, immediately perform on-site adjustments to correct the interweaving state of the weft yarn and warp yarn; After completing all the harness lifting operations, conduct a comprehensive inspection to confirm that the detailed drafting pattern of all areas meets the expected effect.

[0014] Preferably, detecting the surface flatness of the completed wide yarn weaving and recording the uneven areas includes the following steps: Perform a preliminary visual inspection on the entire surface of the Guangsha using a standard light source and a ruler tool, and mark all suspected uneven areas; For the marked suspected uneven areas, confirm their flatness by touching them by hand. For the areas where unevenness is confirmed, use a marking tool to mark on the back of the Guangsha and record the specific positions and degrees of each uneven point; Compile an inspection report, list all areas that need to be adjusted, and provide a reference basis for subsequent tension adjustment operations.

[0015] Preferably, adjusting the tension of the corresponding weft yarn according to the position of the uneven area until the entire surface of the Guangsha reaches a predetermined flatness standard includes the following steps: According to the positions and degrees of the uneven points marked in the inspection report, locate each weft yarn whose tension needs to be adjusted; Preliminarily set the tension adjustment values of the tension adjustment devices at both ends of the weft yarn according to the marked degree. Use the tension adjustment devices to gradually increase or decrease the tension of the weft yarn, and at the same time, check by touching by hand whether the area becomes flatter; After the preliminary adjustment is completed, use the standard light source and the ruler tool again to perform a final visual inspection on the area to confirm that the surface of the Guangsha has reached the predetermined flatness standard.

[0016] Technical effects and advantages of the present invention: A Guangsha weaving process proposed by the present invention has the following advantages compared with the prior art: Through the hierarchical manual weft insertion technology combined with zoning processing and tension adjustment, the present invention realizes the precise control of the weft density and tension, ensures that the weft density and tension in each area are uniform, thereby significantly improving the flatness and texture uniformity of the fabric surface. At the same time, the optimized operation parameters simplify the complex manual warping and shedding steps, improving the clarity and detail restoration of the fabric. In addition, by detecting the surface flatness of the completed fabric and adjusting the weft tension according to the detection results, it further ensures that the entire fabric surface reaches the predetermined flatness standard. This process effectively solves the problems of high pattern complexity and poor texture uniformity in traditional manual weaving, and finally realizes the production of high-quality and high-precision fabrics. Description of the Drawings

[0017] Figure 1 It is a flowchart of a Guangsha weaving process of the present invention. Detailed Embodiments

[0018] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. The specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0019] The present invention provides a Figure 1 kind of wide yarn weaving process as shown below, including the following steps: First step, select the type and specification of the yarn, and determine the weft density according to the dobby; specifically including the following steps: Analyze the color and texture requirements of the design drawing to determine the basic yarn material. By carefully analyzing the color and texture requirements of the design drawing, the appropriate basic yarn material can be accurately selected to ensure that the appearance and texture of the final fabric meet the expectations.

[0020] Select the yarn thickness standard according to the characteristics (such as strength, softness, luster, etc.) of the basic yarn material, thereby optimizing the operating conditions of the subsequent process and improving the overall performance of the fabric.

[0021] Use the yarn thickness standard and combine it with the detail complexity of the design drawing to divide the weft density grades of different regions; according to the detail complexity of the design drawing, reasonably divide the weft density grades of different regions to ensure that the weft density of each region matches the design requirements and avoid problems such as blurred or deformed fabric patterns caused by inconsistent density. By carefully dividing different regions, every detail in the complex design drawing can be accurately presented, improving the clarity and detail restoration of the overall pattern.

[0022] Second step, mark the layering points on the dobby and perform zoning processing according to the density; specifically including the following steps: Calculate the optimal weft density of each region and record the density value; by measuring the number of weft yarns and the unit length (such as per centimeter) of each region, calculate the optimal weft density of this region. For example, if there are 50 weft yarns in a certain region within 10 centimeters, then the weft density of this region is: weft density = 50 / 10 = 5 yarns / cm. Record these density values in detail for use in subsequent steps.

[0023] Use a marking tool to mark the starting and ending points of the layering on the weft yarn at the corresponding positions according to the recorded density value; Starting point of layering = accumulate (weft density_i * paragraph length_i) (i from 1 to n - 1); Ending point of layering = starting point of layering + (weft density_n * paragraph length_n); Based on the recorded weft density values, use a marking tool (such as a marker pen or label) to mark the starting and ending points of each layer on the weft yarn. Assume that the weft density of the first paragraph is 5 yarns per centimeter and the length is 20 centimeters. Then the starting point of the layer is 0 centimeters, and the ending point of the layer is: Ending point of the layer = 0 + (5 * 20) = 100 centimeters; continue to make similar marks for each paragraph to ensure the clarity of the starting and ending points of each paragraph.

[0024] Divide the weft yarn into multiple consecutive paragraphs according to the positions of the starting and ending points of the layer, with each paragraph corresponding to a weft density grade; Number of paragraphs = Total length of weft yarn / Average length of each paragraph.

[0025] Divide the weft yarn into multiple consecutive paragraphs according to the marked starting and ending points of the layer. For example, if the total length of the weft yarn is 500 centimeters and the average length of each paragraph is 20 centimeters, then the number of paragraphs is: Number of paragraphs = 500 / 20 = 25; each paragraph corresponds to a weft density grade to ensure that the differences in weft density in different regions are accurately reflected.

[0026] Adjust the weft yarn within each paragraph to ensure that the spacing between the weft yarns is uniform and consistent, meeting the requirements of the pattern draft. For example, if the length of a certain paragraph is 20 centimeters and the number of weft yarns is 50, then the weft yarn spacing is: Weft yarn spacing = 20 / (50 - 1) ≈ 0.41 centimeters; use a tension adjustment device or other tools to ensure that the weft yarn spacing within each paragraph is uniform and consistent, meeting the requirements of the pattern draft.

[0027] By finely adjusting the weft yarn spacing within each paragraph, the uniformity of the weft yarn distribution is ensured, significantly improving the flatness of the final fabric surface and the clarity of the details of the pattern draft.

[0028] Step 3: Adjust the predetermined tension of the weft yarn in each area based on the results of the zoning process; specifically including the following steps: Determine the initial tension value required for each weft yarn paragraph according to the uniformity of the weft yarn spacing within each paragraph; Initial tension value = Base tension + (Weft yarn spacing deviation coefficient * Adjustment coefficient); Within each paragraph, first measure the uniformity of the weft yarn spacing. Assume that the base tension is 5 Newtons (N), the weft yarn spacing deviation coefficient is 0.2 (indicating the ratio of the increase or decrease in tension that needs to be adjusted for every 1 millimeter deviation from the standard spacing), and the adjustment coefficient is 1 N / mm (the amount of tension adjustment corresponding to each millimeter of spacing deviation). If the weft yarn spacing in a certain paragraph is 2 millimeters larger than the standard spacing, then the initial tension value of this paragraph is calculated as follows: Initial tension value = 5 + (0.2 * 2 * 1) = 5 + 0.4 = 5.4 N; By precisely calculating the initial tension value of each section, it ensures that the weft yarn can maintain an appropriate tension in different areas, thereby improving the flatness and texture uniformity of the fabric surface.

[0029] Set a tension adjustment device at one end of the weft yarn section and input the initial tension value into the device; Set the tension = initial tension value; Install a tension adjustment device (such as a tensiometer or a tension controller) at one end of each weft yarn section. Input the initial tension value calculated in step 1 into this device. For example, if the initial tension value is 5.4 N, then set the tension on the tension adjustment device to 5.4 N.

[0030] By using the tension adjustment device and accurately inputting the initial tension value, it ensures that the tension of the weft yarn in each section can be precisely controlled, avoiding fabric quality problems caused by inconsistent tension.

[0031] Use the tension adjustment device to gradually tighten the weft yarn until the set initial tension value is reached; Use the tension adjustment device to gradually tighten the weft yarn until the actual tension is consistent with the set initial tension value. Assume the set tension is 5.4 N, and the allowable range of tension error is ±0.1 N. During the adjustment process, monitor the actual tension in real time. When the actual tension reaches between 5.3 N and 5.5 N, stop the adjustment and confirm that the weft yarn has reached the set initial tension value.

[0032] By gradually tightening the weft yarn and monitoring the actual tension in real time, it ensures that the tension of the weft yarn in each section reaches the predetermined value, improving the overall quality and consistency of the fabric.

[0033] Step 4: Set the operation parameters for manual weft insertion according to the adjustment result of the predetermined tension; Specifically include the following steps: According to the state of the weft yarn after the tension adjustment, determine the actual tension value of each section of the weft yarn and record the actual tension value; Actual tension value = set tension - tension error; After completing the tension adjustment of each section, use a tension measuring tool (such as a tensiometer) to measure and record the actual tension value of each section of the weft yarn. Assume the set tension is 5.4 N, and the allowable range of tension error is ±0.1 N, then the actual tension value should be between 5.3 N and 5.5 N. For example, if the measured actual tension value of a certain section of the weft yarn is 5.35 N, record it in detail.

[0034] Step 5: Use the operation parameters to guide the manual harnessing process; Specifically include the following steps: According to the adjusted manual strength and speed, formulate a harnessing sequence table and mark the manual harnessing points that need special attention; Harnessing sequence = weft yarn number + warp yarn number + manual strength + manual speed; Assume that the weft yarn numbers range from 1 to 50, the warp yarn numbers range from 1 to 100, the manual force is 10.2N, and the manual speed is 96.55 times per minute. The position of each weft yarn in the warp yarn can be expressed by the following formula: Denting sequence = "weft yarn" + weft yarn number + "_warp yarn" + warp yarn number + "_force" + manual force + "_speed" + manual speed; For example, the denting sequence of weft yarn 1 at the position of warp yarn 10 can be expressed as: Denting sequence = "weft yarn 1_warp yarn 10_force 10.2_speed 96.55"; Based on the denting sequence table, mark the manual denting points that need special attention, such as the complex jacquard pattern area or the places where the warp and weft yarns are intertwined frequently.

[0035] By formulating a detailed denting sequence table and marking the key denting points, the systematicness and accuracy of the manual denting operation are ensured, the possibility of operation errors is reduced, and the clarity and detail restoration of the fabric pattern are improved.

[0036] Use the marked denting points as a reference and perform the manual denting operation step by step according to the said denting sequence table; Denting progress = (number of completed denting points / total number of denting points) * 100%; According to the denting sequence table and the marked denting points, perform the manual denting operation step by step. Assume that the total number of denting points is 1000 and the number of completed denting points is 500, then the denting progress is calculated as follows: Denting progress = (500 / 1000) * 100% = 50%; Record the denting progress in real time and ensure that each denting point is operated according to the predetermined operation parameters (manual force and speed).

[0037] After completing the preliminary denting, check the loom device and make adjustments to the local area according to the said inspection results; Jacquard pattern matching degree = (number of denting points that meet the design requirements / total number of denting points) * 100% After completing the preliminary denting, use a standard light source and a ruler tool to visually inspect the entire fabric surface and mark all areas suspected of not meeting the design requirements. Assume that the total number of denting points is 1000 and the number of denting points that meet the design requirements is 950, then the jacquard pattern matching degree is calculated as follows: Jacquard pattern matching degree = (950 / 1000) * 100% = 95%; For the areas that do not meet the design requirements, conduct a detailed inspection and record the specific positions and degrees of the problem points. According to the inspection results, make necessary adjustments to the local area to ensure that the jacquard pattern details fully meet the design requirements.

[0038] Before the start of the manual weft insertion operation, set the manual force and speed for each weft insertion according to the actual tension value; Manual force = basic force + (actual tension value - basic tension) * adjustment coefficient; Manual speed = basic speed / (1 + (actual tension value - basic tension) * speed adjustment coefficient); Assume that the basic force is 10 Newtons (N), the basic speed is 100 weft insertions per minute, the adjustment coefficient is 0.5 N / N, and the speed adjustment coefficient is 0.01 / min / N. If the actual tension value of a certain weft yarn is 5.35 N and the basic tension is 5 N, then the manual force and speed are calculated as follows: Manual force = 10 + (5.35 - 5) * 0.5 = 10 + 0.175 = 10.175 N; Manual speed = 100 / (1 + (5.35 - 5) * 0.01) ≈ 100 / 1.035 ≈ 96.6 times / minute; By setting the manual force and speed according to the actual tension value, it is ensured that the manual weft insertion operation can adapt to the weft yarn tension changes in different areas, improving the accuracy and consistency of the weft insertion operation.

[0039] Connect the large yarn and the dobby, check the harness lifting sequence according to the dobby, and perform the initial weft insertion operation using the set manual force and speed, and observe whether the performance of the weft yarn in the wide yarn meets the expected effect; Weft insertion quality score = (weft yarn position deviation coefficient + weft yarn spacing uniformity coefficient) / 2; For example, measure the position deviation and spacing uniformity of the weft yarn and calculate the weft insertion quality score. Assume that the weft yarn position deviation coefficient is 0.8 and the weft yarn spacing uniformity coefficient is 0.9, then the weft insertion quality score is: Weft insertion quality score = (0.8 + 0.9) / 2 = 0.85; Through the initial weft insertion operation, the performance of the weft yarn in the wide yarn can be visually observed to preliminarily evaluate the weft insertion quality.

[0040] Adjust the manual force and speed according to the results of the initial weft insertion operation; Adjusted manual force = manual force + (target weft insertion quality score - actual weft insertion quality score) * force adjustment coefficient; Adjusted manual speed = manual speed / (1 + (target weft insertion quality score - actual weft insertion quality score) * speed adjustment coefficient); Assume that the target weft insertion quality score is 0.9, the actual weft insertion quality score is 0.85, the force adjustment coefficient is 0.5 N / score point, and the speed adjustment coefficient is 0.01 / min / score point. Then the adjusted manual force and speed are calculated as follows: Adjusted manual force = 10.175 + (0.9 - 0.85) * 0.5 = 10.175 + 0.025 = 10.2 N; Adjusted manual speed = 96.6 / (1 + (0.9 - 0.85) * 0.01) ≈ 96.6 / 1.0005 ≈ 96.55 times per minute; By analyzing the results of the initial weft insertion operation and adjusting the manual force and speed accordingly, the weft insertion operation was further optimized to ensure that the performance of the weft yarn in the wide yarn reached the best effect, improving the overall quality and consistency of the fabric.

[0041] Connect the large fiber and the dobby pattern. The specific steps for checking the harness lifting sequence according to the dobby pattern include the following: According to the inspection results after the initial harness threading, determine the detailed area of the drafting pattern that needs special attention, and record the specific location of the area; Number of areas to focus on = Total number of harness threading points * (proportion not meeting the design requirements); After completing the initial harness threading, visually inspect the entire fabric surface using a standard light source and a ruler tool. Assuming the total number of harness threading points is 1000 and the proportion not meeting the design requirements is 5%, then the number of detailed areas of the drafting pattern that need special attention is: Number of areas to focus on = 1000 * 0.05 = 50; Detailedly record the specific location and degree (such as weft yarn number, warp yarn number, etc.) of each detailed area of the drafting pattern that needs special attention. For example, the records are as follows: Area 1: Weft yarn 10_ warp yarn 20; Area 2: Weft yarn 30_ warp yarn 45; Through detailed inspection and recording, it is ensured that all detailed areas of the drafting pattern that need special attention are accurately identified, providing a reliable basis for formulating the subsequent harness lifting sequence plan.

[0042] Based on the recorded detailed areas of the drafting pattern, formulate a harness lifting sequence plan to clarify the harness lifting priority and operation sequence for each area; Harness lifting priority = Number of areas to focus on / Number of areas to focus on that can be processed per unit time; Assuming that 10 areas to focus on can be processed per unit time (such as per hour), the harness lifting priority is calculated as follows: Harness lifting priority = 50 / 10 = 5 hours; Formulate a specific harness lifting sequence plan to clarify the harness lifting priority and operation sequence for each area. For example: 1st hour: Process areas 1 to 10; 2nd hour: Process areas 11 to 20; ...; Ensure that the harness lifting priority and operation sequence for each area are reasonably arranged to optimize production efficiency.

[0043] Through a reasonable harness lifting sequence plan, the orderliness and efficiency of the harness lifting operation are ensured, reducing time waste and quality problems caused by unreasonable operation sequence.

[0044] Use the harness lifting sequence plan to perform harness lifting operations on each area in sequence, ensuring that the manual force and speed during each harness lifting are consistent with those during threading; Harness lifting force = Threading force, Harness lifting speed = Threading speed; Assume that the manual force during threading is 10.2 N and the manual speed is 96.55 times per minute. Then, the manual force and speed during harness lifting should be consistent: Harness lifting force = 10.2 N; Harness lifting speed = 96.55 times per minute; Monitor the manual force and speed during harness lifting in real time to ensure they are consistent with those during threading. For complex pattern areas or key parts, special attention should be paid to strictly controlling the manual force and speed.

[0045] After completing the harness lifting operation, check again whether the loom device fully meets the design requirements, and make adjustments to local areas according to the inspection results. Final pattern matching degree = (Number of harness lifting points meeting the design requirements / Total number of harness lifting points) * 100%; After completing the harness lifting operation, use a standard light source and a ruler tool to conduct a final inspection of the entire fabric surface. Assume that the total number of harness lifting points is 1000 and the number of harness lifting points meeting the design requirements is 980. Then, the final pattern matching degree is calculated as follows: Final pattern matching degree = (980 / 1000) * 100% = 98%; For areas that do not meet the design requirements, conduct a detailed inspection and record the specific locations and degrees of the problem points. According to the inspection results, make necessary adjustments to local areas to ensure that the pattern details fully meet the design requirements.

[0046] Step 6: After completing the weaving of the wide yarn according to the harness lifting sequence, check the pattern details; The specific steps are as follows: According to the priorities and operation sequences determined in the harness lifting sequence plan, perform harness lifting operations on each area in sequence. During the harness lifting operation, monitor the interweaving state of the weft yarn and the warp yarn in real time, and record any abnormal situations and their locations; Harness lifting progress = (Number of completed harness lifting points / Total number of harness lifting points) * 100%; According to the priorities and operation sequences in the harness lifting sequence plan, perform harness lifting operations on each area in sequence. Assume that the total number of harness lifting points is 1000 and the number of completed harness lifting points is 500. Then, the harness lifting progress is calculated as follows: Harness lifting progress = (500 / 1000) * 100% = 50%; During the harness lifting operation, use real-time monitoring tools (such as microscopes or sensors) to monitor the interweaving state of the weft yarn and the warp yarn, and record any abnormal situations and their locations. For example, the records are as follows: Abnormality 1: Weft yarn 20 _ Warp yarn 30, loose interweaving; Abnormality 2: The weft yarn is 45 and the warp yarn is 60. The weft yarn deviates from the designed position; By monitoring and recording the interlacing state in real time, it is ensured that problems during the heald lifting process can be discovered and recorded in a timely manner, providing a reliable basis for subsequent adjustments.

[0047] For the recorded abnormal situations, on-site adjustments are immediately carried out to correct the interlacing state of the weft yarn and the warp yarn. Assuming 50 abnormal situations are recorded, 50 adjustments are required: Number of adjustments = 50 During each adjustment, corresponding measures are taken according to the specific situation, such as re-threading the healds, adjusting the tension, etc. For example: For the situation of loose interlacing, re-thread the healds and adjust the manual force.

[0048] For the situation where the weft yarn deviates from the designed position, adjust the weft yarn tension and re-thread the healds.

[0049] After completing all the heald lifting operations, a comprehensive inspection is carried out to confirm that the pattern details in all areas meet the expected effects; through the comprehensive inspection and confirmation, it is ensured that the details of the fabric design drawing are highly restored, improving the quality of the final product and reducing quality problems caused by unclear details.

[0050] Step 7: Detect the surface flatness of the completed Guangsha weaving and record the uneven areas; specifically, it includes the following steps: Use a standard light source and a ruler tool to conduct a preliminary visual inspection of the entire Guangsha surface, and mark all suspected uneven areas; Number of suspected uneven areas = Total number of detected areas * (Proportion of unevenness in preliminary inspection); Use a standard light source (such as a uniform lighting device) and a ruler tool (such as a high-precision ruler) to conduct a preliminary visual inspection of the entire Guangsha surface. Assuming the total number of detected areas is 500 and the proportion of unevenness found in the preliminary inspection is 10%, then the number of suspected uneven areas is: Number of suspected uneven areas = 500 * 0.1 = 50.

[0051] During the preliminary inspection process, specifically record the specific positions and degrees (such as weft yarn numbers, warp yarn numbers, etc.) of each suspected uneven area. For example: Area 1: Weft yarn 20_ Warp yarn 30; Area 2: Weft yarn 45_ Warp yarn 60; Through the preliminary visual inspection with a standard light source and a ruler tool, it is ensured that all suspected uneven areas are accurately identified, providing a reliable basis for subsequent tactile confirmation.

[0052] For the marked suspected uneven areas, confirm their flatness by touching with hands. Further confirm the uneven areas through the hand-touch method, ensuring the accuracy of the problem areas and providing more accurate data support for subsequent marking and adjustment.

[0053] For the areas where unevenness is confirmed to exist, use marking tools to mark on the back of the wide yarn, record the specific positions and degrees of each uneven point; through detailed marking and recording, ensure that the positions and degrees of all uneven points are clearly identified, providing a reliable reference basis for subsequent tension adjustment operations.

[0054] Compile an inspection report, list all the areas that need to be adjusted, and provide a reference basis for subsequent tension adjustment operations. By compiling a detailed inspection report, ensure that all the areas that need to be adjusted are systematically recorded and sorted, providing a reliable basis for subsequent tension adjustment operations and improving the overall flatness and quality of the fabric.

[0055] Step 8: According to the positions of the uneven areas, adjust the tensions of the corresponding weft yarns until the entire surface of the wide yarn reaches the predetermined flatness standard; specifically including the following steps: According to the positions and degrees of the uneven points marked in the inspection report, locate each weft yarn whose tension needs to be adjusted; through detailed recording and positioning, ensure that all the weft yarns whose tensions need to be adjusted are accurately identified, providing a reliable basis for subsequent tension adjustment.

[0056] Preliminarily set the tension adjustment values of the tension adjustment devices at both ends of the weft yarn according to the marked degrees, use the tension adjustment devices to gradually increase or decrease the tension of the weft yarn, and at the same time use the hand-touch method to check whether the area becomes flatter; Tension adjustment value = Basic tension + (Unevenness degree coefficient * Adjustment coefficient); Suppose the basic tension is 5N, the unevenness degree coefficient is 0.5 (indicating the proportion of tension to be adjusted for each unit of unevenness degree), and the adjustment coefficient is 1N / unit of unevenness degree. If the unevenness degree of a certain uneven point is 2 units, the tension adjustment value of this weft yarn is calculated as follows: Tension adjustment value = 5 + (0.5 * 2 * 1) = 5 + 1 = 6N; Use the tension adjustment devices to gradually increase or decrease the tension of the weft yarn, and use the hand-touch method to check whether the area becomes flatter. For example: For slightly sunken areas, appropriately increase the tension of the weft yarn.

[0057] For obviously convex areas, appropriately reduce the tension of the weft yarn.

[0058] By accurately calculating and setting the tension adjustment values, ensure that each uneven area can be subjected to targeted tension adjustment, improving the flatness and texture uniformity of the fabric surface.

[0059] After the preliminary adjustment is completed, use the standard light source and ruler tool again to conduct a final visual inspection of the area to confirm that the surface of the wide yarn has reached the predetermined flatness standard. The final flatness score = (the number of areas meeting the flatness standard / the total number of inspected areas) * 100%; Assume that the total number of inspected areas is 500 and the number of areas meeting the flatness standard is 480. Then the final flatness score is calculated as follows: Final flatness score = (480 / 500) * 100% = 96%; For the areas that do not meet the flatness standard, conduct a detailed inspection and record the specific locations and degrees of the problem points. According to the inspection results, make necessary further adjustments to the local areas until the entire surface of the wide yarn reaches the predetermined flatness standard.

[0060] Through comprehensive inspection and confirmation, the overall flatness and quality of the fabric surface are ensured, reducing quality problems caused by surface unevenness.

[0061] In summary, through the hierarchical hand - weft insertion technology combined with zoning treatment and tension adjustment, the present invention realizes the precise control of the weft density and tension, ensures that the weft density and tension in each area are uniform, thereby significantly improving the flatness and texture uniformity of the fabric surface. At the same time, the optimized operation parameters simplify the complex manual heddle threading and lifting steps, improving the clarity and detail restoration of the fabric.

[0062] In addition, by detecting the surface flatness of the completed fabric and adjusting the weft tension according to the detection results, it is further ensured that the entire fabric surface reaches the predetermined flatness standard. This process effectively solves the problems of high pattern complexity and poor texture uniformity in traditional hand - weaving, and finally realizes the production of high - quality and high - precision fabrics.

[0063] In another embodiment, the weaving of the draft includes the following steps: (1) Design: When drawing the pattern, use silk thread as the warp and cotton thread as the weft to pick separately; referring to the drawn draft, the warp corresponds to the vertical grid on the draft, and the weft corresponds to the horizontal grid on the draft, and pick and make a pattern template "pattern book". When weaving on the loom, connect each foot line with each warp on the loom one by one through the loom harness.

[0064] (2) Mounting: For the mounting of the wide - yarn loom, first prepare the required warp threads, then make the heddle device, divide the warp threads into warp A and warp B, and insert two heddle rods into the plain - weave warp threads; when mounting, let warp A enter the heddle from below warp B from left to right, thread each warped thread with a thread, and then penetrate with one heddle rod; (3)Weaving on the loom: The plain part without patterns is woven with plain weave, and the part showing the hidden pattern is woven with twill weave formed by twisting two adjacent warp threads; that is, a Guangsha weave with a unique yarn hole structure is woven.

[0065] By stepping on the pedal rod with the foot, the lifting and lowering of the heddle frame connected to it are controlled, so that the "warp surface" formed by the warp threads is separated up and down. The weaver holds a shuttle filled with weft and performs "shuttle picking and weft insertion". After the warp and weft are interwoven, the just-woven weft is beaten firmly with a "reed". Only the weaving of one weft thread is completed in this process. By continuously changing the stepping on the pedal rod, the up-and-down alternation of the warp threads can be realized, and thus the weaving of the entire design drawing can be achieved.

[0066] Finally, it should be noted that the above are only the preferred embodiments of the present invention and are not used 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 perform equivalent replacements on some of the technical features. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. A broad yarn weaving process, characterized in that, It includes the following steps: Select the type and specifications of the yarn, determine the weft density according to the dobby, mark the layering points on the dobby, and perform zoning processing based on the density; Based on the results of the zoning processing, adjust the predetermined tension for the weft yarn in each zone, and set the operation parameters for manual weft insertion according to the adjustment results of the predetermined tension; Use the operation parameters to guide the manual harness threading process; After completing the Guangsha weaving according to the harness lifting sequence, check the details of the drafting pattern, perform surface flatness detection on the completed Guangsha weaving, and record the uneven areas; According to the positions of the uneven areas, adjust the tension of the corresponding weft yarn until the entire Guangsha surface reaches the predetermined flatness standard.

2. The broad yarn weaving process according to claim 1, characterized in that, The selection of the type and specifications of the yarn and the determination of the weft density according to the dobby include the following steps: Analyze the color and texture requirements of the drafting pattern to determine the basic yarn material, and select the yarn thickness standard according to the characteristics of the basic yarn material; Use the yarn thickness standard and combine with the detail complexity of the drafting pattern to divide the weft density grades of different regions; Based on the division of the weft density grades, observe whether the effect of the drafting pattern meets the expectations.

3. The wide yarn weaving process according to claim 2, characterized in that, The marking of the layering points on the dobby and the zoning processing based on the density include the following steps: Determine the optimal weft density for each zone and record the density value; Use a marking tool to mark the starting and ending points of the layering at the corresponding positions on the dobby according to the recorded density value; According to the positions of the starting and ending points of the layering, divide the weft yarn into multiple continuous paragraphs, with each paragraph corresponding to a weft density grade; Adjust the weft yarn within each paragraph to ensure that the spacing between the weft yarns is uniform and consistent, meeting the requirements of the drafting pattern.

4. The wide yarn weaving process according to claim 3, characterized in that, The adjustment of the predetermined tension for the weft yarn in each zone based on the results of the zoning processing includes the following steps: Determine the initial tension value required for each weft yarn paragraph according to the uniformity of the weft yarn spacing within each paragraph; Set a tension adjusting device at one end of the weft yarn paragraph and input the initial tension value into the device; Use the tension adjusting device to gradually tighten the weft yarn until the set initial tension value is reached.

5. A Guangsha weaving process according to claim 4, characterized in that, The setting of the operation parameters for manual weft insertion according to the adjustment results of the predetermined tension includes the following steps: Determine the actual tension value of each weft yarn paragraph according to the state of the weft yarn after the tension adjustment is completed, and record the actual tension value.

6. A Guangsha weaving process according to claim 5, characterized in that, The use of the operation parameters to guide the manual harness threading process includes the following steps: According to the adjusted manual strength and speed, formulate a harness threading sequence table and mark the manual harness threading points that require special attention; Use the marked harness threading points as a reference and gradually perform the manual harness threading operation according to the harness threading sequence table; After completing the preliminary harness threading, check the loom device and make adjustments to the local area according to the inspection results; Connect the large fiber and the dobby and check the harness lifting sequence according to the dobby; Before starting the manual weft insertion operation, set the manual strength and speed for each weft insertion according to the actual tension value; Use the set manual strength and speed to perform the first weft insertion operation, observe whether the performance of the weft yarn in the Guangsha meets the expected effect, and adjust the manual strength and speed according to the results of the first weft insertion operation.

7. A Guang yarn weaving process according to claim 6, characterized in that, Connect the large warp and the dobby according to the dobby check heddle lifting sequence, including the following steps: Based on the inspection results after preliminary heddle threading, determine the detailed areas of the pattern draft that require special attention, and record the specific positions of these areas; On the basis of the recorded detailed areas of the pattern draft, formulate a heddle lifting sequence plan, specifying the heddle lifting priority and operation sequence for each area; Use the heddle lifting sequence plan to perform heddle lifting operations on each area in sequence, ensuring that the manual force and speed during each heddle lifting are consistent with those during heddle threading; After completing the heddle lifting operations, check again whether the loom device fully meets the design requirements, and make adjustments to local areas according to the inspection results.

8. A kind of Guangsha weaving process according to claim 7, characterized in that, Check the details of the pattern draft after completing the wide yarn weaving according to the heddle lifting sequence, including the following steps: According to the priority and operation sequence determined in the heddle lifting sequence plan, perform heddle lifting operations on each area in sequence. During the heddle lifting operation, monitor the interweaving state of the weft yarn and the warp yarn in real time, and record any abnormal conditions and their positions; For the recorded abnormal conditions, immediately make on-site adjustments to correct the interweaving state of the weft yarn and the warp yarn; After completing all heddle lifting operations, conduct a comprehensive inspection to confirm that the details of the pattern draft in all areas have achieved the expected effect.

9. A kind of Guangsha weaving process according to claim 8, characterized in that, Detect the surface flatness of the completed wide yarn weaving and record the uneven areas, including the following steps: Use a standard light source and a straightedge tool to conduct a preliminary visual inspection of the entire wide yarn surface, and mark all suspected uneven areas; For the marked suspected uneven areas, use hand feeling to confirm their flatness. For the areas where unevenness is confirmed to exist, use a marking tool to mark on the back of the wide yarn, and record the specific positions and degrees of each uneven point; Compile an inspection report, list all the areas that need to be adjusted, and provide a reference basis for subsequent tension adjustment operations.

10. A kind of Guang yarn weaving process according to claim 9, characterized in that, Adjust the tension of the corresponding weft yarn according to the position of the uneven area until the entire wide yarn surface reaches the predetermined flatness standard, including the following steps: According to the positions and degrees of the uneven points marked in the inspection report, locate each weft yarn whose tension needs to be adjusted; Preliminarily set the tension adjustment values of the tension adjustment devices at both ends of the weft yarn according to the marked degrees, use the tension adjustment devices to gradually increase or decrease the tension of the weft yarn, and at the same time use hand feeling to check whether the area becomes flatter; After completing the preliminary adjustment, use a standard light source and a straightedge tool to conduct a final visual inspection of the area again to confirm that the wide yarn surface has reached the predetermined flatness standard.

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