Fabric double-sided plain weaving method and system adopting flat knitting machine

Abstract

The invention discloses a fabric double-sided plain weaving method and system adopting a flat knitting machine, and relates to the technical field of fabric weaving, a set of double-sided plain weaving system is constructed through the cooperation of the steps S1 to S5: S1, providing a yarn foundation with uniform tension for subsequent weaving, S2, ensuring the consistency of yarn cross winding by optimizing phase difference, and S5, improving the weaving quality of the fabric. S3, correcting the size deviation of a coil in real time to ensure that textures on the two sides are symmetrical, S4, balancing the tension of each area of the fabric and improving the density uniformity, and ensuring the basic form consistency of yarns in the front and back cross winding in the initial weaving stage by a phase difference correlation model established on the basis of the fabric texture interweaving density and model parameters. By collecting interweaving tightness data in real time and dynamically correcting the phase difference, interference factors such as yarn tension fluctuation and environment humidity change can be handled, and texture symmetry and structural stability of the double-faced plain fabric are guaranteed.

Description

Technical Field

[0001] This invention relates to the field of fabric weaving technology, specifically to a method and system for double-sided plain weave fabric using a flat knitting machine. Background Technology

[0002] In the fabric weaving industry, flat knitting machines, with their flexible weaving capabilities, have become the core type of knitting equipment, especially in the production of double-sided plain weave fabrics, where they hold an irreplaceable position. Double-sided plain weave fabrics, due to their perfectly symmetrical textures on both sides, smooth and delicate surface, uniform texture, and excellent breathability, are widely used in high-end apparel, home textiles, and outdoor products, with market demand maintaining steady growth year after year. With the increasing trend of consumption upgrading, downstream enterprises are demanding increasingly stringent quality requirements for double-sided plain weave fabrics, requiring not only millimeter-level symmetry in texture but also higher standards for fabric density uniformity and tensile strength.

[0003] Traditional flat knitting machines rely on a fixed timing sequence for their needle bed movements, making it impossible to dynamically adjust the phase relationship based on the fabric texture, interlacing density, and machine parameters. This results in inconsistent cross-winding patterns of the yarns on the front and back of the fabric, easily leading to quality defects such as asymmetrical textures and loose interlacing. Furthermore, during production, factors such as yarn tension fluctuations (e.g., the tension difference between elastic and non-elastic fibers) and changes in environmental humidity directly affect knitting accuracy. However, traditional flat knitting machines lack real-time monitoring and dynamic correction mechanisms, making it difficult to counteract such interference and resulting in poor stability of fabric interlacing tightness. Summary of the Invention

[0004] The purpose of this invention is to provide a method and system for double-sided plain weave fabric using a flat knitting machine, so as to solve the problems mentioned in the background art.

[0005] The present invention achieves the above objectives through the following technical solutions: A method for double-sided plain weave fabric using a flat knitting machine, the method comprising the following steps: S1: Select and pre-stretch the yarn, and record the yarn tension data; S2: Receive yarn tension data, and when the tension data is within the preset tension range, arrange the front and rear needle beds of the flat knitting machine according to the initial phase difference and alternately raise and lower them to realize the cross-winding of the yarn on the front and back of the fabric. During the weaving process, the initial phase difference is dynamically optimized according to real-time data to generate an optimized phase difference. The initial phase difference is determined based on the fabric texture interlacing density and the flat knitting machine parameters. S3: Monitor the size of the loops formed by the front and back needle beds. When there is a size deviation in the loops on the front and back of the fabric, adjust the hooking force of the corresponding needle bed and generate hooking force adjustment data. S4: Collect tension data of each area of ​​the fabric, and adaptively change the yarn feed speed of the flat knitting machine according to the tension difference between the edge and the middle area to generate yarn feed speed adjustment data; S5: Receives and integrates yarn tension data, optimizes phase difference, adjusts hooking force data and yarn speed adjustment data, and converts them into equipment drive signals for the flat knitting machine through parameter collaborative calculation, thereby controlling the flat knitting machine to complete double-sided plain weave.

[0006] Optionally, the generation of the initial phase difference includes the following steps: The basic phase interval value of the front and back needle beds is determined based on the texture interweaving density of the double-sided plain weave fabric. Based on the machine parameters of the flat knitting machine, the basic phase interval value is corrected to obtain the pre-adjusted phase difference; Through multiple trial weaving experiments, multiple test phase differences were formed by adjusting the initial phase difference up and down. Data on the loop interlacing tightness of the fabric on both sides under different test phase differences were collected, and a correlation model between the test phase difference and the interlacing tightness was established. Based on the required interlacing density of the target fabric, the optimal test phase difference is selected from the correlation model as the initial phase difference.

[0007] By combining fabric texture density and machine parameters to determine the pre-adjusted phase difference, and then optimizing it through trial weaving to obtain the initial phase difference, the phase difference is made to better fit the actual production needs, providing a scientific benchmark for needle bed collaborative control and improving the initial weaving accuracy.

[0008] Optionally, the association model is fitted using a univariate linear regression equation, as shown in the following formula: y=kx+b In the formula, y represents the interweaving tightness, x represents the test phase difference, and k and b are regression coefficients.

[0009] Optionally, step S2, which involves arranging and alternating the raising and lowering of the front and rear needle beds of the flat knitting machine according to the initial phase difference, includes: Obtain the yarn tension data output in step S1. When the tension data is within the preset tension range, start the alternating lifting control program of the front and rear needle beds. Generate the lifting and lowering timing instructions for the front and rear needle beds based on the initial phase difference; During the needle bed raising and lowering process, the contact position between the knitting needle and the yarn is monitored in real time. When the contact position deviates from the preset trajectory, the time interval of the raising and lowering sequence is adjusted. Record the motion parameters of each needle bed alternation and elevation to form a timing control log, and analyze the correlation between the needle contact position deviation and the elevation timing adjustment in the timing control log. This correlation is recorded as the timing deviation rule and used for subsequent dynamic optimization of the initial phase difference.

[0010] Based on the initial phase difference, the needle bed achieves precise alternating motion. Combined with real-time position monitoring and timing adjustment, it ensures accurate yarn winding, reduces contact deviation between the needle and the yarn, and improves knitting stability.

[0011] Optionally, step S2, which involves dynamically optimizing the initial phase difference based on real-time data during the weaving process to generate the optimized phase difference, includes the following steps: During the fabric weaving process, the actual values ​​of the interlacing tightness on both sides of the fabric are collected in real time, and the timing control log is retrieved. By combining the actual value of interleaving tightness with the timing deviation pattern in the timing control log, the deviation between the actual value and the target value is calculated; When the deviation exceeds the preset deviation range more than twice, the phase difference optimization program is activated. Based on the direction and magnitude of the deviation, and combined with the timing deviation pattern in the timing control log, the initial phase difference is adjusted; The adjusted phase difference is applied to the coordinated control of the front and rear needle beds, and the actual value of the interlacing tightness is collected again and the timing control log is updated. The adjustment process is repeated until the deviation is within the preset deviation range. The adjusted phase difference at this time is the optimized phase difference.

[0012] By dynamically optimizing phase parameters during the weaving process, the fabric interlacing density is kept close to the target value, effectively addressing the impact of yarn batch differences and environmental changes, and improving product qualification rate and quality stability. Optionally, the pre-stretching step in step S1 includes: Based on the material properties of the yarn, set the initial tension value for pre-stretching; Real-time monitoring of yarn tension changes during pre-stretching process generates tension change curves; When the fluctuation amplitude of the tension change curve exceeds the preset fluctuation threshold, adjust the rotation speed of the tensioning device to restore the tension to a stable state. After the pre-stretching process is completed, the yarn is subjected to tension maintenance treatment.

[0013] By precisely selecting yarns and pre-stretching them, we ensure that the yarn tension is uniform and stable, providing a high-quality raw material base for subsequent weaving and reducing texture defects caused by yarn tension fluctuations.

[0014] Optionally, step S3, which generates the line tension adjustment data, includes the following steps: Real-time acquisition of images of loops formed by the knitting of the front and rear needle beds; Image processing is performed on the acquired coil images to extract the coil's diameter, circumference, and shape parameters as characteristic indicators of the coil's size; Compare the coil feature indicators at corresponding positions on the front and rear needle beds to calculate the dimensional deviation value; When the dimensional deviation exceeds the preset deviation threshold, preliminary hooking force adjustment data is generated and sent to the corresponding needle bed drive device; After adjustment, the coil image is acquired again and the size deviation value is calculated. When the size deviation value is within the preset deviation threshold range, the adjustment is stopped and the hooking force adjustment data is determined.

[0015] By monitoring and adjusting the coil size deviation in real time, the consistency of the texture on both sides of the fabric is further optimized, and the surface quality of the fabric is improved.

[0016] Optionally, step S4, which generates yarn feed speed adjustment data, includes: During the fabric weaving process, tension data were collected at the edges and middle of the fabric. Calculate the tension difference between the edge area and the middle area. When the tension difference is greater than the preset difference, it is determined that the yarn speed needs to be adjusted. Based on the magnitude of the tension difference, determine the initial adjustment range of the yarn feed speed and generate preliminary yarn feed speed adjustment data; The system monitors the adjusted tension difference in real time. When the tension difference returns to the preset range, the adjustment is stopped and the yarn feed speed adjustment data is confirmed.

[0017] The yarn speed is adaptively adjusted according to the regional tension differences to solve the problems of edge curling and slack in the middle of the fabric, and to ensure uniform overall density.

[0018] A double-sided plain weave fabric weaving system using a flat knitting machine includes: The raw material matching module is used to screen yarns and pre-stretch them, and record yarn tension data; The double-sided needle bed coordination module is used to receive yarn tension data. When the tension data is within the preset tension range, the front and rear needle beds of the flat knitting machine are arranged and alternately raised and lowered according to the initial phase difference to realize the cross-winding of yarn on the front and back of the fabric. During the weaving process, the initial phase difference is dynamically optimized based on real-time data to generate an optimized phase difference. The initial phase difference is determined based on the fabric texture interlacing density and the flat knitting machine parameters. The texture symmetry calibration module is used to monitor the size of the loops formed by the front and back needle beds. When there is a size deviation in the loops on the front and back of the fabric, the hooking force of the corresponding needle bed is adjusted, and hooking force adjustment data is generated. The density dynamic adjustment module is used to collect tension data of various areas of the fabric and adaptively change the yarn feed speed of the flat knitting machine according to the tension difference between the edge and the middle areas, generating yarn feed speed adjustment data. The fabric forming and weaving module is used to receive and integrate yarn tension data, optimize phase difference, adjust hooking force data and yarn speed adjustment data, and convert them into equipment drive signals for the flat knitting machine through parameter collaborative calculation, thereby controlling the flat knitting machine to complete double-sided plain weave.

[0019] The beneficial effects of this invention are as follows: Traditional flat knitting machines often use fixed timing for their needle bed control, such as alternating movements at equal intervals. This makes it impossible to dynamically adjust the coordination relationship based on the fabric texture density and machine parameters, which can easily lead to problems such as asymmetry of the two-sided texture and loose interlacing. This invention establishes a phase difference correlation model based on the fabric texture interlacing density and machine parameters, which ensures the basic consistency of the yarn's cross-wrap on both sides during the initial weaving stage. By collecting interlacing density data in real time and dynamically correcting the phase difference, it can cope with interference factors such as yarn tension fluctuations and changes in environmental humidity, thus ensuring the texture symmetry and structural stability of the double-sided plain weave fabric. This invention constructs a double-sided plain weave system through the coordination of steps S1-S5: step S1 provides a yarn foundation with uniform tension for subsequent weaving; step S2 ensures the consistency of yarn cross-winding by optimizing the phase difference; step S3 corrects the loop size deviation in real time to ensure symmetrical texture on both sides; and step S4 balances the tension in each area of ​​the fabric to improve density uniformity. Compared with the fixed parameters of traditional flat knitting machines, this invention not only solves technical problems such as asymmetrical texture on both sides, loose interlacing, and regional tension imbalance, but also achieves adaptation to different yarn materials and different weight requirements through parameter optimization in each step. Attached Figure Description

[0020] Figure 1 The flowchart provided for this invention; Figure 2 A flowchart illustrating the steps for generating the initial phase difference provided by this invention; Figure 3 The flowchart illustrates the steps for generating the optimized phase difference provided by this invention. Detailed Implementation

[0021] The present application will now be described in further detail with reference to the accompanying drawings. It should be noted that the following specific embodiments are only used to further illustrate the present application and should not be construed as limiting the scope of protection of the present application. Those skilled in the art can make some non-essential improvements and adjustments to the present application based on the above application content.

[0022] Refer to the instruction manual appendix Figure 1 This embodiment discloses a method for double-sided plain weave fabric using a flat knitting machine, including the following steps: S1: Select and pre-stretch the yarn, and record the yarn tension data. Specifically, step S1 is used to select yarns of corresponding fineness according to the weight requirements of the double-sided plain weave fabric and pre-stretch them to make the yarns in a uniform tension state, and record the yarn tension data after processing. The matching relationship between yarn fineness and fabric weight is established based on historical production data. For example, 32-count yarn is suitable for 200 grams per square meter of fabric, and 24-count yarn is suitable for 300 grams per square meter of fabric.

[0023] As a preferred embodiment, the pre-stretching step in step S1 includes: Based on the material characteristics of the yarn, set the initial tensile force value for pre-stretching. The initial tensile force value for elastic fiber materials (such as spandex content ≥5%) is set to 15-20cN, and the initial tensile force value for non-elastic fiber materials (such as pure cotton and polyester) is set to 25-30cN. The initial tensile force value for elastic fiber materials and non-elastic fiber materials can be set according to industry standards or historical experience. The tension change of the yarn during the pre-stretching process is monitored in real time by a tension sensor (measurement range 0-100cN, accuracy ±0.5cN), with a sampling frequency of 10Hz, and a tension change curve is generated. When the fluctuation amplitude of the tension change curve (the difference between the maximum and minimum values) exceeds the preset fluctuation threshold (5cN), adjust the rotation speed of the tensioning device (adjustment range 10-50r / min) to restore the tension to a stable state (fluctuation amplitude ≤3cN). The fluctuation threshold can be set according to industry standards or historical experience. After the pre-stretching treatment is completed, the yarn is subjected to tension holding treatment for 5-10 minutes to ensure that the internal stress of the yarn is fully released and the tension uniformity is stable within ±2cN.

[0024] S2: Receive the yarn tension data, and when the tension data is within the preset tension range, arrange and alternately raise and lower the front and rear needle beds of the flat knitting machine according to the initial phase difference to realize the cross-winding of the yarn on the front and back of the fabric. During the weaving process, the initial phase difference is dynamically optimized according to real-time data to generate an optimized phase difference. The initial phase difference is determined based on the fabric texture interlacing density and the flat knitting machine model parameters.

[0025] It should be noted that the texture interlacing density refers to the number of times the yarns cross within a unit length. Machine parameters include the effective working length of the needle bed and the needle arrangement density (number of needles per centimeter).

[0026] Refer to the instruction manual appendix Figure 2 As a preferred embodiment, the steps for generating the initial phase difference include: The basic phase interval value of the front and back needle beds is determined based on the weave density of the double-sided plain weave fabric. For example, for a fabric with an weave density of 8 times per centimeter, the basic phase interval value is set to 45 degrees. Based on the machine parameters of the flat knitting machine, including needle bed length and needle arrangement density, the basic phase interval value is corrected to obtain the pre-adjusted phase difference. For example, if the needle bed length increases by 10%, the phase interval value correction increases by 5%. Through multiple trial weaving experiments (usually 5-8 times), multiple test phase differences are formed by adjusting the initial phase difference up and down. Data on the loop interlacing tightness of the fabric on both sides under different test phase differences are collected. The interlacing tightness is indirectly characterized by testing the transverse tensile strength of the fabric using a tensile testing machine. A correlation model between the test phase difference and the interlacing tightness is established, and the relationship between the two is fitted by a univariate linear regression equation: y=kx+b, where y is the interlacing tightness, x is the test phase difference, and k and b are regression coefficients; Based on the interlacing density requirements of the target fabric (e.g., transverse tensile strength ≥20N / cm), the optimal test phase difference is selected from the correlation model as the initial phase difference, and the initial phase difference is stored in the control system of the flat knitting machine (usually a PLC controller).

[0027] Furthermore, step S2, which involves arranging and alternating the raising and lowering of the front and rear needle beds of the flat knitting machine according to the initial phase difference, includes: Obtain the yarn tension data (in cN) output in step S1. When the tension data is within the preset tension range (e.g., 20-30 cN), start the alternating lifting control program of the front and rear needle beds. Based on the initial phase difference, the lifting and lowering timing commands of the front and rear needle beds are generated and sent to the needle bed drive motor through pulse signals. When the front needle bed rises, the rear needle bed remains in a descending state. After the front needle bed descends to the initial position (0mm away from the needle bed reference plane), the rear needle bed begins to rise. During the needle bed raising and lowering process, the contact position between the knitting needle and the yarn is monitored in real time by a laser displacement sensor with a measurement accuracy of 0.01mm. When the contact position deviates from the preset trajectory (deviation ≥ 0.1mm), the time interval of the raising and lowering sequence is adjusted (adjustment step size is 0.05 seconds) to ensure that the yarn is accurately wound around the knitting needle. Record the motion parameters for each alternating rise and fall of the needle bed. The motion parameters include the timing interval before and after adjustment, the contact position deviation, and the adjustment time. This forms a timing control log and is stored in the database. Analyze the correlation between the needle contact position deviation and the rise and fall timing adjustment in the timing control log and record it as the timing deviation rule. This rule is used for subsequent dynamic optimization of the initial phase difference.

[0028] Further, the working steps of dynamically optimizing the initial phase difference according to real-time data during the weaving process in step S2 include: During the fabric weaving process, the actual values of the interweaving tightness on both sides of the fabric (unit: N / cm) are collected in real time through pressure sensors (installed at the fabric winding place), the sampling frequency is 1 Hz, and the timing control log is retrieved. Combining the actual values of the interweaving tightness with the timing deviation law in the timing control log, the deviation Δy = y_actual - y_target between the actual value and the target value is calculated; When the deviation Δy continuously exceeds the preset deviation range (±1 N / cm) for more than 2 times, the phase difference optimization program is started; Based on the direction and magnitude of the deviation, combined with the timing deviation law in the timing control log, the initial phase difference is adjusted, and the integral regulation algorithm is adopted: Δx = kI × ΣΔy, where kI is the integral coefficient (0.5 degrees / N). When y_actual < y_target, Δy is negative, indicating insufficient interweaving tightness. At this time, the phase difference needs to be increased to improve the interweaving tightness; when y_actual > y_target, Δy is positive, indicating excessive interweaving tightness. At this time, the phase difference needs to be decreased to reduce the interweaving tightness; The adjusted phase difference is applied to the coordinated control of the front and rear needle beds, and the actual values of the interweaving tightness are collected again and the timing control log is updated. The adjustment process is repeated until the deviation Δy between the actual value and the target value is within the preset deviation range (±0.5 N / cm). The adjusted phase difference at this time is the optimized phase difference and is stored in the parameter library.

[0029] It should be noted that both the initial phase difference and the optimized phase difference include the following parameters: Time interval parameter: The time difference between the front and rear needle beds to complete the same action (such as rising to the highest point and descending to the lowest point); Angle interval parameter (for circular or rotary needle beds): The difference in the rotation angles of the front and rear needle beds; Action logic parameter: The action cooperation sequence of the front and rear needle beds, such as "the front needle bed rises first and then descends → the rear needle bed synchronously descends and rises", "the rear needle bed executes the action when the front needle bed is stationary", etc.

[0030] The control of the needle beds of traditional flat knitting machines is mostly fixed timing, such as alternating actions at equal intervals, and it is impossible to dynamically adjust the cooperation relationship according to the fabric texture density and machine type parameters, which easily leads to problems such as asymmetric textures on both sides and loose interweaving. In this application, by setting step S2, through the coordinated actions of the front and rear needle beds, the yarn is evenly cross-wound on both sides of the fabric, while ensuring symmetric textures and consistent densities.

[0031] S3: Monitor the size of the loops formed by the front and rear needle beds during knitting. When there is a size deviation in the loops on the front and back sides of the fabric, adjust the hook line force of the corresponding needle bed to generate hook line force adjustment data.

[0032] It should be noted that the size of the coil is evaluated by the coil diameter, circumference and shape factor, with the shape factor being the ratio of the coil width to its height.

[0033] As a preferred embodiment, the steps for generating the line tension adjustment data include: The system uses a high-definition camera (1920×1080 pixels resolution) to capture images of loops formed by the knitting of the front and back needle beds in real time. The images are captured every 0.5 seconds. The lens focal length is adjusted to the optimal imaging distance according to the needle spacing, which is usually 10-15cm. Image processing is performed on the acquired coil image, including grayscale conversion, edge detection, contour extraction, etc., to extract the coil's diameter (mm), circumference (mm), and shape parameters (width-to-height ratio) as feature indicators of coil size; Compare the loop characteristic indicators of corresponding positions (same knitting row) of the front and rear needle beds, and calculate the size deviation value. Deviation value = (front needle bed loop diameter - rear needle bed loop diameter) / rear needle bed loop diameter × 100%; When the size deviation exceeds the preset deviation threshold (±5%), preliminary hooking force adjustment data is generated and sent to the corresponding needle bed drive device. When the front needle bed coil is too large, the hooking force of the front needle bed is reduced; when the rear needle bed coil is too large, the hooking force of the rear needle bed is reduced. The preset deviation threshold can be set according to industry standards or historical experience. After adjustment, the coil image is acquired again and the size deviation value is calculated. When the size deviation value is within the preset deviation threshold range (within ±5%), the adjustment of the needle bed hooking force is stopped, and the hooking force adjustment data is determined.

[0034] S4: Collect tension data of each area of ​​the fabric, and adaptively change the yarn feed speed of the flat knitting machine according to the tension difference between the edge and the middle area to generate yarn feed speed adjustment data.

[0035] The yarn feeding speed is controlled by a servo motor, with an adjustment accuracy of up to 0.1 meters per minute; As a preferred approach, the steps for generating yarn feed speed adjustment data include: During the fabric weaving process, tension data (in N) of the fabric edge and middle areas are collected by tension sensors (installed at the guide rollers at the edge and middle of the fabric) at a sampling frequency of 5Hz. Calculate the tension difference between the edge area and the middle area ΔF = |Fedge - FMiddle|. When the tension difference ΔF is greater than the preset difference (2N), it is determined that the yarn speed needs to be adjusted. Based on the magnitude of the tension difference, the adjustment range of the yarn feed speed is determined using a proportional adjustment algorithm: Δv=k×ΔF, where k is the proportional coefficient (0.05m / (min・N)). The larger the tension difference, the larger the adjustment range, and preliminary yarn feed speed adjustment data is generated. Specifically, when the tension in the edge region is greater than that in the middle region (F_edge - F_middle > 2N), the yarn speed in the edge region is reduced; when the tension in the middle region is greater than that in the edge region (F_middle - F_edge > 2N), the yarn speed in the middle region is reduced. The tension difference is monitored in real time. When the tension difference ΔF returns to the preset difference range (≤1.5N), the adjustment of the yarn feed speed is stopped, and the yarn feed speed adjustment data is determined.

[0036] In the entire weaving process, step S2 is the core control link. The optimized phase difference generated by it is synchronized to the entire weaving process in real time. After step S2 optimizes the initial phase difference to the optimized phase difference based on real-time data, this updated parameter becomes the benchmark for the execution of steps S3 and S4. When step S3 monitors the loop size and adjusts the hooking force, it matches the needle bed movement rhythm based on the optimized phase difference. When step S4 adjusts the yarn feed speed, it combines the needle bed alternation frequency determined by the optimized phase difference to ensure the coordination between the yarn feed and the needle bed movement. In other words, steps S3, S4 and step S2 are parallel and linked weaving links. Finally, the coordination of all process parameters is achieved through the integration of step S5 to ensure the stability of weaving.

[0037] A double-sided plain weave fabric weaving system using a flat knitting machine includes: The raw material matching module is used to screen yarns and pre-stretch them, and record yarn tension data; The double-sided needle bed coordination module is used to receive the yarn tension data. When the tension data is within the preset tension range, the front and rear needle beds of the flat knitting machine are arranged and alternately raised and lowered according to the initial phase difference to realize the cross-winding of the yarn on the front and back sides of the fabric. During the weaving process, the initial phase difference is dynamically optimized according to real-time data to generate an optimized phase difference. The initial phase difference is determined based on the fabric texture interlacing density and the flat knitting machine parameters; The texture symmetry calibration module is used to monitor the size of the loops formed by the front and back needle beds. When there is a size deviation in the loops on the front and back of the fabric, the hooking force of the corresponding needle bed is adjusted, and hooking force adjustment data is generated. The density dynamic adjustment module is used to collect tension data of various areas of the fabric and adaptively change the yarn feed speed of the flat knitting machine according to the tension difference between the edge and the middle areas, generating yarn feed speed adjustment data. The fabric forming and weaving module is used to receive and integrate the yarn tension data, optimize the phase difference, adjust the hooking force data and adjust the yarn speed data, and convert them into equipment drive signals for the flat knitting machine through parameter collaborative calculation, so as to control the flat knitting machine to complete the double-sided plain weave.

[0038] The above embodiments merely illustrate several implementation methods of the present invention, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention.

Claims

1. A method for double-sided plain weave fabric using a flat knitting machine, characterized in that, The method includes the following steps: S1: Select and pre-stretch the yarn, and record the yarn tension data; S2: Receive the yarn tension data, and when the tension data is within the preset tension range, arrange and alternately raise and lower the front and rear needle beds of the flat knitting machine according to the initial phase difference to realize the cross-winding of the yarn on the front and back of the fabric, and dynamically optimize the initial phase difference according to the real-time data during the weaving process to generate an optimized phase difference; The initial phase difference is determined based on the fabric texture interlacing density and the flat knitting machine parameters; S3: Monitor the size of the loops formed by the front and back needle beds. When there is a size deviation in the loops on the front and back of the fabric, adjust the hooking force of the corresponding needle bed and generate hooking force adjustment data. S4: Collect tension data of each area of ​​the fabric, and adaptively change the yarn feed speed of the flat knitting machine according to the tension difference between the edge and the middle area to generate yarn feed speed adjustment data; S5: Receives and integrates the yarn tension data, optimized phase difference, hooking force adjustment data, and yarn speed adjustment data, and converts them into equipment drive signals for the flat knitting machine through parameter collaborative calculation, thereby controlling the flat knitting machine to complete double-sided plain weave.

2. The method for double-sided plain weave fabric using a flat knitting machine according to claim 1, characterized in that, The generation of the initial phase difference includes the following steps: The basic phase interval value of the front and back needle beds is determined based on the texture interweaving density of the double-sided plain weave fabric. Based on the machine parameters of the flat knitting machine, the basic phase interval value is corrected to obtain the pre-adjusted phase difference; Through multiple trial weaving experiments, multiple test phase differences were formed by adjusting the initial phase difference up and down. Data on the loop interlacing tightness of the fabric on both sides under different test phase differences were collected, and a correlation model between the test phase difference and the interlacing tightness was established. Based on the required interlacing density of the target fabric, the optimal test phase difference is selected from the correlation model as the initial phase difference.

3. The method for double-sided plain weave fabric using a flat knitting machine according to claim 2, characterized in that, The correlation model is fitted using a univariate linear regression equation, as shown in the following formula: y=kx+b In the formula, y represents the interweaving tightness, x represents the test phase difference, and k and b are regression coefficients.

4. A method for double-sided plain weave fabric using a flat knitting machine according to claim 2, characterized in that, Step S2, which involves arranging and alternating the raising and lowering of the front and rear needle beds of the flat knitting machine according to the initial phase difference, includes the following steps: Obtain the yarn tension data output in step S1. When the tension data is within the preset tension range, start the alternating lifting control program of the front and rear needle beds. Generate the lifting and lowering timing instructions for the front and rear needle beds based on the initial phase difference; During the needle bed raising and lowering process, the contact position between the knitting needle and the yarn is monitored in real time. When the contact position deviates from the preset trajectory, the time interval of the raising and lowering sequence is adjusted. Record the motion parameters of each needle bed alternation and elevation to form a timing control log, and analyze the correlation between the needle contact position deviation and the elevation timing adjustment in the timing control log. This correlation is recorded as the timing deviation rule and used for subsequent dynamic optimization of the initial phase difference.

5. A method for double-sided plain weave fabric using a flat knitting machine according to claim 4, characterized in that, Step S2, which involves dynamically optimizing the initial phase difference based on real-time data during the weaving process to generate the optimized phase difference, includes the following steps: During the fabric weaving process, the actual values ​​of the interlacing tightness on both sides of the fabric are collected in real time, and the timing control log is retrieved. By combining the actual value of interleaving tightness with the timing deviation pattern in the timing control log, the deviation between the actual value and the target value is calculated; When the deviation exceeds the preset deviation range more than twice, the phase difference optimization program is activated. Based on the direction and magnitude of the deviation, and combined with the timing deviation pattern in the timing control log, the initial phase difference is adjusted; The adjusted phase difference is applied to the coordinated control of the front and rear needle beds, and the actual value of the interlacing tightness is collected again and the timing control log is updated. The adjustment process is repeated until the deviation is within the preset deviation range. The adjusted phase difference at this time is the optimized phase difference.

6. A method for double-sided plain weave fabric using a flat knitting machine according to claim 1, characterized in that, The pre-stretching step in step S1 includes: Based on the material properties of the yarn, set the initial tension value for pre-stretching; Real-time monitoring of yarn tension changes during pre-stretching process generates tension change curves; When the fluctuation amplitude of the tension change curve exceeds the preset fluctuation threshold, adjust the rotation speed of the tensioning device to restore the tension to a stable state. After the pre-stretching process is completed, the yarn is subjected to tension maintenance treatment.

7. A method for double-sided plain weave fabric using a flat knitting machine according to claim 1, characterized in that, Step S3, which generates the line tension adjustment data, includes the following steps: Real-time acquisition of images of loops formed by the knitting of the front and rear needle beds; Image processing is performed on the acquired coil images to extract the coil's diameter, circumference, and shape parameters as characteristic indicators of the coil's size; Compare the coil feature indicators at corresponding positions on the front and rear needle beds to calculate the dimensional deviation value; When the dimensional deviation exceeds the preset deviation threshold, preliminary hooking force adjustment data is generated and sent to the corresponding needle bed drive device; After adjustment, the coil image is acquired again and the size deviation value is calculated. When the size deviation value is within the preset deviation threshold range, the adjustment is stopped and the hooking force adjustment data is determined.

8. A method for double-sided plain weave fabric using a flat knitting machine according to claim 1, characterized in that, Step S4, which generates the yarn feed speed adjustment data, includes: During the fabric weaving process, tension data were collected at the edges and middle of the fabric. Calculate the tension difference between the edge area and the middle area. When the tension difference is greater than the preset difference, it is determined that the yarn speed needs to be adjusted. Based on the magnitude of the tension difference, determine the initial adjustment range of the yarn feed speed and generate preliminary yarn feed speed adjustment data; The system monitors the adjusted tension difference in real time. When the tension difference returns to the preset range, the adjustment is stopped and the yarn feed speed adjustment data is confirmed.

9. A double-sided plain weave fabric weaving system using a flat knitting machine, characterized in that, include: The raw material matching module is used to screen yarns and pre-stretch them, and record yarn tension data; The double-sided needle bed coordination module is used to receive the yarn tension data. When the tension data is within the preset tension range, the front and rear needle beds of the flat knitting machine are arranged and alternately raised and lowered according to the initial phase difference to realize the cross-winding of the yarn on the front and back sides of the fabric. During the weaving process, the initial phase difference is dynamically optimized according to real-time data to generate an optimized phase difference. The initial phase difference is determined based on the fabric texture interlacing density and the flat knitting machine parameters; The texture symmetry calibration module is used to monitor the size of the loops formed by the front and back needle beds. When there is a size deviation in the loops on the front and back of the fabric, the hooking force of the corresponding needle bed is adjusted, and hooking force adjustment data is generated. The density dynamic adjustment module is used to collect tension data of various areas of the fabric and adaptively change the yarn feed speed of the flat knitting machine according to the tension difference between the edge and the middle areas, generating yarn feed speed adjustment data. The fabric forming and weaving module is used to receive and integrate the yarn tension data, optimize the phase difference, adjust the hooking force data and adjust the yarn speed data, and convert them into equipment drive signals for the flat knitting machine through parameter collaborative calculation, so as to control the flat knitting machine to complete the double-sided plain weave.

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