Dyeing and weaving integrated weaving equipment and dyeing and weaving method thereof

Abstract

The invention relates to the technical field of textile equipment and weaving, and discloses dyeing and weaving integrated weaving equipment and a dyeing and weaving method thereof. Comprising an equipment frame body, and a let-off unit, a dyeing unit, a warp stopping unit, a weaving unit, a post-processing unit, a drafting and winding unit and an integrated control unit which are integrally arranged on the equipment frame body, the warp feeding unit conveys primary color warp yarns to the dyeing unit, the dyeing unit comprises a coloring and color fixing mechanism, after the primary color warp yarns are subjected to online dyeing and color fixing, the dyed yarns are conveyed to the warp stopping unit to be layered, fabric is woven in the weaving unit, and the fabric is wound by the drafting and curling unit after being cleaned and shaped by the post-processing unit. And the integrated control unit synchronously performs dyeing and weaving actions. The dyeing and weaving integrated continuous production is realized, the period is shortened, the problems of non-uniform dyeing and unstable quality in the traditional process are solved, the color uniformity and the size stability of the fabric are improved, and the method is suitable for small-batch personalized woven product production.

Description

Technical Field

[0001] This application relates to the field of textile equipment and weaving technology, and in particular to an integrated dyeing and weaving machine and its dyeing and weaving method. Background Technology

[0002] Woven textiles, with their advantages of structural stability, high strength, and wide applicability, are widely used in various fields such as clothing, home textiles, and industrial textiles. However, as market demand shifts towards personalization, small batches, and rapid response, some problems have gradually emerged in traditional weaving production processes.

[0003] Currently, textile production mainly employs two separate processes: "dyeing before weaving" and "weaving followed by dyeing." The "dyeing before weaving" process requires pretreatment, dyeing, and drying of the undyed yarn before transferring it to the weaving workshop for weaving. This process suffers from long production cycles and cumbersome transfer procedures. Furthermore, multi-color pattern production requires frequent changes of warp beams, making the operation complex and time-consuming, and difficult to meet the demands of flexible production. Additionally, the secondary unwinding of the dyed yarn can easily cause tension fluctuations, leading to an increased fabric defect rate.

[0004] The "post-weaving dyeing" process involves first weaving the undyed yarn into a greige fabric, and then dyeing it through post-treatment processes such as printing, steaming for color fixing, and washing. While this process eliminates the pre-dyeing step, the dye penetration into the fabric is prone to unevenness, especially for thick or complex fabrics, resulting in poor dyeing effects. Furthermore, the fabric requires repeated stretching and setting during finishing, which can easily lead to problems such as weft skew and edge curling, affecting the dimensional stability of the product. Additionally, the overall production process remains relatively fragmented, making it difficult to effectively shorten the production cycle.

[0005] Therefore, there is an urgent need for equipment and methods that can achieve integrated continuous production of dyeing and weaving to solve the problems of low production efficiency, insufficient flexibility, and poor product quality stability in traditional processes. Summary of the Invention

[0006] The purpose of this application is to provide an integrated dyeing and weaving machine and its dyeing and weaving method to solve the problems existing in the prior art.

[0007] To achieve the above objectives, the technical solution adopted in this application is as follows: On the one hand, this application provides an integrated dyeing and weaving machine, including an equipment frame, and further including a warp feeding unit, a dyeing unit, a warp stopping unit, a weaving unit, a post-processing unit, a drafting and crimping unit, and an integrated control unit integrated on the equipment frame. The warp feeding unit is used to feed the original color warp yarn and to feed the original color warp yarn to the dyeing unit; The dyeing unit is located between the back beam and the warp stop unit, and includes a dyeing mechanism and a fixing mechanism arranged sequentially along the warp yarn travel direction. The dyeing mechanism is used to dye the warp yarn, and the fixing mechanism is used to fix the dyed warp yarn in real time to form colored yarn. The output end of the dyeing unit is connected to the warp stop unit. The stop unit is used to layer the dyed yarn and then connect and transport it to the weaving unit; The weaving unit is used to form a fabric with a color pattern and to transport the fabric to the post-processing unit; The post-processing unit includes a cleaning mechanism and a drying and setting mechanism arranged sequentially along the fabric travel direction. The cleaning mechanism is used to clean residual dyes and impurities on the fabric surface, and the drying and setting mechanism is used to dry and set the size of the fabric. The stretching and crimping unit is used to wind up the finished fabric; The integrated control unit is connected to at least the dyeing unit and the weaving unit, and is used to synchronously control the dyeing / fixing action of the dyeing unit and the weaving action of the weaving equipment.

[0008] Furthermore, the warp feeding unit includes a warp beam, a back beam, and an electronic control module. The warp beam and the back beam are arranged sequentially along a third direction. The electronic control module and the warp beam are arranged along a first direction and integrated into the integrated control unit. The electronic control module drives the warp beam to release the primary color warp yarn, which is then conveyed to the dyeing unit after the tension is adjusted by the back beam. And / or, the back beam maintains the tension fluctuation range of the yarn layer within ≤±2.5%.

[0009] Furthermore, the coloring mechanism and the color-fixing mechanism are arranged sequentially at intervals along the warp direction; the coloring mechanism includes at least four independent coloring components, each of which includes an ink cartridge, a micro hydraulic pump, a solenoid valve, an inkjet tube, and a printhead. The ink cartridge contains ink, the micro hydraulic pump is located inside the ink cartridge and connected to the ink inlet of the solenoid valve to pressurize and output ink, and the ink outlet of the solenoid valve is connected to the printhead through the inkjet tube; the nozzles of the multiple printheads are arranged in an array to cover the width of the yarn layer laterally, and each nozzle corresponds to a single warp yarn. The ink cartridges of each coloring component contain different colored inks; and / or, the ink cartridges of the coloring components respectively contain cyan, yellow, magenta, and black inks; and / or, the distance between the printhead and the yarn is 5-10mm; and / or, the output pressure adjustment range of the micro hydraulic pump is 0.2-0.5MPa, and the response time of the solenoid valve is ≤10ms.

[0010] Furthermore, the color-fixing mechanism includes a drying chamber and a multimodal energy module. The drying chamber has a double-layer stainless steel insulation structure and its inner wall is lined with a high-temperature resistant ceramic layer. The multimodal energy module is located inside the drying chamber to release energy to achieve instant color fixing. The multimodal energy module includes a distributed electric heating wire array assembly and / or a UV-LED array assembly. And / or, the drying chamber has warp yarn inlets and outlets at both ends, and soft silicone curtains are installed at the inlets and outlets. The temperature adjustment range inside the drying chamber is 80-120℃.

[0011] Furthermore, the weaving unit includes an shedding unit, a weft insertion unit, and a beat-up unit. The shedding unit includes a driving component, a heddle selection device, a heddle return system, and heddle frames and heddle yarns arranged along a second direction. The driving component provides power to the heddle frames to drive them up and down, thereby opening the shed with the colored yarn. The heddle selection device selects the heddle frames participating in the shedding action according to the fabric weave diagram. After the driving component completes its pull-down action, the heddle return system drives the heddle frames back to their initial position. The heddle yarns drive the colored yarns through the eyelets, ensuring that the colored yarns move synchronously with the heddle frames. The driving component is a combination of a permanent magnet synchronous servo motor and a cam transmission assembly. The movement frequency adjustment range of the heddle frames is 100-300 times / minute. And / or, the heddle return system is a spring heddle return or a weighted heddle return. And / or, the heddle yarns include jacquard heddle yarns and / or skein heddle yarns.

[0012] Furthermore, the weft insertion unit includes a weft storage device, a weft insertion execution component, and a weft yarn detector; the weft storage device is used to store weft yarn and control the weft yarn output, and its length error for a single weft yarn delivery is ≤±1mm; the weft insertion execution component is used to deliver the weft yarn output by the weft storage device to the shed, and the weft insertion execution component is connected to the power drive module; the weft yarn detector is used to detect the weft yarn delivery status in real time, and if a weft break occurs, it sends a signal to the integrated control unit; wherein, the weft insertion execution component is one of a rapier assembly, an air jet nozzle assembly, and a water jet nozzle assembly.

[0013] Furthermore, the weft insertion unit includes a reed and a reed base. The reed is fixed on the reed base, and the reed base is connected to a servo motor via a crank-connecting rod mechanism. The servo motor drives the reed base to reciprocate and swing the reed to achieve weft insertion; and / or, the length adjustment range of the crank-connecting rod mechanism is ±5mm to adjust the weft insertion force.

[0014] Furthermore, the cleaning mechanism includes a cleaning tank, a circulating filter box, and a mechanical dewatering assembly; the cleaning tank is equipped with multiple sets of guide rollers to guide the fabric to be fully immersed in the cleaning solution; the circulating filter box includes a pre-particle filter and a post-activated carbon filter, which are connected to the cleaning tank via a water pump to achieve recycling of the cleaning solution; the mechanical dewatering assembly includes two opposing pressure rollers, at least one of which is connected to a pneumatic pressure module with a pressure adjustment range of 0.2-0.8 MPa, used to squeeze and dewater the cleaned fabric.

[0015] Furthermore, the drying and setting mechanism includes an insulation box, a heating component, and a tension adjustment component; the heating component includes heating wires arranged in an array along the circumference of the insulation box, and a hot air circulation system is provided on the top of the insulation box; the heating temperature adjustment range of the heating wires is 100-150℃; the tension adjustment component includes a drive motor and a tension roller connected to each other, used to provide real-time feedback on the fabric tension and adjust the pressure of the tension roller to maintain a constant fabric tension.

[0016] Furthermore, the drafting and crimping unit includes a pressure roller assembly and a transmission mechanism arranged sequentially along a third direction; the pressure roller assembly includes at least two oppositely arranged take-up pressure rollers, the surface of which is covered with a nitrile rubber layer for clamping the fabric; the transmission mechanism includes a take-up drum, a variable frequency motor, a gearbox, a torque sensor, and a magnetic powder brake, the variable frequency motor drives the take-up drum to rotate through the gearbox, the torque sensor monitors the take-up torque, the magnetic powder brake finely adjusts the take-up tension, and the take-up rate of the take-up drum is adjustable in the range of 0.5-2 m / min.

[0017] Furthermore, the integrated control unit includes a main control system and an operation control panel; the main control system includes an industrial PLC and a distributed I / O module, the industrial PLC has a built-in color-structure synchronization engine, used to decompose pattern data into dyeing instructions and weaving instructions, which are respectively sent to the dyeing unit and the weaving unit; the operation control panel is a touch screen, used to input production parameters, display equipment operating status and fault alarm information; the integrated control unit and the weaving unit are arranged at intervals along a first direction, the dyeing unit, warp stop unit, weaving unit, post-processing unit and drafting and crimping unit are arranged at intervals along a second direction, and the warp feed unit and dyeing unit are arranged at intervals along a third direction, the first direction, the second direction and the third direction are perpendicular.

[0018] On the other hand, this application also provides a dyeing and weaving method based on the above-mentioned integrated dyeing and weaving equipment, comprising the following steps: S1. Warp feeding and dyeing: The warp feeding unit feeds the original color warp yarn to the dyeing unit, the dyeing mechanism dyes the warp yarn, and the color fixing mechanism fixes the dyed warp yarn to form colored yarn in an instant. S2. Warp yarn detection and weaving: The warp stop unit detects broken colored yarns and combs them in layers, then sends them to the weaving unit for weaving to form a fabric, which is then sent to the post-processing unit. S3. Fabric post-treatment: The cleaning mechanism cleans the residual dyes and impurities on the fabric surface, and the drying and setting mechanism dries and sets the fabric. S4. Finished product take-up: The stretching and crimping unit takes up the finished fabric after shaping; wherein, the integrated control unit synchronously controls the dyeing / fixing action of the dyeing unit and the weaving action of the weaving equipment. Furthermore, step S1 also includes: S11. The warp beam (21) of the warp feeding unit (2) releases the original color warp yarn, and the tension is adjusted by the back beam (22) arranged in the third direction with the warp beam (21) so that the yarn layer is evenly and flatly distributed. S12. According to the fabric pattern, structure and color requirements, each dyeing component of the dyeing mechanism (31) sprays dye in proportion to dye a single warp yarn online. S13. The dyed warp yarns enter the color-fixing mechanism (32), and the multimodal energy module releases energy to complete the instant color fixation at a temperature of 80-120℃. Step S2 also includes: S21, the opening unit (5) causes the colored yarn to form a shed; S22, the weft insertion unit (6) introduces the weft yarn into the shed; S23, the beat-up unit (7) pushes the weft yarn toward the weft opening; Step S3 further includes: S31, the cleaning tank of the cleaning mechanism (81) soaks and cleans the fabric, the circulating filter box purifies the cleaning liquid, and the mechanical dehydration component squeezes and dehydrates the cleaned fabric; S32, the dehydrated fabric enters the drying and shaping mechanism (82), the heating component heats the fabric and the hot air circulation system makes the temperature in the heat preservation box uniform, and the tension adjustment component maintains the tension of the fabric to complete the drying and shaping.

[0019] The beneficial effects of the technical solution provided in this application include at least the following: (1) Achieve integrated continuous production and shorten the production cycle. By integrating the entire process units such as warp feeding, dyeing, weaving and post-processing on the equipment frame, the transfer and waiting links in the traditional process are eliminated, forming a continuous production link of "warp feeding - dyeing - weaving - post-processing - winding", which greatly shortens the production cycle and quickly responds to the needs of small batch and personalized orders.

[0020] (2) Enhance production flexibility and color diversity. The coloring mechanism uses at least four independent coloring components, supporting multi-color mixing such as cyan, yellow, magenta, and black. With the precise control of the integrated control unit, it can achieve millisecond-level color switching without stopping the machine to replace the warp beam, meeting the production needs of complex color patterns and adapting to extremely small batch orders starting from 1 meter.

[0021] (3) Improve product quality stability. The integrated control unit synchronously controls the dyeing and weaving actions, avoiding tension fluctuations caused by process separation in traditional processes; the color fixing mechanism enables immediate color fixing after dyeing, making the dye and yarn fibers more firmly bonded, solving the problem of uneven dye penetration; at the same time, the post-processing unit precisely controls the cleaning and setting parameters, reducing defects such as weft skew and curling of fabrics, and lowering the defect rate.

[0022] (4) Reduce production costs. The integrated design reduces the workshop floor space and storage space, and reduces the capital tied up in inventory; the design of cleaning fluid recycling and energy synergy optimization reduces energy and material consumption, and reduces wastewater treatment costs and unit product energy consumption; the equipment has a high degree of automation, which can reduce manual input and further reduce production costs. Attached Figure Description

[0023] The accompanying drawings are provided to further illustrate the present application and form part of the specification. They are used together with the embodiments of the present application to explain the application and do not constitute a limitation thereof. In the drawings: Figure 1 This is a schematic diagram of the structure of the weaving equipment in one embodiment of the present invention; Figure 2 This is a side view of the weaving equipment in one embodiment of the present invention; Figure 3 This is a schematic diagram of the flow structure of the warp weaving path in one embodiment of the present invention.

[0024] Explanation of key figure labels: 1. Equipment frame; 2. Warp feeding unit; 21. Warp beam; 22. Rear beam; 3. Dyeing unit; 31. Coloring mechanism; 32. Color fixing mechanism; 4. Warp stop unit; 5. Shedding unit; 6. Weft insertion unit; 7. Weft beating unit; 71. Rapier; 72. Reed; 8. Post-processing unit; 81. Cleaning mechanism; 82. Drying and shaping mechanism; 9. Drafting and crimping unit; 10. Integrated control unit. Detailed Implementation

[0025] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0026] In this specification, identical components are represented by the same reference numerals. It should be noted that the terms "front," "rear," "left," "right," "upper," and "lower" used in the following description refer to directions in the accompanying drawings, while the terms "bottom surface," "top surface," "inner," and "outer" refer to directions towards or away from a specific component, respectively. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this specification, "multiple" means two or more.

[0027] The raw materials for unbleached yarns may include natural fibers and / or chemical fibers; natural fibers may include plant fibers such as cotton and linen; and / or animal fibers such as wool, rabbit hair, camel hair, cashmere, and silk; and / or mineral fibers such as silica, alumina, and magnesium oxide; chemical fibers may include man-made fibers such as viscose fiber, acetate fiber, and cuprammonium fiber; and / or synthetic fibers such as polyester fiber, polyamide fiber, polyacrylonitrile fiber, polypropylene fiber, polyurethane fiber, aramid, polyetherimide fiber, and ultra-high molecular weight polyethylene fiber; unbleached yarns may be various organic or inorganic filament fibers, or at least one of various organic or inorganic short fibers, with the diameter of the filament fibers ranging from 5D to 3000D, and may also be applicable to monofilaments, multifilaments, ply yarns, and covered yarns, without any particular limitation in this application.

[0028] Example 1 Please see Figure 1 , Figure 2 and Figure 3 A dyeing and opening integrated weaving machine includes an equipment frame 1, and also includes a warp feeding unit 2, a dyeing unit 3, a warp stopping unit 4, a weaving unit, a post-processing unit 8, a drafting and crimping unit 9, and an integrated control unit 10, all integrated on the equipment frame 1.

[0029] In this embodiment, the equipment frame 1 serves as the main support structure of the equipment. It is fixed to the ground or work platform using adjustable anchor bolts, allowing for adjustment of the equipment's level. The interior of the equipment frame 1 is divided into multiple functional areas by horizontal and vertical beams, with each unit integrated within its corresponding area to ensure the independent and stable operation of each process.

[0030] In this embodiment, the integrated control unit 10 and the weaving unit are arranged at intervals along the first direction (X-axis direction, horizontal direction), facilitating operators to adjust control parameters without affecting weaving production. The dyeing unit 3, warp stop unit 4, weaving unit, post-processing unit 8, and drafting and crimping unit 9 are arranged at intervals along the second direction (Y-axis direction, vertical direction), forming a linear production flow for easy visual management. The warp feed unit 2 and dyeing unit 3 are arranged at intervals along the third direction (Z-axis direction, vertical direction), ensuring a straight yarn transport path and reducing tension fluctuations. The first, second, and third directions are perpendicular; this three-dimensional arrangement reduces the equipment footprint and avoids mutual interference between units during operation.

[0031] In this embodiment, the warp feeding unit 2 includes a warp beam 21, a rear beam 22, and an electronic control module. The warp beam 21 and the rear beam 22 are arranged sequentially along a third direction, and the electronic control module is arranged along a first direction and integrated into the integrated control unit 10.

[0032] The warp beam is a steel cylindrical structure with a width matching the working width of the equipment. Its surface is coated with a polyurethane anti-slip coating for winding and storing the primary color warp yarns. The electronic control module includes a servo motor and encoder, connected to the warp beam via a coupling, driving the warp beam to release the primary color warp yarns. The rear beam is horizontally installed downstream of the warp beam along the second direction to adjust the warp yarn tension, maintaining a yarn layer tension fluctuation range of ≤±2.5%, ensuring smooth delivery of the warp yarns to dyeing unit 3.

[0033] During operation, the integrated control unit 10 sends a warp feeding command to the electronic control module according to the weaving speed. The servo motor drives the warp beam to rotate and release the warp yarns. After the tension is adjusted by the back beam, the warp yarns are delivered to the dyeing unit 3 in a uniform and flat state.

[0034] The dyeing unit 3 is located between the rear beam and the warp stop unit 4, and includes a dyeing mechanism 31 and a color fixing mechanism 32 arranged sequentially along the warp yarn travel direction.

[0035] The coloring mechanism 31 and the fixing mechanism 32 are arranged alternately along the warp direction. The coloring mechanism 31 includes at least four independent coloring components, each containing an ink cartridge, a micro hydraulic pump, a solenoid valve, an inkjet tube, and a printhead. The ink cartridges hold ink, with the four coloring components holding cyan, yellow, magenta, and black inks respectively, supporting multi-color mixing. The micro hydraulic pump is located inside the ink cartridge and connected to the ink inlet of the solenoid valve, with an output pressure adjustable range of 0.2-0.5 MPa, used for pressurizing and outputting ink. The solenoid valve has a response time ≤10ms, and the ink outlet is connected to the printhead via the inkjet tube, enabling precise control of ink flow. The nozzles of multiple printheads are arranged in an array to cover the width of the yarn layer laterally, with each nozzle corresponding to a single warp yarn. The distance between the printhead and the yarn is 5-10mm to ensure optimal ink droplet atomization and prevent ink splatter.

[0036] The color-fixing mechanism 32 includes a drying chamber and a multimodal energy module. The drying chamber has a double-layer stainless steel insulation structure with a high-temperature resistant ceramic layer on the inner wall to reduce dye residue. The drying chamber has warp yarn inlets and outlets at both ends, with soft silicone curtains installed at these points to minimize heat loss. The multimodal energy module, located inside the drying chamber, includes a distributed electric heating wire array assembly and / or a UV-LED array assembly, used to release energy for immediate color fixing. The temperature range inside the drying chamber is 80-120℃, which can be flexibly adjusted according to the type of dye.

[0037] During operation, the integrated control unit 10 sends instructions to each dyeing component according to the fabric's color requirements. The micro hydraulic pump pressurizes the ink, the solenoid valve opens according to the instructions, and the nozzle sprays dye onto individual warp yarns. The target color is achieved through multi-color mixing. After dyeing, the warp yarns enter the drying chamber, where the multi-modal energy module releases energy to complete instant color fixing at a temperature of 80-120℃. After forming colored yarn, it is transported to the warp stop unit 4.

[0038] The warp stop unit 4 includes a warp stop frame arranged along the warp travel direction, and the warp stop frame is integrated with a detection component and a warp stop plate.

[0039] The detection components include a tension sensor and a signal transmission module, used to detect warp yarn breakage in real time. If a breakage is detected, a signal is immediately sent to the integrated control unit 10, the equipment stops operating and an alarm is triggered. Drop warp pieces are evenly distributed on the drop warp rack, used to layer and comb the dyed yarn, ensuring that each yarn is independently and parallelly arranged before being conveyed to the weaving unit.

[0040] The weaving unit includes the shedding unit 5, the weft insertion unit 6, and the beat-up unit 7.

[0041] The opening unit 5 includes a driving component, a heddle selection device, a heddle return system, and a heddle frame and heddle wires arranged along the second direction.

[0042] The drive unit is a combination of a permanent magnet synchronous servo motor and a cam transmission assembly, providing power to the heald frame and driving its up-and-down movement. The movement frequency of the heald frame is adjustable from 100 to 300 times per minute. The heald selection device is connected to the integrated control unit 10 and selects the heald frame to participate in the shedding action according to the fabric weave diagram. The heald return system is a spring return or a counterweight return; after the drive unit completes the pull-down action, it drives the heald frame back to its initial position. The heald yarns include jacquard heald yarns and / or skein heald yarns, which drive the colored yarn through the eyelets, ensuring that the colored yarn moves synchronously with the heald frame.

[0043] During operation, the integrated control unit 10 sends instructions to the heald selection device to select the corresponding heald frame. The driving component drives the heald frame to move up and down, causing the colored yarn to form a shed, preparing for weft insertion.

[0044] The weft insertion unit 6 includes a weft feeder 62, a weft insertion execution component 61, and a weft yarn detector; the weft insertion execution component 61 is used to transport the weft yarn output by the weft feeder 62 to the shed, and the weft insertion execution component 61 is connected to the power drive module; the weft yarn detector is used to detect the weft yarn transport status in real time, and if a weft break occurs, it sends a signal to the integrated control unit.

[0045] The weft feeder 62 stores weft yarn and controls its output, with an output error ≤ ±1mm, ensuring stable weft yarn supply. The weft insertion actuator 61 is one of a rapier assembly, an air jet nozzle assembly, or a water jet nozzle assembly. When the weft insertion actuator 61 is a rapier assembly, it includes a weft insertion rapier head and a rapier rod. The weft insertion rapier head has an open guide profile and an elastic clamp. The elastic clamp is used to clamp the weft yarn, and the guide profile is used to hold the weft yarn on a preset conveying trajectory. When the weft insertion actuator 61 is an air jet nozzle assembly, the power drive module is a pneumatic control module. The pneumatic control module controls the airflow pressure of the air jet nozzle assembly, and it is linked to the weft yarn detector signal. When the weft yarn conveying speed decreases, the airflow pressure is reduced synchronously. When the weft insertion actuator is a water jet nozzle assembly, the water outlet of the water jet nozzle assembly has a guide channel. The inner diameter of the guide channel gradually narrows along the weft yarn conveying direction to enhance the pushing force of the water flow on the weft yarn. Specific adjustments can be made flexibly according to the weft yarn type and fabric density. The weft yarn detector is located at the shed exit and is used to detect the weft yarn introduction status. If a weft break or abnormal weft yarn introduction occurs, a signal is immediately sent to the integrated control unit 10.

[0046] During operation, the weft feeder 61 releases a set length of weft yarn, the weft insertion actuator 61 quickly introduces the weft yarn into the shed, and the weft yarn detector monitors the weft yarn status in real time and feeds it back to the integrated control unit 10.

[0047] The weft insertion unit 7 includes a steel reed and a reed seat. The steel reed is fixed on the reed seat, and the reed seat is connected to the servo motor through a crank-connecting rod mechanism.

[0048] The crank-connecting rod mechanism has a length adjustment range of ±5mm, which can be used to change the weft-beating force to adapt to fabrics of different thicknesses and densities. The servo motor drives the reed holder to oscillate back and forth, pushing the weft yarn introduced into the shed towards the weft inlet to form a fabric with a color pattern, and then conveying the fabric to the post-processing unit 8.

[0049] The post-processing unit 8 includes a cleaning mechanism 81 and a drying and setting mechanism 82 arranged sequentially along the fabric travel direction.

[0050] The cleaning mechanism 81 includes a cleaning tank, a circulating filter box, and a mechanical dewatering assembly. The cleaning tank is equipped with multiple sets of guide rollers to guide the fabric to be fully immersed in the cleaning solution. The circulating filter box includes a pre-particle filter and a post-activated carbon filter, connected to the cleaning tank via a water pump to achieve the recycling of the cleaning solution. The mechanical dewatering assembly includes two opposing pressure rollers, at least one of which is connected to a pneumatic pressure module with a pressure adjustment range of 0.2-0.8 MPa, used to squeeze and dewater the cleaned fabric.

[0051] The drying and setting mechanism 82 includes a heat preservation box, a heating component, and a tension adjustment component. The heating component includes heating wires arranged in an array along the circumference of the heat preservation box, with a heating temperature adjustment range of 100-150℃. A hot air circulation system is provided at the top of the heat preservation box to ensure uniform temperature within the box. The tension adjustment component includes a connected drive motor and a tension roller, used to provide real-time feedback on the fabric tension and adjust the pressure of the tension roller to maintain constant fabric tension.

[0052] During operation, the fabric enters the washing tank and is fully immersed under the guidance of guide rollers. The washing solution is purified by a circulating filter box and recycled to remove residual dyes and impurities from the fabric surface. After washing, the fabric is squeezed and dehydrated by the mechanical dehydration unit and then enters the heat preservation box. The heating unit heats the fabric, and the hot air circulation system ensures uniform temperature. The tension adjustment unit maintains the fabric tension, completing the drying and dimensional setting process.

[0053] The stretching and crimping unit 9 includes pressure roller assemblies and a transmission mechanism arranged sequentially along a third direction.

[0054] The pressure roller assembly includes at least two opposing take-up pressure rollers, each coated with a layer of nitrile rubber for stable fabric clamping. The transmission mechanism includes a take-up drum, a variable frequency motor, a gearbox, a torque sensor, and a magnetic powder brake. The variable frequency motor drives the take-up drum to rotate via the gearbox, and the take-up rate of the take-up drum is adjustable from 0.5 to 2 m / min. The torque sensor monitors the take-up torque, and the magnetic powder brake fine-tunes the take-up tension to ensure a smooth take-up of the finished fabric.

[0055] The integrated control unit 10 includes a main control system and an operation control panel. The main control system includes an industrial PLC and distributed I / O modules. The industrial PLC has a built-in color-structure synchronization engine, which is used to decompose the pattern data into dyeing instructions and weaving instructions, and send them to the dyeing unit 3 and the weaving unit respectively, so as to realize the synchronous and coordinated control of each unit.

[0056] The control panel is a touch screen used to input production parameters, display equipment operating status and fault alarm information. The surface is covered with scratch-resistant and wear-resistant tempered glass, supports glove operation mode, and is equipped with a shock-absorbing bracket at the bottom to adapt to the vibration environment of the workshop.

[0057] Example 2: Based on the above-mentioned integrated dyeing and weaving equipment, this application also provides a dyeing and weaving method, including the following steps: S1, delivery and dyeing; S11. Under the drive of the electronic control module, the warp beam 21 of the warp feeding unit 2 releases the original color warp yarns. The tension is adjusted by the back beam 22 arranged in the third direction with the warp beam 21, so that the yarn layer is evenly and flatly distributed and the tension fluctuation range is ≤±2.5%.

[0058] S12. According to the fabric pattern, structure and color requirements, the integrated control unit 10 sends instructions to the coloring mechanism 31, and each coloring component sprays dyes such as cyan, yellow, magenta and black in proportion, and dyes the single warp yarn online through the nozzle.

[0059] S13. After dyeing, the warp yarn enters the drying chamber of the color-fixing mechanism 32. The multimodal energy module releases energy to complete the instant color fixation at a temperature of 80-120℃, forming colored yarn.

[0060] S2, Warp yarn inspection and weaving; S21. The colored yarn enters the warp stop unit 4. The detection component detects the yarn breakage in real time. The stop piece combs the colored yarn in layers and then conveys it to the opening unit 5.

[0061] S22, the heddle selection device of the opening unit 5 selects the heddle frame according to the fabric structure diagram, and the driving component drives the heddle frame to move up and down, thereby driving the colored yarn to form the shed.

[0062] S23, the weft feeder 62 of the weft insertion unit 6 releases the weft yarn of a set length, the weft insertion execution component 61 introduces the weft yarn into the shed, and the weft yarn detector detects the weft yarn introduction status.

[0063] S24, the servo motor of the beat-up unit 7 drives the reed holder to swing back and forth, pushing the weft yarn towards the weft hole to form a fabric with a color pattern, and then transporting the fabric to the post-processing unit 8.

[0064] S3, Fabric post-treatment S31. The fabric enters the cleaning tank of the cleaning mechanism 81 and is fully soaked under the guidance of the guide roller. The ultrasonic cleaner helps to remove residual dyes and impurities. The circulating filter box purifies the cleaning solution through the particle filter and the activated carbon filter to achieve recycling. The pressure roller of the mechanical dewatering component squeezes and dewaters the cleaned fabric under the drive of the pneumatic pressure module. The pressure adjustment range is 0.2-0.8MPa.

[0065] S32. After dehydration, the fabric enters the heat preservation box of the drying and shaping mechanism 82. The heating wire of the heating component heats within the range of 100-150℃, and the hot air circulation system makes the temperature inside the box uniform. The tension adjustment component provides real-time feedback on the fabric tension and adjusts the pressure of the tension roller to maintain constant fabric tension, thus completing the drying and dimensional shaping.

[0066] S4. Finished product winding The pressure roller assembly of the stretching and crimping unit 9 clamps the finished fabric after shaping. The variable frequency motor of the transmission mechanism drives the winding drum to rotate through the reduction gearbox. The winding speed adjustment range is 0.5-2m / min. The torque sensor monitors the winding torque, and the magnetic powder brake finely adjusts the winding tension to ensure that the finished fabric is wound flat.

[0067] Throughout the process, the integrated control unit 10 synchronously controls the dyeing / fixing action of the dyeing unit 3 and the weaving action of the weaving equipment to ensure a continuous production process and stable product quality.

[0068] In the embodiments disclosed in this application, the terms "installation," "connection," "linking," and "fixing" should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; "linking" can be a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in the embodiments disclosed in this application according to the specific circumstances.

[0069] The above description is only a preferred embodiment of this application. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of this application, and these improvements and modifications should also be considered within the scope of protection of this application.

Claims

1. A dyeing and weaving integrated machine weaving equipment, comprising an equipment frame body (1), characterized in that, The equipment rack (1) is integrated with a warp feeding unit (2), a dyeing unit (3), a warp stopping unit (4), a weaving unit, a post-processing unit (8), a draft crimping unit (9) and an integrated control unit (10); The warp feeding unit (2) is used for feeding the original color warp and delivering the original color warp to the dyeing unit (3); The dyeing unit (3) comprises a dyeing mechanism (31) and a fixing mechanism (32) arranged in sequence along the warp running direction, the dyeing mechanism (31) is used for dyeing the warp, and the fixing mechanism (32) is used for fixing the dyed warp to form colored yarn; the output end of the dyeing unit (3) is connected to the warp stopping unit (4); The warp stopping unit (4) is used for connecting and delivering the layered dyed yarn to the weaving unit; The weaving unit is used for forming fabric with color patterns and delivering the fabric to the post-processing unit (8); The post-processing unit (8) comprises a cleaning mechanism (81) and a drying and setting mechanism (82) arranged in sequence along the fabric running direction, the cleaning mechanism (81) is used for cleaning the residual dye and impurities on the surface of the fabric, and the drying and setting mechanism (82) is used for drying and size setting of the fabric; The draft crimping unit (9) is used for winding the finished fabric; The integrated control unit (10) is connected with at least the dyeing unit (3) and the weaving unit, and is used for synchronously controlling the dyeing / fixing action of the dyeing unit (3) and the weaving action of the weaving equipment.

2. The dyeing weaving all-in-one machine according to claim 1, characterized in that, The warp feeding unit (2) comprises a warp beam (21), a back rest (22) and an electronic control module, the warp beam (21) and the back rest (22) are arranged in sequence along a third direction, the electronic control module is arranged along a first direction with the warp beam (21) and integrated in the integrated control unit (10), and the electronic control module drives the warp beam (21) to release the original color warp, which is delivered to the dyeing unit (3) after the tension is adjusted by the back rest (22); And / or, the back rest (22) maintains the tension fluctuation range of the yarn layer to be less than or equal to ±2.5%.

3. The dyeing weaving all-in-one machine according to claim 1, characterized in that, The dyeing mechanism (31) and the fixing mechanism (32) are arranged in sequence along the warp running direction; the dyeing mechanism (31) comprises at least four independent dyeing components, each dyeing component comprises an ink cartridge, a micro hydraulic pump, an electromagnetic valve, an ink jet pipe and a nozzle, the ink cartridge contains ink, the micro hydraulic pump is arranged in the ink cartridge and connected with the ink inlet of the electromagnetic valve to pressurize and output ink, and the ink outlet of the electromagnetic valve is connected with the nozzle through the ink jet pipe; the nozzles of a plurality of nozzles are arrayed transversely to cover the width of the yarn layer, a single nozzle corresponds to a single warp, and the ink cartridges of each dyeing component contain different color inks. And / or, the ink cartridges of the dyeing components contain cyan, yellow, magenta and black inks respectively; And / or, the distance between the nozzle and the yarn is 5-10mm; And / or, the output pressure adjustment range of the micro hydraulic pump is 0.2-0.5MPa, and the response time of the electromagnetic valve is less than or equal to 10ms.

4. The dyeing weaving all-in-one machine according to claim 1, characterized in that, The fixing mechanism (32) comprises a drying box and a multi-modal energy module, the drying box is a double-layer stainless steel heat preservation structure and the inner wall is coated with a high-temperature-resistant ceramic layer, and the multi-modal energy module is arranged in the drying box to release energy to realize instant fixing; the multi-modal energy module comprises a distributed electric heating wire array assembly and / or a UV-LED array assembly. And / or, the drying box is provided with warp inlet and outlet at both ends, and soft silica gel curtains are installed at the inlet and outlet, and the temperature adjustment range in the drying box is 80-120℃.

5. The dyeing weaving all-in-one machine according to claim 1, characterized in that, The stopping unit (4) comprises a stopping frame arranged along the warp running direction, the stopping frame is integrally provided with a detection assembly and a stopping piece, the detection assembly is used for detecting the warp breakage, and the stopping piece is used for connecting and conveying the layered dyed yarn to the opening unit (5).

6. The dyeing and weaving all-in-one machine according to claim 1, characterized in that, The weaving unit comprises an opening unit (5), a weft insertion unit (6) and a beating-up unit (7), the opening unit (5) comprises a driving component, a selection harness device, a harness returning system and a harness frame and harness wire arranged along the second direction; the driving component provides power for the harness frame to drive it to move up and down, and drives the colored yarn to open the shed; The selection harness device selects the harness frame participating in the opening action according to the fabric organization chart; the harness returning system drives the harness frame to return to the initial position after the driving component completes the downward action; The harness wire drives the colored yarn through the burr eye to ensure that the colored yarn moves synchronously with the harness frame. The driving component is a combination of a permanent magnet synchronous servo motor and a cam transmission assembly, and the movement frequency adjustment range of the harness frame is 100-300 times / minute; And / or, the harness returning system is a spring returning system or a weight returning system; And / or, the harness wire comprises a jacquard harness wire or a twisting harness wire.

7. The dyeing weaving all-in-one machine according to claim 6, characterized in that, The weft insertion unit (6) comprises a weft accumulator (62), a weft insertion execution assembly (61) and a weft detector; the weft accumulator (62) is used for storing weft and controlling the weft output, and the length error of single weft conveying is ≤±1mm; the weft insertion execution assembly (61) is used for conveying the weft output by the weft accumulator (62) to the shed, and the weft insertion execution assembly (61) is connected with a power driving module; the weft detector is used for real-time detection of the conveying state of the weft, and if the weft breaks, a signal is sent to the integrated control unit (10).

8. The dyeing weaving all-in-one machine according to claim 6, characterized in that, The beating-up unit (7) comprises a reed and a reed seat, the reed is fixed on the reed seat, the reed seat is connected with a servo motor through a crank connecting rod mechanism, and the servo motor drives the reed seat to reciprocate to realize beating-up; And / or, the length adjustment range of the crank connecting rod mechanism is ±5mm to adjust the beating-up force.

9. The dyeing weaving all-in-one machine according to claim 1, characterized in that, The cleaning mechanism (81) comprises a cleaning tank, a circulating filter box and a mechanical dehydration assembly; a plurality of groups of guide rollers are arranged in the cleaning tank to guide the fabric to soak in the cleaning liquid; the circulating filter box comprises a front particle filter and a rear active carbon filter, and is communicated with the cleaning tank through a water suction pump to realize recycling of the cleaning liquid; the mechanical dehydration assembly comprises two oppositely arranged compression rollers, at least one of the compression rollers is connected with a pneumatic pressure module, the pressure adjustment range is 0.2-0.8 MPa, and the compression roller is used for extruding and dehydrating the cleaned fabric.

10. The dyeing weaving all-in-one machine according to claim 1, characterized in that, The drying and setting mechanism (82) comprises a heat preservation box, a heating assembly and a tension adjusting assembly; the heating assembly comprises heating wires arranged in an array along the circumference of the heat preservation box, the top of the heat preservation box is provided with a hot air circulation system, and the heating temperature of the heating wires is adjusted in the range of 100-150 DEG C; the tension adjusting assembly comprises a driving motor and a tension compression roller connected with each other, is used for real-time feedback of the fabric tension and adjustment of the tension compression roller pressure, and maintains constant tension of the fabric.

11. The dyeing weaving all-in-one machine according to claim 1, characterized in that, The drafting and crimping unit (9) comprises a compression roller assembly and a transmission mechanism arranged in sequence along a third direction; the compression roller assembly comprises at least two oppositely arranged compression rollers, the surfaces of the compression rollers are covered with nitrile rubber layers, and are used for clamping the fabric; the transmission mechanism comprises a winding drum, a variable frequency motor, a speed reducer, a torque sensor and a magnetic powder brake, the variable frequency motor drives the winding drum to rotate through the speed reducer, the torque sensor monitors the winding torque, the magnetic powder brake fine tunes the winding tension, and the winding speed of the winding drum is adjusted in the range of 0.5-2 m / min.

12. The dyeing weaving all-in-one machine according to claim 1, characterized in that, The integrated control unit (10) comprises a main control system and an operation control panel; the main control system comprises an industrial PLC and a distributed I / O module, the industrial PLC is built-in with a color-structure synchronous engine, is used for decomposing pattern data into dyeing instructions and weaving instructions, and respectively conveying the dyeing instructions and the weaving instructions to the dyeing unit (3) and the weaving unit; the operation control panel is a touch display screen, is used for inputting production parameters, displaying equipment running states and fault alarm information; the integrated control unit (10) and the weaving unit are arranged in sequence along a first direction, the dyeing unit (3), the stopping unit (4), the weaving unit, the post-processing unit (8) and the drafting and crimping unit (9) are arranged in sequence along a second direction, and the warp feeding unit (2) and the dyeing unit (3) are arranged in sequence along a third direction, the first direction and the second direction and the third direction are perpendicular.

13. A dyeing and weaving method based on the dyeing and weaving integrated machine equipment according to any one of claims 1-12, characterized in that, The method comprises the following steps: S1, warp feeding and dyeing: the warp feeding unit (2) feeds the original color warp to the dyeing unit (3), the dyeing mechanism (31) dyes the warp, and the fixing mechanism (32) fixes the dyed warp to form colored yarn; S2, warp detection and weaving: the stopping unit (4) detects the yarn breakage of the colored yarn and layers the colored yarn to be fed to the weaving unit to weave the fabric and feed the fabric to the post-processing unit (8); S3, fabric post-processing: the cleaning mechanism (81) cleans the residual dye and impurities on the surface of the fabric, and the drying and setting mechanism (82) dries and sets the fabric. S4, product winding: the drafted and curled unit (9) winds the finished fabric; wherein the integrated control unit (10) synchronously controls the dyeing unit (3) and the weaving equipment.

14. The dyeing weaving method according to claim 13, characterized in that, In step S1, further comprising: S11, the warp beam (21) of the warp feeding unit (2) releases the original color warp yarn, and the back rest (22) arranged along the third direction adjusts the tension to make the yarn layer evenly and flatly distributed; S12, according to the fabric pattern, texture and color requirements, each dyeing component of the dyeing mechanism (31) sprays dye in proportion to on-line dyeing of single warp yarn; S13, the dyed warp yarn enters the fixing mechanism (32), the multi-modal energy module releases energy to complete instant fixing at 80-120℃; In step S2, further comprising: S21, the shedding unit (5) forms a shed with the colored yarn; S22, the weft insertion unit (6) inserts weft yarn into the shed; S23, the beating-up unit (7) pushes the weft yarn to the shed; In step S3, further comprising: S31, the cleaning tank of the cleaning mechanism (81) soaks and cleans the fabric, the circulating filter box purifies the cleaning liquid, and the mechanical dehydration component squeezes and dehydrates the cleaned fabric; S32, the dehydrated fabric enters the drying and setting mechanism (82), the heating component heats and the hot air circulating system makes the temperature in the heat preservation box uniform, and the tension adjusting component maintains the fabric tension to complete drying and setting.

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