Fabric weaving and dyeing production process

Abstract

The invention particularly relates to a cloth weaving and dyeing production process, which comprises the following steps of: forming stretch yarns from yarn raw materials through an elasticizer, directly feeding the stretch yarns into a knitting machine for knitting and weaving, directly feeding the woven cloth into a cloth inspecting machine for inspecting, rolling the woven cloth through a tension-free rolling machine to form gray cloth, and storing the gray cloth in a gray cloth storehouse; gray cloth stored in the gray cloth storehouse is conveyed to a plurality of dye vats beside the gray cloth storehouse through a conveying device; the cloth dyed and washed by the dye vat is sequentially scutched, washed, squeezed and shaped and then enters the cloth inspecting machine again to be inspected, and the inspected cloth is conveyed to a three-dimensional automatic finished cloth warehouse through an automatic conveying system to be stored. Original independent links such as elasticizing, knitting and weaving and dyeing and finishing are integrated into full-process automatic production, the labor requirement and the cloth vehicle using amount are greatly reduced, meanwhile, by means of a reasonable space utilization mode, the floor occupation of a plant is effectively reduced, and space waste caused by cloth pulling channels, cloth vehicle storage and the like in a traditional plane layout is avoided.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of textile printing and dyeing, and particularly relates to a weaving and dyeing production process. BACKGROUND

[0002] In the traditional weaving and dyeing production process, the overall process usually includes multiple relatively independent links, and there is a lack of close cooperation and linkage between the links. Specifically, first, the knitting weaving link needs to process the silk thread through the elasticizer, and then the elasticized silk thread is sent to the loom for weaving to form the gray cloth; the woven gray cloth needs to be inspected by manual or simple equipment for preliminary inspection of the quality of the gray cloth, and after screening out the qualified gray cloth, it is transferred to the gray cloth warehouse for temporary storage. Next, the dyeing and finishing link, the gray cloth warehouse needs to divide the gray cloth into cylinders according to the production needs, and then the gray cloth is transferred to the dyeing cylinder for dyeing treatment, and after dyeing, it needs to be washed to remove the floating color and impurities; after washing, the gray cloth is sent to the setting machine for setting to stabilize the size and shape of the gray cloth; the set product also needs to be inspected again, and the qualified and unqualified products are distinguished by manual screening, and the qualified products are rolled, packaged by hand, and finally transferred to the finished product warehouse by the truck for storage. In this process, the elasticizing, knitting weaving, dyeing and finishing core links often run independently, and the material transfer between the links relies on a large number of manual operation and truck transportation, and the equipment layout of each link is also in a plane dispersed manner, lacking systematic space planning.

[0003] The existing technology has many problems in actual operation. On the one hand, the independent operation of each production link leads to fragmented process, and the connection between elasticizing, weaving and dyeing and finishing relies on manual transfer and truck transportation, which not only requires a large number of labor, but also occupies a large amount of workshop space due to the frequent shuttle of trucks, resulting in low utilization rate of the workshop, and frequent manual intervention and truck transfer increases the risk of damage and pollution of the gray cloth, affecting the product quality stability. On the other hand, the quality control efficiency is low, and the inspection link mainly relies on manual judgment, which is easy to cause inaccurate quality screening due to human factors, and it is difficult to realize accurate quality monitoring of the whole process. In addition, the traditional plane layout of the factory design makes the equipment of each link distributed dispersedly, and the ground space is occupied by a large amount of ground space such as the truck storage area, further reducing the space utilization efficiency; at the same time, the whole process from weaving to dyeing and finishing to finished product storage lacks automatic monitoring, and it is difficult to track the production progress and trace the quality, which is difficult to meet the needs of efficient and intelligent production. SUMMARY

[0004] In order to solve the problems in the prior art, the present application provides a weaving and dyeing production process, which integrates the weaving and dyeing process and uses part of the equipment to provide material conveying work, thereby improving the efficiency and reducing the production cost, integrating two process steps in a limited space and saving transportation space and equipment, and saving manpower.

[0005] The technical scheme adopted by the present application is: In a first aspect, the present application provides a weaving and dyeing production process, and the specific steps are as follows: Step 100, after the yarn raw material is formed into elastic yarn by the elasticizer, the elastic yarn is directly fed into the knitting machine for knitting weaving, and the woven fabric is directly fed into the fabric inspection machine for inspection, and then is rolled by the tensionless rolling machine to form the grey fabric which is stored in the grey fabric warehouse; Step 200, the grey fabric stored in the grey fabric warehouse is conveyed to the dyeing vat beside the grey fabric warehouse by the conveying device; Step 300, after the fabric dyed and washed in the dyeing vat is rolled, opened, flat-washed and shaped, it is again fed into the fabric inspection machine for inspection, and the inspected fabric is transferred to the finished fabric warehouse for storage.

[0006] In combination with the first aspect, the present application provides a first embodiment of the first aspect, wherein a yarn guide structure is arranged between the knitting machine and the elasticizer, and the yarn coming out of the elasticizer is guided into the corresponding knitting machine by the yarn guide structure for weaving.

[0007] In combination with the first aspect, the present application provides a second embodiment of the first aspect, wherein the conveying device comprises an opening machine, and the grey fabric in the grey fabric warehouse is pre-shaped by the opening machine before being fed into the dyeing vat for dyeing and washing.

[0008] In combination with the first aspect, the present application provides a third embodiment of the first aspect, wherein the fabric inspection machine is arranged above the weaving machine in the height direction, a lifting mechanism is arranged between the fabric inspection machine and the discharge position of the weaving machine, the fabric coming out of the weaving machine is lifted to the fabric inspection machine by the lifting mechanism for inspection, the rolling machine arranged in the same height space as the weaving machine rolls the inspected fabric, and the lifting mechanism lifts the rolled fabric to the grey fabric warehouse in the same height space as the weaving machine.

[0009] With the third implementation manner of the first aspect, the fourth implementation manner of the first aspect is provided, at least two platforms with height difference are arranged in the vertical height direction of the same factory space, the bottom platform is provided with a texturing machine, a loom and a grey cloth warehouse, a cloth lifting mechanism and a cloth roll lifting mechanism are arranged between the platforms at different heights, the cloth woven by the loom on the lower platform is lifted to the interfacing cloth inspection machine on the upper platform through the cloth lifting mechanism, and the cloth roll is transmitted to the grey cloth warehouse on the lower platform through the interfacing cloth roll lifting mechanism of the cloth roll lifting mechanism.

[0010] With the fourth implementation manner of the first aspect, the fifth implementation manner of the first aspect is provided, the cloth lifting mechanism is a conveying device with a traction roller, the cloth roll lifting mechanism is a fixed guide frame depending on the gravity accumulation and falling of the cloth roll, and the cloth roll out of the cloth roll lifting mechanism is stacked in the grey cloth warehouse by manual operation.

[0011] With the second implementation manner of the first aspect, the sixth implementation manner of the first aspect is provided, in the step 200, a setting machine is arranged above the grey cloth warehouse in the height direction, the cloth roll in the grey cloth warehouse is opened and transmitted to the setting machine above the grey cloth warehouse for setting through the opening machine with different guide rollers at the corresponding heights of the grey cloth warehouse and the setting machine, and then the cloth after setting is transmitted to the dyeing and washing machine at the same height of the grey cloth warehouse through the lifting mechanism.

[0012] With the fourth or fifth implementation manner of the first aspect, the seventh implementation manner of the first aspect is provided, in the step 300, the grey cloth warehouse is interfaced in the bottom platform for dyeing and washing, and then the cloth after washing is opened and brought into the platform above the bottom platform through the opening machine between the two platforms for flat washing and setting, and after the setting, the cloth is inspected, rolled and packaged in the same height platform, and then the cloth roll after dyeing is transported to the finished cloth warehouse of the bottom platform through the cloth roll lifting mechanism.

[0013] With the first aspect or the implementation manners of the first aspect, the eighth implementation manner of the first aspect is provided, the cloth quality is checked through the device with the visual cloth inspection algorithm in the cloth inspection process, in the step 100, the cloth that does not meet the standard in the cloth inspection process is stored in the grey cloth warehouse as waste cloth, and in the step 300, the cloth that does not meet the standard in the cloth inspection process is sent back to the grey cloth warehouse for re-dyeing process.

[0014] The beneficial effects of the present application are as follows: (1) The application integrates the originally independent links of elasticizing, knitted fabric weaving, dyeing and finishing into full-process automatic production, breaks the traditional mode of separate operation of each link, realizes seamless connection of production links, greatly reduces the demand for manual labor and the amount of cloth vehicles through the application of mechanical transmission and automatic equipment, and effectively reduces the floor space occupation of the factory building by means of reasonable space utilization, avoiding the waste of space caused by the traditional layout of cloth channels and cloth vehicle storage; (2) In the application, the elasticizer and the loom are arranged close to each other, and the elastic yarn coming out of the elasticizer is directly woven into the loom, thereby reducing the packaging cost of the product, directly feeding into the machine room for direct machine operation, saving space and reducing labor; (3) The application can prevent the elastic internal stress of the gray cloth with elastic yarn by rolling and loosening the cloth through the tensionless rolling machine after weaving and cloth inspection, and the application of the tensionless rolling machine shortens the cloth loosening time; (4) The application uses infrared identification equipment to automatically screen the quality in the links of cloth inspection and setting, replaces the traditional manual cloth inspection method, improves the accuracy and efficiency of quality control, and reduces the quality misjudgment caused by human factors; (5) The full process in the application realizes automatic transmission through the devices such as conveyors and elevators, realizes full-process monitoring and automatic operation from weaving to finished product storage by combining automatic rolling machines and automatic packaging machines, and is convenient for production progress tracking and quality tracing; (6) The application utilizes the three-dimensional space layout, more machine tables can be placed on the first floor, and conveying equipment is installed on the second floor, which utilizes the space advantages of different floors and reduces labor consumption through short-distance lifting transmission; at the same time, through dry-wet partition management, the gray cloth is prevented from being stained with stains in the transmission process, and the warehouse turnover efficiency is further optimized by cooperating with a small amount of active cloth vehicles for first-in first-out management; at the same time, the reasonable layout of the elasticizer and the loom reduces the packaging cost of the product, facilitates direct machine operation, and improves the economy and efficiency of production as a whole. BRIEF DESCRIPTION OF DRAWINGS

[0015] Figure 1 is a flow chart of the first weaving and dyeing production process in the embodiment of the application; Figure 2 is a flow chart of the second weaving and dyeing production process in the embodiment of the application; Figure 3 is a flow chart of the third weaving and dyeing production process in the embodiment of the application. DETAILED DESCRIPTION

[0016] The application will be further explained in combination with the drawings and specific embodiments.

[0017] In order to make the objects, technical solutions and advantages of the embodiments of the present application clearer, the following will clearly and completely describe the technical solutions in the embodiments of the present application with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only some but not all of the embodiments of the present application. The components of the embodiments of the present application described and shown in the drawings can be arranged and designed in various different configurations.

[0018] Therefore, the following detailed description of the embodiments of the present application provided in the drawings is not intended to limit the scope of the claimed application, but only represents selected embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative work are within the scope of protection of the present application.

[0019] It should be noted that: similar reference numerals and letters represent similar items in the following drawings, therefore, once an item is defined in one drawing, it does not need to be further defined and explained in subsequent drawings.

[0020] In the description of the present application, it should be noted that if the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, or the orientation or positional relationship when the product of the application is usually placed, which is only for the convenience of describing the present application and simplifying the description, and does not indicate or imply that the indicated device or element must have a particular orientation, be constructed and operated in a particular orientation, therefore, it cannot be understood as a limitation on the present application. In addition, if the terms "first", "second" and the like appear in the description of the present application, they are only used to distinguish the description and cannot be understood as indicating or implying relative importance.

[0021] In addition, if the terms "horizontal", "vertical" and the like appear in the description of the present application, they do not mean that the component must be absolutely horizontal or vertical, but can be slightly inclined. For example, "horizontal" only means that its direction is relatively more horizontal than "vertical", and does not mean that the structure must be completely horizontal, but can be slightly inclined.

[0022] In the description of the present application, it should also be noted that unless otherwise explicitly specified and limited, if the terms "set", "mount", "connected", "connected" appear, they should be understood in a broad sense, for example, they can be fixedly connected, or can be detachably connected, or integrally connected; can be mechanically connected, or can be electrically connected; can be directly connected, or indirectly connected through an intermediate medium; can be the communication inside two elements. For those of ordinary skill in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0023] Embodiment 1: The embodiment discloses a weaving and dyeing production process, and aims to solve the problem of low efficiency of manpower and material resources caused by the existing process of separate weaving and dyeing.

[0024] It should be noted that the yarn of various materials in the embodiment is processed to form cloth, and then dyed and shaped, and finally packed and shipped. The process mainly involves process optimization and adjustment in a closed factory and related process layout in the factory. By optimizing the above, the efficiency is improved and the cost is saved. Referring to Figure 1 or Figure 2 , the specific steps are as follows: First, the weaving operation is performed: first, the yarn raw material is processed into elastic yarn by the elasticizer, and then directly sent to the knitting machine through the guide structure to form cloth; the woven cloth is transmitted to the cloth inspection machine by the lifting mechanism, and the quality is detected by the cloth inspection machine equipped with a visual cloth inspection algorithm. The qualified cloth is rolled by the rolling machine and stored in the grey cloth warehouse for use. The unqualified cloth is temporarily stored as waste cloth; Then, the dyeing operation is performed: the cloth roll in the grey cloth warehouse is divided into cylinders as needed, and the cloth determined to be divided into cylinders is directly sent to the corresponding dyeing cylinder for dyeing and washing. The cloth in the dyeing cylinder is treated by rolling and water absorption, and then opened by the opening machine. Then, the cloth is washed and shaped. The shaped cloth is detected by the cloth inspection machine. The qualified cloth is packed and then transmitted to the finished cloth warehouse on the bottom platform by the cloth roll lifting mechanism. The unqualified cloth is sent back to the grey cloth warehouse to re-enter the dyeing process.

[0025] It should be noted that based on the process, the elasticizer is arranged beside the weaving device, and the grey cloth warehouse is arranged beside the dyeing cylinder. Dry and wet separation is achieved by the partition plate or other isolation device arranged at intervals. In this process, the material transfer is carried out by automatic mechanical equipment. Only in the grey cloth warehouse and the finished cloth warehouse, manpower is used to twist and stack the materials at low cost.

[0026] In some embodiments, the cloth inspection equipment used in the weaving and dyeing process can be used in coordination with the same batch of equipment, that is, at least two cloth inspection machines are designed in the same area at the beginning, and the cloth inspection algorithm and threshold value are adjusted for classification and inspection according to the material transmission condition, the material output frequency, and the transmission equipment. The cloth from the weaving machine and the cloth from the setting machine are inspected in the same batch of cloth inspection machines. At the same time, the PLC control module determines the batch and source of the cloth for this time, so as to adjust the cloth inspection algorithm and threshold value for classification and inspection.

[0027] In some embodiments, the fabric warehouse and the finished fabric warehouse involved in the fabric weaving and dyeing process can be arranged in the same area, and the ground is marked or a spacing structure is arranged to separate them. At the same time, a fully automated warehouse management method can also be used, that is, a material trolley with automatic path planning is used to receive the fabric roll from the conveying belt or the rolling machine, each fabric roll is automatically coded according to the connected equipment, so that the material trolley can determine the information of the fabric according to the coding information of each connected fabric roll, and then randomly placed in the corresponding coding block of the warehouse for placement. When the fabric is taken out, the operator or the material trolley can find the fabric roll in the corresponding area according to the code to collect and transport uniformly, further improving the space utilization.

[0028] Further, the embodiment provides a basic fabric weaving and dyeing implementation mode, which is described below with reference to Figure 3 , as follows: A production platform in a factory building is determined, and a weaving area, a dyeing area and a fabric storage area are arranged in sequence along a straight line in the same production platform. The fabric storage area includes a fabric warehouse and a finished fabric warehouse, and the distances between the three areas are 8 m, 5 m respectively. A stainless steel conveying belt with a width of 0.8 m and a conveying speed of 12 m / min is used to realize seamless connection between the areas. Only 2 standby fabric cars are used when the fabric is temporarily stored in the cylinder. Compared with the traditional process, this setting method reduces the amount of fabric cars by 80%.

[0029] In the weaving area, two elastic machines with a model of FK6-1000 and three knitting machines with a model of JUKI-MH5000 are arranged in parallel with a spacing of 3 m. The elastic machine processes the yarn into elastic yarn with a draft ratio of 1.8, a setting temperature of 180°C and a speed of 80 m / min, and the yarn is directly fed into the knitting machine through a yarn guide structure with a spacing of 20 cm and a diameter of 5 mm ceramic guide roller.

[0030] The knitting machine weaves the fabric at a speed of 350 r / min. The woven fabric is directly conveyed to the fabric inspection machine at the edge of the area through the conveying belt. The model of the fabric inspection machine in the embodiment is YG033, the visual detection accuracy is 0.1 mm, and the detection speed is 20 m / min. The qualified fabric is rolled by a tensionless rolling machine with a model of XDJ-1200. The rolling parameters are a rolling diameter of 1.2 m and a tension of 60 N. The rolled fabric roll is conveyed to the fabric storage area within 5 min through the conveying belt. The temperature in the fabric warehouse is kept at 25°C and the humidity is kept at 60%.

[0031] The dyeing area is adjacent to the weaving area, and is internally provided with four dyeing machines of HCD-1000 type, one mangle of YPA-1600 type with a water pressure of 0.4 MPa and a liquid rate of 65%, one opening machine of KFJ-2000 type with an opening width of 1.8 m, one flat washing machine of SX-2000 type with a water temperature of 80 ℃ and a washing time of 5 min, and one setting machine of ZDG-3000 type with a setting temperature of 190 ℃ and a speed of 15 m / min.

[0032] The grey cloth in the cloth warehouse is directly sent into the dyeing vat through a conveying belt, the dyeing vat completes dyeing at a bath ratio of 1:10, a temperature of 135 ℃ and a holding time of 45 min, and then completes preliminary washing in the dyeing vat by washing with 80 ℃ hot water for 10 min. The cloth out of the vat is treated by the mangle, is opened by the opening machine at a speed of 12 m / min, and is then sent into the flat washing machine through the conveying belt to supplement washing to remove the floating color, wherein the washing water temperature is 70 ℃ and the time is 3 min, and then the cloth is set in the setting machine.

[0033] The cloth after setting is conveyed to the cloth inspection machine at the edge of the dyeing area through the conveying belt, the qualified cloth enters the automatic rolling machine to be rolled, and is conveyed to the finished product warehouse in the cloth storage area through the conveying belt within 3 min. In this embodiment, the finished product cloth warehouse is isolated from the grey cloth warehouse, and the environmental conditions in the finished product cloth warehouse are kept at a temperature of 23 ℃ and a humidity of about 55%. The unqualified cloth is returned to the grey cloth warehouse through a special conveying belt to be dyed again. Only two standby cloth vehicles are used when the grey cloth is divided into vats, and the use amount of the cloth vehicle is also reduced by 80% compared with the traditional process. The regions are directly connected through the conveying belt to realize the efficient linkage of weaving, dyeing and storage.

[0034] Further, another embodiment is provided in this embodiment, and the details are as follows: In the same production platform, four regions are arranged in a triangular shape, which are a weaving area, a dyeing area, a grey cloth storage area and a finished product storage area, and the distance between adjacent regions is 6 m. The regions are seamlessly connected through a stainless steel conveying belt with a width of 0.9 m and a conveying speed of 15 m / min, and only one standby cloth vehicle is used when the cloth is temporarily transferred.

[0035] In the weaving area, three FK6-1200 type elasticizers and four JUKI-MH6000 type knitting machines are arranged in parallel with a distance of 4 m. The elasticizer processes the yarn into elastic yarn at a draft ratio of 2.0, a setting temperature of 185 ℃ and a processing speed of 90 m / min, and the yarn is directly sent into the knitting machine through a yarn guide structure composed of ceramic guide rollers with a diameter of 6 mm.

[0036] The knitted machine is used to weave cloth at a rotating speed of 380 r / min. The elastic cloth containing spandex and the ordinary cotton non-elastic cloth are distinguished by a shunt device at the end of the conveying belt, and are respectively transported to the special storage positions of the elastic cloth and the non-elastic cloth in the cloth storage area, and the whole transmission time is not more than 4 min.

[0037] The woven cloth is first inspected by a cloth inspection machine with a visual detection accuracy of 0.08 mm and a detection speed of 22 m / min. The qualified cloth is rolled by a tension-free rolling machine with a roll diameter of 1.3 m and a tension of 70 N, and then is sent to the cloth storage area by a conveying belt.

[0038] In the cloth dyeing area, five HCD-1500 type dyeing kettles, one KFJ-2200 type open-width pre-setting machine, one YPA-1800 type mangle, one SX-2500 type open-width washing machine and one ZDG-3500 type setting machine are arranged.

[0039] The elastic cloth in the cloth storage area is first sent to the open-width pre-setting machine by the conveying belt, and the pre-setting is completed at an open-width width of 2.0 m, a setting temperature of 130℃ and a processing speed of 10 m / min. Then, the elastic cloth is transported to the dyeing kettle by the conveying belt. The non-elastic cloth is directly sent to the dyeing kettle by the conveying belt.

[0040] The dyeing kettle completes dyeing at a bath ratio of 1:4, a dyeing temperature of 138℃ and a holding time of 50 min, and then is washed by 85℃ hot water for 12 min. The cloth out of the kettle is treated by the mangle at a mangle pressure of 0.5 MPa and a liquid rate of 60%, is flattened by the open-width machine at an open-width width of 2.2 m, is sent to the open-width washing machine by the conveying belt at a transmission speed of 14 m / min, and then is set by the setting machine at a setting temperature of 195℃ and a processing speed of 12 m / min.

[0041] The set cloth is secondly inspected by the cloth inspection machine with a visual detection accuracy of 0.08 mm. The qualified cloth is rolled by the automatic rolling machine with a roll diameter of 1.3 m, and is transported to the finished product storage area by the conveying belt within 3 min. The unqualified cloth is transported to the cloth storage area by the special conveying belt to re-enter the cloth dyeing process. Only one standby cloth vehicle with a capacity of 600 kg is used in the whole process when the elastic cloth and the non-elastic cloth are temporarily stored in different kettles. The high-efficiency linkage of cloth weaving, cloth dyeing and cloth storage is realized by the triangular area layout and the direct connection of the conveying belt.

[0042] Further, the embodiment provides another implementation manner, which is specifically as follows. The two-layer layout is adopted in the same factory building, wherein the height of the bottom platform is 4.5 m, the knitting area, the dye vat area, the grey cloth warehouse and the finished product warehouse are arranged in the bottom platform according to the layered platform, then the height of the upper platform is 3.2 m, the inspection area, the pre-setting area and the setting area are arranged in the upper platform, the two layers are connected through the elevator with a bearing capacity of 500 kg and a lifting speed of 0.6 m / s and the anti-skid conveying belt with a width of 1.0 m and a conveying speed of 14 m / min, and only one spare cloth vehicle is used in the whole process when the cloth is abnormally sorted.

[0043] In the knitting area, four FK6-1500 type elastic machines and five JUKI-MH8000 type knitting machines are arranged transversely with a spacing of 5 m; the elastic machine processes the yarn into elastic yarn at a draft ratio of 1.9, a setting temperature of 182 ℃ and a processing speed of 85 m / min, and the yarn is directly sent to the knitting machine through the guide yarn structure composed of ceramic guide rollers with a diameter of 5.5 mm; the knitting machine is knitted into cloth at a speed of 360 r / min, and the knitted cloth is conveyed to the upper inspection area within 30 seconds through the elevator, and is inspected by the cloth inspection machine with a visual detection accuracy of 0.09 mm and a detection speed of 20 m / min, the qualified cloth is rolled by the tensionless rolling machine with a roll diameter of 1.25 m and a tension of 65 N, and is returned to the bottom grey cloth warehouse within 25 seconds through the elevator, and the whole transmission time is not more than 3 minutes; the unqualified cloth is returned to the bottom through the elevator and re-enters the knitting process.

[0044] The dye vat area is located on one side of the bottom knitting area, and six HCD-1600 type dye vats are arranged; the grey cloth in the grey cloth warehouse is divided into vats as needed, wherein the non-elastic grey cloth is directly sent to the dye vat through the conveying belt with a conveying speed of 12 m / min, and the elastic grey cloth containing spandex is first conveyed to the upper pre-setting area through the elevator, then is treated by the pre-setting machine at a setting temperature of 135 ℃ and a processing speed of 11 m / min, and then is returned to the bottom dye vat through the elevator. The dye vat completes dyeing with a bath ratio of 1:11, a dyeing temperature of 136 ℃ and a holding time of 48 min, and simultaneously performs preliminary washing; after the dyed cloth is treated by the mangle with a mangle pressure of 0.45 MPa and a liquid rate of 62%, it is conveyed to the upper layer through the raised opening machine, enters the open-width washing machine with a water temperature of 72 ℃ and a washing time of 4 min, and the tail end of the open-width washing machine is directly connected to the setting machine with a setting temperature of 192 ℃ and a processing speed of 13 m / min.

[0045] The set cloth is inspected again by the same type of cloth inspection machine in the lower layer inspection area, the qualified cloth is rolled by the automatic rolling machine with a roll diameter of 1.3 m, then is conveyed to the automatic packaging machine through the conveying belt with a conveying speed of 15 m / min, and finally is conveyed to the bottom finished product warehouse within 30 seconds through the elevator; the unqualified cloth is returned to the grey cloth warehouse through the special conveying belt and re-enters the dyeing process. Through the three-dimensional distribution of the two-layer space, the efficient connection of the equipment is realized, the use amount of cloth vehicles is reduced by 90% compared with the traditional process, and the space utilization rate of the workshop is improved by 40%.

[0046] Further, in order to achieve better dry-wet zoning effect, the embodiment further provides an implementation manner, which is specifically as follows: In the same factory building, the first floor is a dry area including a weaving area, a grey cloth warehouse, and a finished product warehouse, and the second floor is a water-using process area including a dye vat area, a water rolling area, and a flat water washing area. The two floors are connected by an anti-corrosion elevator with a load capacity of 600 kg and a lifting speed of 0.5 m / s and a waterproof conveyor belt with a width of 1.1 m and a transmission speed of 13 m / min. Only one spare cloth vehicle is used when the cloth is temporarily stored abnormally.

[0047] In the weaving area on the first floor, five FK6-1400 type elasticizers and six JUKI-MH7000 type knitting machines are arranged longitudinally with a spacing of 6 m. The elasticizer processes the yarn into elastic yarn at a draft ratio of 1.85, a setting temperature of 183°C, and a processing speed of 88 m / min, and the yarn is directly sent to the knitting machine through a yarn guide structure composed of ceramic guide rollers with a diameter of 5.8 mm. The knitting machine knits the cloth at a speed of 370 r / min. The woven grey cloth is conveyed to the elevator on the first floor and lifted to the second floor inspection station within 15 seconds.

[0048] The inspection is carried out by a cloth inspection machine with a visual detection accuracy of 0.09 mm and a detection speed of 21 m / min. The qualified grey cloth is returned to the grey cloth warehouse on the first floor within 20 seconds by the elevator and is stored by a tension-free rolling machine with a rolling diameter of 1.2 m and a tension of 63 N. The whole process is in a dry environment and there is no risk of water contamination.

[0049] The water-using process area on the second floor is arranged in a straight line and includes, from the outlet of the elevator, a dye vat area, a water rolling area, and a flat water washing area with a spacing of 5 m and connected by a waterproof conveyor belt. The grey cloth in the grey cloth warehouse on the first floor is conveyed to the dye vat area on the second floor within 30 seconds by the elevator. The elastic grey cloth containing spandex is first pretreated by a pre-setting machine at the entrance of the second floor to reduce wrinkles after dyeing, and then enters the dye vat. The dye vat completes dyeing at a bath ratio of 1:12, a dyeing temperature of 138°C, and a holding time of 50 min, and simultaneously performs preliminary hot washing.

[0050] The dyed cloth is sequentially dehydrated in the water rolling area to reduce the liquid rate to 60% and deepened to remove the floating color in the flat water washing area. After the treatment is completed, the cloth is returned to the dry setting area on the first floor within 40 seconds by the elevator at the end of the second floor, and the setting temperature is 195°C and the processing speed is 14 m / min. The set cloth is inspected again by the cloth inspection machine on the first floor. The qualified cloth is arranged by the automatic rolling machine and sent to the finished product warehouse within 5 minutes by the conveyor belt. The unqualified cloth is returned to the grey cloth warehouse on the first floor by a special conveyor belt and re-enters the dye vat process on the second floor.

[0051] The whole process is separated by dry and wet partition to avoid the influence of the second floor water process on the first floor dry area, and the fabric contamination rate is reduced to 0.3%; only relying on the connection of the elevator and the conveyor belt between the two floors, the use amount of cloth vehicle is reduced by 90% compared with the traditional process, only one standby cloth vehicle with a capacity of 800 kg is used when the elastic gray cloth is divided into cylinders, and the utilization rate of the workshop floor is improved.

[0052] Further, on the basis of the original PLC control module, the production rhythm linkage algorithm is optimized, specifically as follows: The knitted fabric output per hour of the knitting machines in the first floor weaving area is transmitted to the second floor dyeing cylinder area control system through industrial Ethernet, and the dyeing cylinder area automatically adjusts the cylinder dividing rhythm according to the gray fabric output.

[0053] When the first floor produces 1680m of gray fabric per hour at full load, the second floor 6 HCD-1600 dyeing cylinders automatically distribute materials according to 280m of gray fabric per cylinder, avoiding the accumulation of gray fabric in the elevator / conveyor belt.

[0054] The dyeing temperature and holding time data of the second floor dyeing cylinder are reversely synchronized to the first floor gray fabric warehouse management system, and if color difference occurs after dyeing of a batch of gray fabric, the system automatically marks the raw yarn batch number and knitting machine number of the batch of gray fabric, facilitating the tracing of whether there is a yarn tension unevenness problem in the weaving link, and realizing the weaving-dyeing quality traceability cooperation.

[0055] Further, between the first floor and the second floor, a 1.8m high transition dehumidification layer is newly added to further improve the dry-wet separation effect, and the specific structure and function are as follows: The transition layer is 4.5m away from the ground of the first floor and 0.3m away from the ground of the second floor, adopts a stainless steel sealing frame, and is internally provided with two rotary dehumidifiers, of which the model is DH-800 and the dehumidification capacity is 800kg / day.

[0056] The post-dyeing gray fabric with a liquid carrying rate of 60% treated by the water roller in the second floor water area first enters the transition layer through the waterproof conveyor belt, is treated by the dehumidifier for 120 seconds, and then is transported to the first floor setting area by the elevator; the gray fabric in the first floor gray fabric warehouse is also preheated by the transition layer before entering the second floor dyeing cylinder, avoiding the problem of uneven dyeing caused by directly putting low-temperature gray fabric into high-temperature dyeing cylinder.

[0057] A condensate collection tank is arranged at the bottom of the transition layer to collect the dye wastewater dripping from the second floor water area, which is uniformly transported to the plant wastewater treatment station through the pipeline to avoid the pollution of the wastewater to the gray fabric in the first floor dry area.

[0058] Further, in some embodiments, an RFID tag is automatically attached when each roll of gray fabric is rolled, and the tag has a temperature resistance range of-20℃~200℃; RFID readers are arranged at the entrances of the second floor dyeing cylinder and the first floor setting machine, and the system automatically matches "gray fabric information-dyeing cylinder parameters-setting parameters" to avoid cylinder and process errors.

[0059] Then the elevator priority response rule is set through the PLC system. When the dyeing on the second floor is completed and the knitting on the first floor is completed at the same time, the system allocates the elevator to the dyeing cloth transfer, and the woven cloth is temporarily stored through the first floor conveying belt, the temporary storage time is not more than 5 minutes, and a constant temperature fan is equipped to prevent the cloth from being damp, so that the transfer efficiency is maximized.

[0060] Between the water area on the second floor and the drying area on the first floor, an emergency inclined conveying belt is newly added. When the elevator fails, the conveying belt can realize emergency transfer of the cloth, so that the problem of complete production stop caused by elevator failure in the traditional process is avoided.

[0061] The application is not limited to the above-mentioned optional embodiments, and anyone can derive other various forms of products under the inspiration of the application. The above-mentioned specific embodiments should not be understood as limiting the protection scope of the application, and the protection scope of the application should be defined by the claims, and the specification can be used to explain the claims.

Claims

1. A fabric weaving and dyeing production process, characterized in that: The specific steps are as follows: Step 100: After the yarn raw material is processed into elastic yarn by the texturing machine, it is directly put into the knitting machine for knitting and weaving. The woven fabric is directly put into the fabric inspection machine for inspection, and then rolled into greige fabric by the tensionless winding machine and stored in the greige fabric warehouse. Step 200: The grey fabric stored in the grey fabric warehouse is transported to several dyeing vats next to the grey fabric warehouse by a conveying device; Step 300: After being dyed and washed in the dyeing vat, the fabric is then subjected to a series of processes including water squeezing, opening, washing, and setting. It is then inspected again by the fabric inspection machine. The inspected fabric is then transferred to the finished fabric warehouse for storage.

2. The fabric weaving and dyeing production process according to claim 1, characterized in that: In step 100, a yarn guide structure is provided between the knitting machine and the texturing machine. The yarn from the texturing machine is guided into the corresponding knitting machine for weaving.

3. The fabric weaving and dyeing production process according to claim 1, characterized in that: In step 200, the conveying device includes a fabric spreading machine. After the fabric in the fabric warehouse is pre-shaped by the fabric spreading machine, it is put back into the fabric warehouse to be dyed and washed in the dyeing vat.

4. The fabric weaving and dyeing production process according to claim 1, characterized in that: In step 100, the fabric inspection machine is set above the height of the weaving machine. A lifting mechanism is provided between the fabric inspection machine and the discharge position of the weaving machine. The fabric coming out of the weaving machine is lifted to the fabric inspection machine for inspection by the lifting mechanism. A rolling machine is set in the same space as the weaving machine to roll up the inspected fabric and lift it to the grey fabric warehouse at the same height as the weaving machine for storage by the lifting mechanism.

5. The fabric weaving and dyeing production process according to claim 4, characterized in that: At least two platforms with a height difference are set up in the vertical direction of the same factory space. The bottom platform is equipped with a texturing machine, a weaving machine and a fabric warehouse. A fabric lifting mechanism and a fabric roll lifting mechanism are set between the platforms at different heights. The fabric lifting mechanism lifts the fabric woven by the weaving machine on the lower platform to the upper platform to connect with the fabric inspection machine. The fabric roll lifting mechanism connects with the rolling machine on the upper platform to transfer the fabric roll to the fabric warehouse on the lower platform for storage.

6. The fabric weaving and dyeing production process according to claim 5, characterized in that: The fabric lifting mechanism is a conveying device with traction rollers, and the fabric roll lifting mechanism is a fixed guide frame that relies on the gravity of the fabric roll to fall. The fabric rolls coming out of the fabric roll lifting mechanism are manually stacked and placed in the raw fabric warehouse.

7. The fabric weaving and dyeing production process according to claim 3, characterized in that: In step 200, a setting machine is installed above the fabric warehouse in the height direction. The fabric roll in the fabric warehouse is opened and transmitted to the setting machine above the fabric warehouse by a spreading machine with different guide rollers at the corresponding heights of the fabric warehouse and the setting machine. Then, the pre-shaped fabric is transmitted to a dyeing vat at the same height as the fabric warehouse for dyeing and washing by a lifting mechanism.

8. A fabric weaving and dyeing production process according to claim 5 or 6, characterized in that: In step 300, the fabric is dyed, washed, and rubbed in the bottom platform and then the sizing machine between the two platforms opens the rubbed fabric and brings it to the platform above the bottom platform for flat washing and shaping. After shaping, the fabric is inspected, rolled, and packaged in the same height platform. The dyed fabric roll is then transported to the finished fabric warehouse on the bottom platform for storage by the fabric roll lifting mechanism.

9. A fabric weaving and dyeing production process according to any one of claims 1-7, characterized in that: During the fabric inspection process, the fabric quality is checked using a device equipped with a visual fabric inspection algorithm. In step 100, fabrics that do not meet the specifications during the fabric inspection process are stored as waste fabrics in the grey fabric warehouse. In step 300, fabrics that do not meet the specifications during the fabric inspection process are sent back to the grey fabric warehouse for re-dyeing.

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