One-time forming method, device and system for double-sided heterogeneous seamless underwear

Abstract

The invention relates to the technical field of knitting forming, in particular to a one-time forming method, device and system for a double-faced heterogeneous seamless underwear, and the method comprises the steps: constructing a physically isolated double-channel yarn feeding path, and independently conveying yarns with different functions to a first needle bed and a second needle bed; upper and lower yarn tension is adjusted in real time through a high-frequency closed-loop tension control mechanism; based on the organization structure and the yarn parameters, differential control over the sedimentation depth, the yarn bending angle and the knocking-over time sequence is carried out through a looping stage self-adaptive algorithm; and yarn switching, tension setting and looping parameters are synchronously adjusted in combination with an ergonomic model and a function partition instruction. High-precision one-time forming of seamless underwear with heterogeneous front and back structures, performance or appearance can be achieved, and fabric density uniformity, cloth cover stability and function adaptability are improved.

Description

Technical Field

[0001] This invention belongs to the field of textile and apparel technology, and specifically relates to a one-time forming method, apparatus and system for double-sided heterogeneous seamless close-fitting garments. Background Technology

[0002] Seamless knitting technology is a key process in the production of high-end close-fitting garments. It involves knitting a tubular garment blank in one go using a circular weft knitting machine, eliminating side seams and significantly improving the comfort and fit of the garment. In recent years, with the growing demand for functional textiles, double-sided heterogeneous seamless knitted close-fitting garments have attracted much attention because their front and back sides can be designed differently in terms of structure, performance, or appearance. For example, in sportswear, the outer layer can be designed with a hydrophobic and abrasion-resistant structure to cope with environmental friction, while the inner layer can be designed with a skin-friendly and moisture-wicking structure to enhance wearing comfort. In the medical rehabilitation field, it allows for the organic combination of pressure and comfort surfaces to meet the dual needs of treatment and comfort.

[0003] Existing circular weft knitting technology and equipment still face significant technical bottlenecks in achieving high-quality double-sided heterogeneous seamless knitting. For example, Chinese invention patent CN105019121B discloses a "method for manufacturing knitted textile articles with variable shrinkage, a circular weft knitting machine, and knitted textile articles." This technology creates areas with different shrinkage levels within the same row by adjusting the feeding tension of the elastic yarn, with the core technology focusing on controlling the shrinkage variation of a single surface layer.

[0004] Chinese invention patent CN102864566B discloses a "fabric preparation method, preparation control method, preparation control device, and preparation system". This technology can divide functional areas and integrate them into a single form during the weaving process based on input human body data. Its advanced nature is mainly reflected in the pattern programming level.

[0005] The aforementioned prior art has the following drawbacks: 1. The Chinese invention patent with authorization announcement number CN105019121B does not have two sets of yarn guiding and loop forming mechanisms that are completely separated in physical space and can be independently programmed. This results in insufficient independence of its yarn guiding and loop forming system, making it difficult to completely independent parameter control of the front and back sides of the fabric. This greatly limits the freedom of double-sided heterogeneous design and the complexity of functional implementation.

[0006] 2. In existing double-sided heterogeneous weaving techniques, the yarns on the front and back sides undergo complex mechanical interactions at the loop formation points, and their tensions couple and interfere with each other. The lack of online monitoring and feedback on the real-time tension or loop shape of the double-sided yarns prevents the control system from dynamically adjusting its respective action parameters within microseconds to counteract this interference. This results in deviations from the intended double-sided structure during actual weaving, leading to poor forming stability.

[0007] 3. When dealing with yarn combinations exhibiting significant differences in elastic modulus, coefficient of friction, and yarn thickness, existing technologies often suffer from uncontrollable fluctuations in the loop length of single-sided or double-sided yarns due to the mutual coupling and restraint of tension in shared or adjacent paths. These fluctuations directly manifest as uneven fabric density, decreased fabric smoothness, and even quality issues such as horizontal stripes and cloudiness, severely hindering the stable production and performance consistency of double-sided heterogeneous products in high-standard application scenarios.

[0008] In summary, existing technologies, limited by integrated rather than isolated hardware architectures, open-loop rather than closed-loop control strategies, and statically preset rather than dynamically adaptive process algorithms, have significant shortcomings in achieving high-precision, high-stability one-time forming of double-sided heterogeneous seamless close-fitting garments. Therefore, constructing a circular weft knitting forming device with a physically isolated dual-channel yarn guiding and loop forming system, integrated high-frequency real-time sensing and closed-loop tension control functions, and equipped with an intelligent algorithm capable of online adaptive compensation for double-sided interaction has become crucial for overcoming current industry technological bottlenecks and meeting the manufacturing needs of high-end functional fabrics. Summary of the Invention

[0009] This invention provides a one-time forming method, apparatus, and system for double-sided heterogeneous seamless close-fitting garments. Its main purpose is to solve the problems of uneven fabric density, unstable fabric quality, and limited functional combinations caused by the lack of physically isolated yarn guide paths, double-sided tension coupling interference, and insufficient control ability in the loop-forming stage when existing circular weft knitting equipment knits double-sided heterogeneous structures.

[0010] To achieve the above objectives, the present invention provides a one-time forming device for double-sided heterogeneous seamless close-fitting garments. The device includes: a yarn feeding mechanism (3) for feeding a first type of yarn and a second type of yarn into a first needle bed (201) area and a second needle bed (202) area, respectively. The yarn feeding mechanism (3) is composed of a first yarn guide group (301) and a second yarn guide group (302), which are spatially isolated from each other and do not interfere with each other; and a tension control mechanism (4), including a first tension sensor (401) and a first servo pull roller (402) disposed at the outlet of the first yarn guide group (301), and a second tension sensor (403) and a second servo pull roller (404) disposed at the outlet of the second yarn guide group (302). The first tension sensor (401) and the second tension sensor (403) respectively collect the real-time tension signals of the upper channel yarn and the lower channel yarn, and transmit the signals to a central controller (101). The central controller (101) generates control commands according to a preset tension threshold, driving the first servo pull roller (402) and the second servo pull roller (404) to independently adjust their respective pull speeds; the loop forming mechanism (2) includes a first needle bed (201) and a second needle bed (202) that can be raised and lowered independently. The first needle bed (201) and the second needle bed (202) are respectively equipped with an independent sinker drive assembly (5) and a yarn bending triangle assembly (6). The motion parameters of the sinker drive assembly (5) and the yarn bending triangle assembly (6) are differentially adjusted by the central controller (101) according to the control signal output by the adaptive algorithm of the loop forming stage; the central controller (101) is used to receive fabric structure design data, yarn physical parameters and ergonomic models, and coordinate the operation sequence of the loop forming mechanism (2), the yarn feeding mechanism (3) and the tension control mechanism (4) to ensure that the front and back fabric structures are synchronously formed in each row according to the preset heterogeneous logic.

[0011] The present invention also provides a one-time forming method for double-sided heterogeneous seamless close-fitting garments, comprising: constructing a dual-channel yarn feeding path that is separated and physically isolated, and independently feeding yarns with different material properties or functional characteristics to the first needle bed (201) and the second needle bed (202) of the knitting needles respectively; during each loop forming cycle, the tension of the upper channel yarn and the lower channel yarn is monitored and dynamically adjusted in real time by a tension control mechanism (4) so ​​that the two yarns maintain their respective preset tension states during the loop forming process; based on the current transverse structure data and yarn elastic modulus parameters, the loop forming stage adaptive algorithm is called to differentiate the sinking depth, bending angle and loop release sequence of the first needle bed (201) and the second needle bed (202) to form heterogeneous fabrics with different loop lengths, structure densities or structural forms on the front and back sides; during the knitting process of the entire garment, the yarn type switching logic and tension setting value in the dual-channel yarn feeding path are adjusted synchronously according to the preset ergonomic model and functional partition instructions to complete the one-time forming of the double-sided heterogeneous seamless close-fitting garment.

[0012] This invention also provides a one-piece forming system (700) for double-sided heterogeneous seamless close-fitting garments. The system (700) includes: a dual-channel yarn feeding module (701) for establishing physically isolated upper and lower yarn paths and switching yarns of different materials or functional attributes according to functional partition instructions; a tension closed-loop control module (702) for real-time acquisition of yarn tension in the upper and lower yarn paths and applying differentiated tensioning to the two yarn paths through independent servo tensioning mechanisms to maintain the tension within their respective preset working ranges; and a loop forming adaptive control module. (703) is used to calculate the required sinking depth, yarn bending angle and loop release sequence of the first and second needle beds according to the current horizontal structure requirements, yarn elastic modulus and historical loop data, and generate corresponding drive signals; the collaborative scheduling module (704) is used to integrate the ergonomic model, fabric functional partition data and equipment operating status, and to perform global timing synchronization of the dual-channel yarn feeding module (701), tension closed-loop control module (702) and loop adaptive control module (703) to realize continuous, seamless and high-precision weaving of double-sided heterogeneous structure in the whole garment.

[0013] This invention constructs a dual-channel yarn feeding path that is physically isolated and separate from the upper and lower sections, ensuring that the yarns on the front and back sides do not interfere with each other during the conveying process. This avoids tension fluctuations caused by yarn cross-friction or path coupling in traditional single-channel or non-isolated dual-channel structures. By setting independent tension sensors and servo traction rollers at the exit of each yarn path and connecting their real-time feedback signals to the central controller, a high-frequency closed-loop tension control circuit is formed. This allows the traction tension of the upper and lower channels to be maintained within their respective preset stable ranges when dealing with yarn combinations with significant differences in elastic modulus, thereby suppressing abnormal fluctuations in coil length. By introducing an adaptive algorithm for the coiling stage, the central controller (101) dynamically adjusts the first needle bed (201) and the second needle bed (202) based on the current transverse structure data and yarn physical characteristics. The sinking depth, bending angle, and unwinding sequence enable the front and back loops to obtain different geometric shapes and density distributions during the forming process, thereby achieving heterogeneous design in terms of structure, performance, or appearance. In the knitting process of the entire garment, the collaborative scheduling module (704) plans and dynamically adjusts the yarn switching logic in the dual-channel yarn feeding module (701), the tension setting value in the tension closed-loop control module (702), and the loop forming parameters in the loop forming adaptive control module (703) according to the preset ergonomic model and functional partition instructions. This ensures that different double-sided functional combinations are configured as needed in key areas such as the shoulders, waist, and joints, such as a hydrophobic and wear-resistant outer layer and a skin-friendly and moisture-wicking inner layer, or a high-elastic support outer layer and a low-pressure contact inner layer, thereby meeting the composite functional requirements of close-fitting garments in scenarios such as sports protection, medical rehabilitation, and high-end underwear.

[0014] Compared with the prior art, the present invention has the following beneficial effects: 1. The physically isolated yarn feeding mechanism solves the problem of mutual interference of yarn paths in double-sided heterogeneous weaving, providing a hardware foundation for using yarns of different materials, thicknesses, or functions on the front and back sides. 2. The tension control mechanism effectively eliminates the double-sided tension coupling effect caused by the difference in the elastic modulus of the yarns by independently sensing and dynamically compensating for the tension of the yarns in the upper and lower channels, thus ensuring the uniformity of fabric density and the stability of fabric quality. 3. The adaptive algorithm in the loop-forming stage enables the loop-forming actions of the first and second needle beds to be executed differently according to actual needs, breaking the limitation of traditional equipment on the synchronous consistency of the front and back structures, and realizing one-time forming of double-sided heterogeneous structures; 4. Under the unified scheduling of the central controller, the entire system can seamlessly switch between different double-sided combination strategies within the entire garment based on ergonomic data and functional zoning requirements, significantly improving the functional adaptability, wearing comfort, and production efficiency of double-sided heterogeneous seamless close-fitting garments. Attached Figure Description

[0015] Figure 1 This is a front view structural schematic diagram of a one-piece forming device for double-sided heterogeneous seamless close-fitting garments provided in an embodiment of the present invention; Figure 2 for Figure 1 A magnified view of a section in area B shows the relationship between the dual-channel yarn feeding path and the needle bed; Figure 3 This is a schematic flowchart of a one-time forming method for double-sided heterogeneous seamless close-fitting garments provided in an embodiment of the present invention; Figure 4 This is a functional block diagram of a one-piece molding system for double-sided heterogeneous seamless close-fitting garments provided in an embodiment of the present invention.

[0016] 1. Base; 101. Central Controller; 102. Human-Machine Interaction Terminal; 2. Forming mechanism; 201 First needle bed; 202 Second needle bed; 3. Yarn feeding mechanism; 301 First yarn guide group; 302 Second yarn guide group; 4. Tension control mechanism; 401 First tension sensor; 402 First servo pull roller; 403 Second tension sensor; 404 Second servo pull roller; 5. Drive components: 501 First settling plate drive component; 502 Second settling plate drive component; 6-curved yarn triangle assembly 601 First curved yarn triangle assembly 602 Second curved yarn triangle assembly. Detailed Implementation

[0017] It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0018] Reference Figure 1 As shown, the one-time forming device for double-sided heterogeneous seamless close-fitting garments includes: a loop forming mechanism 2, a yarn feeding mechanism 3, a tension control mechanism 4, and a central controller 101.

[0019] The yarn feeding mechanism 3 is used to guide the first type of yarn and the second type of yarn into the first needle bed area and the second needle bed area respectively. The yarn feeding mechanism 3 is composed of a first yarn guide group 301 and a second yarn guide group 302. The two are arranged vertically and horizontally along the axial direction of the circular weft knitting machine, and there is no intersection or overlap in the radial and circumferential positions, ensuring that the upper channel yarn path and the lower channel yarn path are physically completely isolated.

[0020] The tension control mechanism 4 includes a first tension sensor 401 and a first servo pull roller 402 located at the outlet of the first yarn guide group 301, and a second tension sensor 403 and a second servo pull roller 404 located at the outlet of the second yarn guide group 302. The first tension sensor 401 and the second tension sensor 403 are electrically connected to the central controller 101 via signal lines to collect the tension signals of the yarn in the upper channel and the yarn in the lower channel in real time. The first servo pull roller 402 and the second servo pull roller 404 are electrically connected to the central controller 101 via drive lines to receive control commands output by the central controller 101 and independently adjust their respective pull speeds, thereby dynamically compensating for the yarn tension in the upper channel and the lower channel.

[0021] The loop-forming mechanism 2 includes a first needle bed 201 and a second needle bed 202 that can be independently raised and lowered. The first needle bed 201 is equipped with a first sinker drive assembly 501 and a first yarn bending cam assembly 601, and the second needle bed 202 is equipped with a second sinker drive assembly 502 and a second yarn bending cam assembly 602. The first sinker drive assembly 501, the second sinker drive assembly 502, the first yarn bending cam assembly 601 and the second yarn bending cam assembly 602 are all electrically connected to the central controller 101 through control lines, and their motion parameters are independently adjusted by the central controller 101 according to the differentiated control signals output by the adaptive algorithm of the loop-forming stage.

[0022] The first needle bed 201 is a circular needle bed containing several evenly distributed knitting needles, with 200 needles and a needle pitch of 2mm. The knitting needles are made of special steel. The first sinker drive assembly 501 includes a stepper motor, a transmission mechanism, and a sinker body. The stepper motor drives the sinker to move vertically via a screw transmission mechanism, with a movement range of 0.5-3.0mm. The first yarn bending cam assembly 601 is a rotatable and adjustable triangular guide, driven by a servo motor, with an adjustment range of 30°-60°.

[0023] The central controller 101 is an industrial-grade embedded computer system. Its input port is connected to the fabric structure design database, the yarn physical parameter storage module, and the ergonomic model database. Its output port is connected to the yarn feeding mechanism 3, the tension control mechanism 4, and the loop forming mechanism 2, respectively. It is used to coordinate the running sequence of each mechanism in each horizontal weaving cycle to ensure that the front and back fabric structures are formed synchronously according to the preset heterogeneous logic.

[0024] For example, when knitting a sports bra, the first yarn guide group 301 feeds polyester filament as the outer layer fabric, and the second yarn guide group 302 feeds spandex core-spun yarn as the inner layer fabric; the first tension sensor 401 monitors the tension value of the polyester filament in real time as 0.8 N, and the second tension sensor 403 monitors the tension value of the spandex core-spun yarn as 1.2 N; the central controller 101 generates control commands according to the preset tension thresholds (outer layer 0.75±0.05 N, inner layer 1.15±0.05 N), driving the first servo pull roller 402 and the second servo pull roller 404 to adjust their rotation speeds respectively, so that the tension of the two yarns is stabilized within their respective set ranges, avoiding fluctuations in coil length caused by differences in elastic modulus.

[0025] Furthermore, the first yarn guide group 301 and the second yarn guide group 302 in the yarn feeding mechanism 3 are each composed of multiple independent yarn guide ceramic parts arranged in a circumferential direction. The outlet axis of each yarn guide ceramic part is aligned with the center line of the knitting needles of the corresponding needle bed to ensure that the yarn does not deviate or rub against the needles during the feeding process. The first yarn guide group 301 is located 10 mm above the first needle bed 201, and the second yarn guide group 302 is located 10 mm below the second needle bed 202, forming a symmetrical and non-interfering dual-channel yarn feeding path.

[0026] Furthermore, the spatial arrangement of the first yarn guide group 301 and the second yarn guide group 302 can be implemented in various ways: Implementation method 1: The first yarn guide group 301 is located above the first needle bed 201, and the second yarn guide group 302 is located below the second needle bed 202, forming an upper and lower layered arrangement; Implementation method 2: The first yarn guide group 301 and the second yarn guide group 302 can be located on the front and rear sides of the circular weft knitting machine, respectively, forming a front-to-back separated arrangement; Implementation method 3: The first yarn guide group 301 and the second yarn guide group 302 can be located at different radial levels to form a coaxial multi-layer arrangement.

[0027] Furthermore, in the loop-forming mechanism 2, the first needle bed 201 and the second needle bed 202 are driven by independent servo motors, enabling precise lifting and lowering within a range of ±2 mm in the vertical direction; the first sinker drive assembly 501 and the second sinker drive assembly 502 control the sinking depth of the upper and lower sinkers respectively, with an adjustment range of 0.5 to 3.0 mm; the first yarn bending cam assembly 601 and the second yarn bending cam assembly 602 control the angles of the upper and lower yarn bending cams respectively, with an adjustment range of 30° to 60°; the loop-removal sequence is dynamically allocated by the central controller 101 according to the current weave structure data of the row, and there can be a time difference of 0 to 5 ms between the loop-removal actions of the first needle bed 201 and the second needle bed 202.

[0028] Therefore, through the differentiated control of the coiling mechanism 2, the coil length formed by the first needle bed 201 can be 2.8 mm and the coil length formed by the second needle bed 202 can be 2.2 mm, thereby forming a double-sided heterogeneous structure with a loose outer layer and a dense inner layer in the same row.

[0029] Furthermore, the settling plate drive assembly 5 can adopt the following drive method: Preferably, a stepper motor is used to drive the settling plates to rise and fall via a screw drive; Alternatively, a servo motor can be used to drive the sinker plate to rise and fall via a rack and pinion transmission. Alternatively, pneumatic or hydraulic cylinders can be used to directly drive the sinking plates to rise and fall.

[0030] Furthermore, the fabric structure data of multiple functional zones are spatially mapped according to the ergonomic model. For example, the shoulder area requires high elastic support on the outer layer and low pressure contact on the inner layer. In this area, the central controller 101 calls a combination of high elastic spandex and ultra-fine modal fiber yarns, and sets the upper channel tension to 1.0 N and the lower channel tension to 0.6 N. At the same time, the sinking depth of the first needle bed 201 is set to 2.5 mm and the sinking depth of the second needle bed 202 is set to 1.8 mm, and the yarn bending angles are set to 45° and 50° respectively, thereby forming a preset double-sided heterogeneous structure in the shoulder area.

[0031] Preferably, the sampling frequency of the tension control mechanism 4 is not less than 1 kHz and the control period is not greater than 1 ms, so as to ensure that the tension can be maintained stably under high-speed weaving (up to 300 rpm); the tension sensor adopts the non-contact optical tension detection principle to avoid damage to the yarn surface.

[0032] Furthermore, the central controller 101 incorporates an adaptive algorithm for the loop-forming stage. This algorithm, based on the current weave structure data, yarn elastic modulus parameters, and historical loop-forming data, calculates the required sinking depth, yarn bending angle, and loop-removal sequence for the first needle bed 201 and the second needle bed 202 using a multivariate optimization model. The algorithm model is expressed as follows: , in, Indicates the settlement depth. Indicates the bending angle of the yarn. Indicates the timing of exiting the loop. This is the organizational structure data for the current row. The elastic modulus of the yarn. For historical circle data, subscript and These correspond to the first and second needle beds, respectively.

[0033] In this embodiment of the invention, the knitting process of the entire garment is divided into multiple functional zones according to a preset ergonomic model, including the shoulder, chest, waist, hip and joint areas; when crossing the boundaries of different zones, the central controller 101 synchronously switches the yarn type in the yarn feeding mechanism 3, the tension setting value in the tension control mechanism 4 and the loop forming parameters in the loop forming mechanism 2 to achieve a seamless transition.

[0034] For example, through the coordinated operation of the yarn feeding mechanism 3 and the tension control mechanism 4, a double-sided heterogeneous structure with a hydrophobic and abrasion-resistant outer layer and a skin-friendly and moisture-wicking inner layer can be achieved. The organizational structure includes: representing the organizational structure of the outer fabric, which is a plain weave structure woven from polyester filaments; representing the organizational structure of the inner fabric, which is a pique mesh structure woven from modal fibers; and representing the cross-section of the composite double-sided heterogeneous fabric, clearly showing the physical separation and structural differences between the upper and lower fabrics.

[0035] Furthermore, in the shoulder area, the outer layer uses high-elastic spandex core-spun yarn, and the inner layer uses low-pressure microfiber. After being adjusted by the central controller 101, the fabric cross-section shows that the outer layer has a coil density of 18 coils / inch and the inner layer has a coil density of 24 coils / inch, meeting both support and comfort requirements. In the waist area, the outer layer uses antibacterial polyester, and the inner layer uses moisture-wicking fiber, with coil lengths of 2.6 mm and 2.0 mm respectively, achieving functional adaptation.

[0036] Therefore, the one-time forming device for double-sided heterogeneous seamless close-fitting garments provided by the present invention can independently and precisely control the yarn path, tension state and loop forming action on both sides, and realize true one-time forming of double-sided heterogeneous garments.

[0037] Preferably, the one-time forming device for double-sided heterogeneous seamless close-fitting garments may further include a human-machine interface terminal 102, which is communicatively connected to the central controller 101, for inputting fabric design parameters, monitoring equipment operating status, and displaying real-time tension data.

[0038] Specifically, the human-machine interface terminal 102 can be an industrial touch screen or a keypad screen, supporting graphical fabric structure editing and real-time process parameter visualization. The first needle bed 201 is a ring-shaped needle bed structure, arranged in a horizontal ring, with several needle grooves evenly distributed on the upper surface; the yarn guide ceramic component in the first yarn guide group 301 is a ceramic ring-shaped yarn guide component with a circular through hole in the center, and the inner diameter of the hole is 3-5mm; the first servo pull roller 402 and the second servo pull roller 404 are cylindrical rollers with a rubber layer on the surface, a roller diameter of 50mm, and a roller length of 80mm; the sinker is a thin sheet metal component with a thickness of 1-2mm, a length of 30-50mm, and a width of 10-15mm, which can move in the vertical direction; the yarn bending triangle is a triangular guide component, and the three guide surfaces form adjustable guide angles with the yarn path.

[0039] Furthermore, in this embodiment, the needle bed diameter of the circular weft knitting machine is 400-600mm, the number of needles is 200-400, and the needle pitch is 1.5-3.0mm.

[0040] Furthermore, the detection range of the first tension sensor 401 and the second tension sensor 403 is 0-10N, the accuracy is ±0.01N, and the response time is <1ms.

[0041] Furthermore, the yarn diameter applicable to this device is 0.1-2.0mm, and the yarn material can be polyester, spandex, nylon, modal fiber, etc.

[0042] Specifically, the central controller 101 is fixedly connected to the mounting plate inside the base 1 by bolts; the first needle bed 201 and the second needle bed 202 are slidably connected to the base 1 by lifting guide rails, which are fixed to the inner wall of the base 1; the first yarn guide assembly 301 is fixedly connected to the first needle bed 201 by bolts through an L-shaped bracket; the first tension sensor 401 is fixedly connected to the yarn outlet of the first yarn guide assembly 301 by a sensor bracket; the sinker is connected to the drive rod of the sinker drive assembly by a sliding connection, and the drive rod pushes the sinker to move up and down in the guide groove; the first servo traction roller 402 is fixedly connected to the base 1 by bolts through a bearing seat, and the roller body is rotatably installed in the bearing seat through a bearing; the electrical components are connected by cables, and the cables are connected by quick-connect connectors for easy assembly and maintenance.

[0043] Furthermore, the first needle bed 201 and the lifting guide rail are in a sliding fit with a clearance of 0.1-0.3mm to ensure smooth lifting of the needle bed; the sinker plate and the guide groove are in a clearance fit with a clearance of 0.05-0.15mm to ensure smooth movement of the sinker plate without wobbling; the roller body of the first servo pull roller 402 and the inner ring of the bearing are in an interference fit with an interference amount of 0.01-0.03mm to ensure a tight fit between the roller body and the bearing; when the yarn passes through the inner hole of the yarn guide ceramic, it is in a clearance fit, and the inner hole diameter of the yarn guide ceramic is 1-3mm larger than the yarn diameter to ensure smooth passage of the yarn; the yarn and the surface of the first servo pull roller 402 are in a friction fit, and the rubber layer on the surface of the servo pull roller generates appropriate friction between itself and the yarn, with a friction coefficient of 0.3-0.5 to ensure effective yarn pulling.

[0044] This application provides a one-step forming method for double-sided heterogeneous seamless close-fitting garments. The main body executing this method is the central controller 101 in the aforementioned device, which achieves fully automated knitting by running a preset control program.

[0045] Reference Figure 3The diagram shown is a flowchart illustrating a one-step forming method for a double-sided heterogeneous seamless bodysuit according to an embodiment of the present invention. In this embodiment, the method includes: S1. Construct a dual-channel yarn feeding path that is separated and physically isolated, and independently feed yarns with different material properties or functional characteristics to the first and second needle beds of the knitting needles respectively.

[0046] In this embodiment of the invention, the dual-channel yarn feeding path is physically isolated by the spatial layering arrangement of the first yarn guide group 301 and the second yarn guide group 302, ensuring that the yarn in the upper channel and the yarn in the lower channel do not cross or rub against each other during the conveying process.

[0047] Specifically, constructing a dual-channel yarn feeding path includes: selecting a first type of yarn and a second type of yarn from the yarn library according to the fabric functional zoning instructions; threading the first type of yarn into the yarn guiding ceramic sequence of the first yarn guide group 301, and threading the second type of yarn into the yarn guiding ceramic sequence of the second yarn guide group 302; adjusting the position of each yarn guiding ceramic to precisely align the yarn exit axis with the center line of the knitting needles on the corresponding needle bed.

[0048] S2. During each looping cycle, the tension of the upper and lower channel yarns is monitored and dynamically adjusted in real time by the tension control mechanism, so that the two yarns maintain their respective preset tension states during the looping process.

[0049] In this embodiment of the invention, the tension control mechanism 4 acquires tension signals at a frequency of not less than 1 kHz and completes the generation and execution of control commands within 1 ms.

[0050] Specifically, the dynamic adjustment includes: the first tension sensor 401 and the second tension sensor 403 respectively collect the real-time tension values ​​of the upper channel and the lower channel; the central controller 101 compares the real-time tension value of the upper channel with a preset threshold, and if the deviation exceeds ±0.05 N, it generates a speed adjustment command to drive the first servo traction roller 402; similarly, the lower channel is adjusted.

[0051] S3. Based on the current row structure data and yarn elastic modulus parameters, call the loop-forming stage adaptive algorithm to differentiate the sinking depth, yarn bending angle and loop release sequence of the first and second needle beds, so as to form heterogeneous fabrics with different loop lengths, structure densities or structural forms on the front and back.

[0052] In this embodiment of the invention, the adaptive algorithm for the loop formation stage calculates the optimal combination of loop formation parameters in real time based on the input parameters.

[0053] Specifically, the differentiated control includes: reading the functional partition identifier of the current row; retrieving the corresponding organizational structure data, upper yarn elastic modulus and lower yarn elastic modulus from the database; substituting into the pre-trained multivariate optimization model to calculate the sinking depth, yarn bending angle, loop release sequence of the first needle bed 201 and the corresponding parameters of the second needle bed 202; and outputting control signals to each drive component to execute differentiated loop forming actions.

[0054] S4. During the weaving process of the entire garment, based on the preset ergonomic model and functional zoning instructions, the yarn type switching logic and tension setting value in the dual-channel yarn feeding path are adjusted synchronously to complete the one-time forming of the double-sided heterogeneous seamless close-fitting garment.

[0055] In this embodiment of the invention, the ergonomic model divides the clothing into N functional zones, each zone being associated with a specific yarn combination and process parameters.

[0056] Specifically, the synchronous adjustment includes: when the knitting row enters a new functional zone, the central controller 101 triggers a yarn switching command to control the yarn feeding mechanism 3 to change the corresponding yarn; at the same time, the upper and lower channel preset thresholds in the tension control mechanism 4 are updated; and new loop forming parameters are loaded to the loop forming mechanism 2 to ensure that each module is seamlessly connected at the zone boundary.

[0057] In this embodiment of the invention, the one-time forming method provided by the invention can achieve full heterogeneity of the front and back sides in terms of yarn material, coil structure, weave density and functional characteristics in a single weaving process. This overcomes the fabric defects caused by path coupling and tension interference in traditional equipment, and significantly improves the functional adaptability and production efficiency of double-sided heterogeneous seamless close-fitting garments.

[0058] like Figure 4 The diagram shown is a functional block diagram of a one-piece molding system for double-sided heterogeneous seamless close-fitting garments provided in an embodiment of the present invention.

[0059] The one-piece forming system 700 for double-sided heterogeneous seamless close-fitting garments of the present invention can be installed in the central controller 101. According to the functions implemented, the system 700 includes a dual-channel yarn feeding module 701, a tension closed-loop control module 702, a loop forming adaptive control module 703, and a collaborative scheduling module 704. Each module refers to a computer program segment stored in the memory and executable by the processor.

[0060] In this embodiment, the functions of each module are as follows: the dual-channel yarn feeding module 701 is used to establish physically isolated upper and lower yarn paths, and to switch yarns of different materials or functional attributes according to the functional partitioning instructions. The tension closed-loop control module 702 is used to collect the yarn tension in the upper and lower yarn paths in real time, and apply differentiated pulling action to the two yarns through an independent servo pulling mechanism to maintain the tension within their respective preset working ranges. The loop-forming adaptive control module 703 is used to calculate the required sinking depth, yarn bending angle and loop-breaking sequence of the first and second needle beds based on the current weave structure requirements, yarn elastic modulus and historical loop-forming data, and generate corresponding drive signals. The collaborative scheduling module 704 is used to integrate the ergonomic model, fabric functional zoning data and equipment operating status, and to perform global timing synchronization of the dual-channel yarn feeding module 701, tension closed-loop control module 702 and loop forming adaptive control module 703, so as to realize continuous, seamless and high-precision weaving of double-sided heterogeneous structure in the whole garment.

[0061] In detail, each module in the one-piece molding system 700 for double-sided heterogeneous seamless close-fitting garments in this embodiment of the invention adopts the same technical means as the above-mentioned device and method when in use, and can produce the same technical effect, which will not be repeated here.

[0062] An embodiment of the present invention provides an electronic device for implementing a one-time forming method for double-sided heterogeneous seamless close-fitting garments, namely a central controller 101, which includes a processor, a memory, a communication bus and a communication interface.

[0063] The base 1 is a hollow box structure made of cast iron or welded steel plate, with external dimensions of 800mm × 800mm × 600mm (length × width × height). The internal cavity is used to house the central controller 101 and related electrical components. The processor is a multi-core ARM Cortex-A series chip with a main frequency of no less than 1.5 GHz. The memory includes 8 GB DDR4 RAM and 64 GB eMMC flash memory, used to store the operating system, control program, and process database. The communication bus adopts a hybrid architecture of CAN bus and EtherCAT industrial Ethernet to achieve high-speed communication with each execution unit. The communication interfaces include RS485, USB, and Wi-Fi modules, supporting remote monitoring and data upload.

[0064] Specifically, the processor's implementation method for the above instructions can be found in the description of the relevant steps in the corresponding embodiments in the accompanying drawings, and will not be repeated here.

[0065] To enable those skilled in the art to fully understand and implement this invention, the specific implementation principles of this invention are further supplemented below with a specific application scenario.

[0066] When weaving a double-sided heterogeneous seamless compression garment for sports rehabilitation, the central controller 101 first retrieves the corresponding three-dimensional partition data from the ergonomic model database. This divides the garment into seven functional areas: shoulder, upper arm, elbow, forearm, chest and back, waist, and hip. For each area, the yarn combination and structural parameters for both sides are preset. Taking the elbow area as an example, this area needs to balance the high elasticity and resilience of the outer layer to provide dynamic support, while the inner layer requires low-pressure contact to avoid skin compression damage. At this time, the central controller 101 sends a command to the yarn feeding mechanism 3 to control the first yarn guide group 301 to switch to 70D spandex core-spun yarn as the first type of yarn, and the second yarn guide group 302 to switch to 30D ultra-fine modal fiber as the second type of yarn. The two groups of yarn guides are arranged vertically and horizontally along the axis of the circular weft knitting machine. The first yarn guide group 301 is located 10 mm above the first needle bed 201, and the second yarn guide group 302 is located 10 mm below the second needle bed 202. The outlet axis of each yarn guide ceramic piece is strictly aligned with the center line of the corresponding knitting needle, thereby ensuring that the two yarn paths are completely isolated during the conveying process, without crossing or friction, and avoiding tension transmission interference caused by path coupling.

[0067] After entering the loop-forming cycle, the tension control mechanism 4 begins to operate: the first tension sensor 401 adopts a non-contact optical tension detection principle and is fixedly installed 10mm below the yarn outlet of the first yarn guide group 301 via a bracket. Its detection range is 0-5N, and its accuracy is ±0.01N. The first servo pull roller 402 is a rubber-coated cylindrical roller with a diameter of 50mm and a length of 80mm. Its surface is made of wear-resistant rubber material, generating appropriate friction when in contact with the yarn. The roller is driven to rotate by a servo motor with a speed range of 0-500rpm. The first tension sensor 401 detects the tension of the spandex core-spun yarn in the upper channel in real time, measuring a value of 1.02 N. The second tension sensor 403 detects the tension of the modal fiber in the lower channel at 0.58 N. The central controller 101 compares the measured values ​​with preset thresholds (1.00±0.05 N for the upper channel and 0.60±0.05 N for the lower channel), determining that the tension in the upper channel is slightly higher and the tension in the lower channel is slightly lower, and then generates a speed adjustment command. and The first servo pull roller 402 is driven to slightly decelerate, and the second servo pull roller 404 is driven to slightly accelerate; since the tension sensor adopts a non-contact optical detection principle, the sampling frequency reaches 1.2 kHz, and the control cycle is 0.8. Therefore, even at a high-speed knitting machine speed of 280 rpm, it can still complete more than two tension closed-loop adjustments within the time of a single row of loops, ensuring that the tension of the two yarns remains stable within the set tolerance range, effectively suppressing the high elastic modulus of spandex ( ) and Modal low modulus ( The difference caused by the coil length mismatch.

[0068] At the same time, the loop-forming adaptive control module 403 calls the loop-forming stage adaptive algorithm, based on the current row being the elbow joint area, the tissue structure data G being a double-sided jacquard composite structure, and the elastic modulus of the upper yarn. With the elastic modulus of the lower yarn Based on the loop formation deviation of similar yarns at similar bending angles recorded in historical loop data H, the required sinking depth of the first needle bed 201 is calculated. = 2.4 mm, yarn bending angle = 42°, timing of uncoupling = 3.2ms, the corresponding parameters for the second needle bed 202 are = 1.7 mm = 52° = 3.5 ms; The central controller 101 sends the above parameters to the first sinker drive assembly 501, the first yarn bending cam assembly 601, the second sinker drive assembly 502, and the second yarn bending cam assembly 602 respectively via the EtherCAT bus, driving each actuator to operate independently; The first needle bed 201, due to its larger sinking depth and smaller yarn bending angle, forms a longer loop, giving the outer fabric high extensibility and resilience; The second needle bed 202, due to its smaller sinking depth and larger yarn bending angle, forms a shorter loop, improving the density and softness of the inner fabric; The timing difference between the loop release of the upper and lower needle beds is 0.3 ms. This avoids interference from the movement of the knitting needles and ensures that the double-sided coils unwind synchronously but remain structurally independent.

[0069] When the knitting row transitions from the elbow area to the forearm area, the collaborative scheduling module 804 identifies the partition boundary in advance and triggers the yarn switching logic: the first yarn guide group 301 switches from spandex core-spun yarn to antibacterial polyester filament, and the second yarn guide group 302 switches from modal to moisture-wicking fiber or polyester fiber; at the same time, the tension closed-loop control module 802 updates the upper channel tension setting value to 0.78 N and the lower channel to 0.92 N; the loop forming adaptive control module 803 loads the corresponding weave structure data G' of the forearm area, recalculates and outputs the new sinking depth, bending angle and loop release sequence; the entire switching process completes the parameter smooth transition within three consecutive rows, avoiding fabric wrinkling or loop misalignment due to sudden changes, and finally achieves seamless integration of multiple areas of dual-sided heterogeneous functions such as high shoulder support, dynamic elbow cushioning, forearm breathability and sweat wicking, and waist gradient compression on the whole garment.

[0070] Therefore, it can be seen that the physical isolation path design of the yarn feeding mechanism 3 fundamentally cuts off the mechanical coupling between the front and back yarns; the tension control mechanism 4 achieves independent and stable tension control of the dual channels with millisecond-level response, solving the tension imbalance problem when high-elasticity and low-elasticity yarns are knitted together; under the differentiated instructions of the central controller 101, the loop forming mechanism 2 enables the first needle bed 201 and the second needle bed 202 to independently execute different loop forming trajectories, thereby forming front and back structures with different loop geometry in the same row; and the collaborative scheduling module 804 performs global timing alignment of each functional module based on the ergonomic model to ensure continuous process parameters, smooth yarn handover, and complete fabric structure during partition switching, ultimately achieving one-time forming of high-performance double-sided heterogeneous seamless close-fitting garments.

[0071] In the embodiments provided by this invention, it should be understood that the disclosed devices, systems, and methods can be implemented in other ways. For example, the system embodiments described above are merely illustrative, and the module division is only a logical functional division; in actual implementation, there may be other division methods.

[0072] The modules described as separate components may or may not be physically separate. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs.

[0073] Furthermore, the functional modules in the various embodiments of the present invention can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or in the form of hardware plus software functional modules.

[0074] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the present invention.

[0075] Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be embraced within the invention. No appended diagram markings in the claims should be construed as limiting the scope of the claims.

[0076] Furthermore, it is clear that the word "including" does not exclude other units or steps, and the singular does not exclude the plural. Terms such as "first," "second," etc., are used to indicate names, but do not indicate any specific order.

[0077] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. A forming device for double-sided heterogeneous seamless close-fitting garments, used on a seamless circular knitting machine, comprising a base (1), a loop-forming mechanism (2), and a yarn feeding mechanism (3), characterized in that, include: The base (1) is used to support the coiling mechanism (2), and the base (1) includes: The central controller (101) is located inside the base (1) and is used to receive, process and output various parameters and instructions of the forming device; The human-computer interaction terminal (102) is located outside the base (1) and is connected to the central controller (101) by signal. It is used to input interactive commands from the outside and output the internal parameter status of the forming device. The loop-forming mechanism (2) is used for loop weaving, and the loop-forming mechanism (2) includes: The first needle bed (201) is located above the base (1) and can be raised and lowered independently in the vertical direction for processing the first type of yarn; The second needle bed (202) is located below the first needle bed (201) and can be raised and lowered independently in the vertical direction for processing the second type of yarn; The first needle bed (201) and the second needle bed (202) are each equipped with an independent sinker drive assembly (5), and the motion parameters of the sinker drive assembly (5) are provided by the central controller (101). The yarn bending triangle assembly (6) is provided with independent yarn bending triangle assemblies (6) on the first needle bed (201) and the second needle bed (202), and the motion parameters of the yarn bending triangle assembly (6) are provided by the central controller (101). The yarn feeding mechanism (3) is used to guide the yarn into the looping mechanism (2) for weaving. The yarn feeding mechanism (3) includes: The first yarn guide assembly (301) is located at the yarn feeding position of the first needle bed (201) and is used to guide the first type of yarn; The second yarn guide assembly (302) is located at the yarn feeding position of the second needle bed (202) and is used to guide the second type of yarn; The first yarn guide group (301) and the second yarn guide group (302) are arranged in layers along the axial direction of the base (1) and do not interfere with each other in space. Tension control mechanism (4) for adjusting the yarn tension fed by the yarn feeding mechanism (3) to the loop forming mechanism (2), the tension control mechanism (4) comprising: The first tension sensor (401) is disposed on the yarn path between the yarn outlet of the first yarn guide group (301) and the first needle bed (201) for collecting the real-time tension signal of the first type of yarn exported by the first yarn guide group (301). The first servo pull roller (402) is set on the first needle bed (201) to receive the direction of the first type of yarn. The first servo pull roller (402) adjusts its own speed according to the signal output by the central controller (101), controls the tension of the first type of yarn, and pulls the first type of yarn into the first yarn guide group (301). The second tension sensor (403) is disposed in the direction of the second type of yarn out of the second yarn guide group (302) and is used to collect the real-time tension signal of the second type of yarn out of the second yarn guide group (302); The second servo pull roller (404) is set on the second needle bed (202) to receive the direction of the second type of yarn. The second servo pull roller (404) adjusts its own speed according to the signal output by the central controller (101), controls the tension of the second type of yarn, and pulls the second type of yarn into the second yarn guide group (302). The central controller (101) calculates the motion parameters of the sinker drive assembly (5) and the yarn bending triangle assembly (6) based on the real-time tension signals collected by the first tension sensor (401) and the second tension sensor (403) through an adaptive algorithm for the looping stage, and controls the speed of the first servo pull roller (402) and the second servo pull roller (404).

2. The one-piece forming device for double-sided heterogeneous seamless close-fitting garments as described in claim 1, characterized in that, The first yarn guide assembly (301) is located 5-15 mm above the first needle bed (201), and the second yarn guide assembly (302) is located 5-15 mm below the second needle bed (202).

3. The one-piece forming device for double-sided heterogeneous seamless close-fitting garments as described in claim 1, characterized in that, The first needle bed (201) and the second needle bed (202) are driven by independent servo motors, and can achieve lifting within ±2 mm in the vertical direction; The settling plate drive assembly (5) includes a first settling plate drive assembly (501) and a second settling plate drive assembly (502), and the settling depth adjustment range of the first settling plate drive assembly (501) and the second settling plate drive assembly (502) is 0.5 mm to 3.0 mm. The yarn bending triangle assembly (6) includes a first yarn bending triangle assembly (601) and a second yarn bending triangle assembly (602), with a yarn bending angle adjustment range of 30° to 60°. There is a time difference of 0 to 5 ms between the uncoiling action of the first needle bed (201) and the second needle bed (202).

4. A one-time forming method for double-sided heterogeneous seamless close-fitting garments, characterized in that, The method includes: S1: Construct a dual-channel yarn feeding path that is separated and physically isolated, and independently feed yarns with different material properties or functional characteristics to the first needle bed (201) and the second needle bed (202) of the knitting needles respectively; S2: During each looping cycle, the tension of the first channel yarn and the second channel yarn is monitored and dynamically adjusted in real time by the tension control mechanism, so that the two yarns maintain their respective preset tension states during the looping process. S3: Based on the current horizontal structure data and yarn elastic modulus parameters, call the loop-forming stage adaptive algorithm to differentiate the sinking depth, yarn bending angle and loop-removal sequence of the first needle bed (201) and the second needle bed (202) to form heterogeneous fabrics with different loop lengths, structure densities or structural forms on the front and back sides. S4: During the weaving process of the entire garment, based on the preset ergonomic model and functional zoning instructions, the yarn type switching logic and tension setting value in the dual-channel yarn feeding path are adjusted synchronously to complete the one-time forming of the double-sided heterogeneous seamless close-fitting garment.

5. The one-time forming method for double-sided heterogeneous seamless close-fitting garments as described in claim 4, characterized in that, The construction of a dual-channel yarn feeding path that is separated and physically isolated includes: The first type of yarn is threaded into the yarn guiding ceramic sequence of the first yarn guide group (301), and the second type of yarn is threaded into the yarn guiding ceramic sequence of the second yarn guide group (302). Adjust the position of each yarn guide ceramic piece so that the yarn exit axis is aligned with the center line of the knitting needles on the corresponding needle bed; The first yarn guide group (301) and the second yarn guide group (302) are arranged vertically and horizontally along the axial direction of the circular weft knitting machine, and there is no overlap in the radial and circumferential positions.

6. The one-time forming method for double-sided heterogeneous seamless close-fitting garments as described in claim 4, characterized in that, The dynamic adjustment includes: The real-time tension values ​​of the upper and lower channels are collected by the first tension sensor (401) and the second tension sensor (403) respectively. The real-time tension value of the upper channel is compared with the preset threshold. If the deviation exceeds ±0.05 N, a speed adjustment command is generated to drive the first servo traction roller (402). The real-time tension value of the lower channel is compared with the preset threshold. If the deviation exceeds ±0.05 N, a speed adjustment command is generated to drive the second servo traction roller (404).

7. The one-time forming method for double-sided heterogeneous seamless close-fitting garments as described in claim 4, characterized in that, The differential control includes: Read the function partition identifier of the current row; Retrieve the corresponding fabric structure data, upper yarn elastic modulus, and lower yarn elastic modulus from the database; Substitute the values ​​into the adaptive algorithm for the loop-forming stage to calculate the sinking depth, bending angle, and loop-breaking sequence of the first needle bed (201) and the sinking depth, bending angle, and loop-breaking sequence of the second needle bed (202); Output control signals to the first sinker drive assembly (501), the second sinker drive assembly (502), the first yarn bending triangle assembly (601), and the second yarn bending triangle assembly (602) to perform differentiated loop forming operations; The adaptive algorithm for the cyclic formation stage is expressed as follows: ; in, This is historical data.

8. The one-time forming method for double-sided heterogeneous seamless close-fitting garments as described in claim 4, characterized in that, The synchronization adjustment includes: When the knitting row enters a new functional zone, a yarn switching command is triggered, controlling the yarn feeding mechanism to change the corresponding yarn; Simultaneously update the upper channel tension preset threshold and the lower channel tension preset threshold in the tension control mechanism; New looping parameters are loaded into the looping mechanism to ensure seamless connection of each module at the partition boundary.

9. A one-piece molding system (700) for double-sided heterogeneous seamless bodysuits, characterized in that, include: The dual-channel yarn feeding module (701) is used to establish physically isolated upper and lower yarn paths and switch yarns of different materials or functional attributes according to functional partition instructions. The tension closed-loop control module (702) is used to collect the yarn tension in the upper yarn path and the lower yarn path in real time, and apply differentiated pulling action to the two yarns through an independent servo pulling mechanism to keep the tension within their respective preset working ranges. The loop-forming adaptive control module (703) is used to calculate the required sinking depth, yarn bending angle and loop-breaking sequence of the first and second needle beds according to the current weave structure requirements, yarn elastic modulus and historical loop-forming data, and generate corresponding drive signals. The collaborative scheduling module (704) is used to integrate the ergonomic model, fabric functional partition data and equipment operating status to perform global timing synchronization of the dual-channel yarn feeding module (701), tension closed-loop control module (702) and loop forming adaptive control module (703) to achieve continuous, seamless and high-precision weaving of double-sided heterogeneous structure in the whole garment.

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