A modular weaving system compatible with rapier, air jet and water jet weft insertion modes

Abstract

This invention belongs to the field of textile machinery technology and discloses a modular weaving system compatible with rapier, air-jet, and water-jet weft insertion modes. The system includes a frame, on which are mounted a warp feed mechanism, a heald frame mechanism, a beat-up mechanism, a take-up mechanism, and a weft yarn bobbin. A weft insertion port is provided on one side of the frame corresponding to the weft insertion side of the loom. A position sensor is installed inside the frame at a position corresponding to the weft insertion port. A weft insertion switching device is installed on the outside of the frame, and this device includes a rapier weft insertion mechanism, an air-jet weft insertion mechanism, and a water-jet weft insertion mechanism. This solution integrates rapier, air-jet, and water-jet weft insertion modes on the same loom system. The weft insertion switching device enables rapid and precise mode switching to meet the weaving needs of different weft yarn materials. The position sensor detects the position of the rapier or nozzle in real time, and in conjunction with the closed-loop control of the controller, ensures that the weft insertion components are accurately aligned with the weft insertion port after each switch, reducing weft insertion errors and fabric defects.

Description

Technical Field

[0001] This invention relates to the field of textile machinery technology, and more specifically, to a modular weaving system compatible with rapier, air-jet, and water-jet weft insertion modes. Background Technology

[0002] In the weaving process, weft insertion is a crucial step in introducing the weft yarn into the shed. Based on the different weft yarn raw materials and weaving techniques, existing looms are mainly divided into rapier looms, air-jet looms, and water-jet looms. Rapier weft insertion is suitable for a wide variety of weft yarns in multiple colors and types, offering broad adaptability; air-jet weft insertion is fast and suitable for long fibers such as cotton and wool; while water-jet weft insertion is suitable for hydrophobic fibers such as polyester and nylon.

[0003] However, traditional looms are typically equipped with only one type of weft insertion method, resulting in limited functionality. When companies need to produce fabrics with different materials or processing requirements, they must purchase multiple looms of different types, leading to high equipment costs and large space requirements. Although some attempts have been made to achieve multi-functionality by changing the weft insertion components, the switching operation is cumbersome, the positioning accuracy is poor, and it is difficult to meet the needs of rapid and flexible production. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of existing technologies and propose a modular weaving system that is compatible with rapier, air-jet, and water-jet weft insertion modes.

[0005] To solve the above problems, the present invention adopts the following technical solution:

[0006] A modular weaving system compatible with rapier, air-jet, and water-jet weft insertion modes includes a frame, on which a warp feeding mechanism, heald frame mechanism, beat-up mechanism, take-up mechanism, and weft bobbin are installed. A weft insertion port is provided on one side of the frame corresponding to the weft insertion side of the loom, and a position sensor is installed inside the frame at a position corresponding to the weft insertion port.

[0007] The outer side of the frame is provided with a weft insertion switching device, which is equipped with a rapier weft insertion mechanism, an air jet weft insertion mechanism and a water jet weft insertion mechanism.

[0008] The weft insertion switching device includes a bracket, on which a movable plate is slidably connected, the rapier weft insertion mechanism is mounted on the movable plate, and a rotating mechanism is provided on the movable plate;

[0009] The air jet weft insertion mechanism includes an air jet head, and the water jet weft insertion mechanism includes a water jet head. Both the air jet head and the water jet head are mounted on the rotating mechanism.

[0010] The system also includes a controller, which is electrically connected to the position sensor, the weft insertion switching device, the rapier weft insertion mechanism, the air jet weft insertion mechanism, and the water jet weft insertion mechanism.

[0011] As a preferred technical solution, the top of the bracket is provided with a sliding groove, in which a slider is slidably connected, and the slider is fixedly connected to the bottom of the movable plate; the top of the bracket is also provided with a strip-shaped opening, in which a connecting block is inserted; an electric push rod is fixedly connected to the inner top wall of the bracket, and the telescopic end of the electric push rod is fixedly connected to the connecting block. The electric push rod drives the movable plate to reciprocate along the sliding groove. This structure realizes the overall displacement of the rapier weft insertion mechanism and the rotating mechanism, making it convenient for the rapier head or nozzle to be aligned with the weft insertion opening.

[0012] As a preferred technical solution, the rotating mechanism includes a support plate fixedly mounted on the movable plate, a servo rotary motor fixedly mounted on the support plate, a rotating shaft fixedly connected to the output shaft of the servo rotary motor, and a rotating plate fixedly connected to the rotating shaft. The jet nozzle and the water spray nozzle are detachably mounted on the rotating plate. Through precise angle control of the servo rotary motor, rapid switching between the jet nozzle and the water spray nozzle is possible.

[0013] As a preferred technical solution, the outer circumference of the rotating plate is provided with a notch arc adapted to the shape of the air jet head and water jet head. A slot is provided on the rotating plate within the notch arc. Insert blocks adapted to the slots are fixedly connected to the air jet head and water jet head respectively. The insert blocks are inserted into the slots and locked with screws. This detachable structure facilitates the replacement of nozzles of different specifications to accommodate different yarn types and widths.

[0014] As a preferred technical solution, the rapier weft insertion mechanism includes a housing, a rapier wheel rotatably connected inside the housing, a flexible rapier belt wound around the rapier wheel, a rapier head connected to the extended end of the flexible rapier belt, a limit block provided inside the housing for limiting and guiding the flexible rapier belt, and a motor fixedly installed on the outer wall of the housing, the output shaft of the motor extending into the housing and fixedly connected to the rapier wheel.

[0015] As a preferred technical solution, the jet weft insertion mechanism further includes an air pump and an air pipe. The air pump is installed in the bracket, and the air pipe connects the air pump and the jet head. The air pipe is a flexible hose.

[0016] As a preferred technical solution, the water-spraying weft insertion mechanism further includes a water tank, a water pump, and a water delivery pipe. The water tank is mounted on a bracket, the water pump is mounted on the water tank, the water pump inlet is connected to an inlet pipe, the inlet pipe extends into the water tank, and the water delivery pipe connects the water pump outlet to the spray head. The water delivery pipe is a flexible hose.

[0017] As a preferred technical solution, the movable plate is provided with a through hole, and the top of the bracket is provided with a clearance opening. The air pipe and water pipe pass through the through hole and the clearance opening in sequence and are connected to the air pump and water pump respectively. This design ensures the mobility and safety of the pipeline when the movable plate moves.

[0018] As a preferred technical solution, a water tank is provided at the inner bottom of the frame, and a return water pipe is provided on the frame. One end of the return water pipe is connected to the water tank, and the other end is connected to a water container. A filter screen is provided at the end of the return water pipe located in the water tank. This circulation system can recover most of the working water during the weft insertion process, reducing water consumption. The filter screen can prevent fiber impurities from clogging the water pump.

[0019] Compared with the prior art, the advantages of this invention are:

[0020] I. This solution integrates three weft insertion modes—rapier, air-jet, and water-jet—on the same loom system. It achieves rapid and precise mode switching through a weft insertion switching device to meet the weaving needs of different weft yarn materials.

[0021] Second, the position sensor in this solution detects the position of the scissor head or nozzle in real time, and works with the controller for closed-loop control to ensure that the weft insertion component is accurately aligned with the weft insertion opening after each switch, thereby reducing weft insertion errors and fabric defects.

[0022] Third, this solution features a compact system structure and a high degree of automation, effectively reducing equipment procurement costs and factory floor space requirements, while improving production flexibility. Furthermore, the water circulation design of the water jet weft insertion system conserves water resources, and the filter screen prevents impurities from clogging the pipelines. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the structure of the present invention in the rapier mode;

[0024] Figure 2 This is a schematic diagram of the structure of the present invention in water spray mode;

[0025] Figure 3 This is a schematic diagram of the structure of the weft switching device of the present invention;

[0026] Figure 4 This is a schematic diagram of the rapier weft insertion mechanism of the present invention;

[0027] Figure 5 This is a schematic diagram of the rotating plate of the present invention.

[0028] Explanation of the labels in the diagram:

[0029] 1. Frame; 101. Weft insertion point; 102. Position sensor; 2. Warp feed mechanism; 3. Heald frame mechanism; 4. Weft insertion mechanism; 5. Rewinding mechanism;

[0030] 6. Weft insertion switching device; 61. Bracket; 611. Slide groove; 612. Slider; 613. Strip opening; 6131. ​​Connecting block; 614. Electric push rod; 615. Clearance opening; 62. Movable plate; 621. Through hole; 63. Rotating mechanism; 631. Support plate; 632. Servo rotary motor; 633. Rotating shaft; 634. Rotating plate; 635. Notch arc; 636. Slot; 637. Insert block; 638. Screw;

[0031] 7. Rapier weft insertion mechanism; 71. Housing; 72. Rapier wheel; 73. Flexible rapier belt; 74. Rapier head; 75. Limiting block; 76. Motor;

[0032] 8. Jet-driven weft insertion mechanism; 81. Air pump; 82. Air pipe; 83. Jet nozzle;

[0033] 9. Water jet weft insertion mechanism; 91. Water tank; 92. Water pump; 93. Water supply pipe; 94. Spray head; 95. Water inlet pipe;

[0034] 10. Controller; 11. Water tank; 12. Return water pipe; 13. Weft yarn spool. Detailed Implementation

[0035] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0036] Example 1

[0037] Please see Figure 1-3 A modular weaving system compatible with rapier, air-jet, and water-jet weft insertion modes includes a frame 1, on which a warp feeding mechanism 2, a heald frame mechanism 3, a weft beating mechanism 4, a winding mechanism 5, and a weft bobbin 13 are provided. These are all conventional loom mechanisms and will not be described in detail.

[0038] A weft insertion port 101 is provided on one side of the frame 1, corresponding to the weft insertion side of the loom, for the weft yarn to enter the shed. A position sensor 102 (which can be a photoelectric sensor or a proximity switch) is provided inside the frame 1 at a position corresponding to the weft insertion port 101, for detecting whether the rapier or nozzle has reached the accurate weft insertion position.

[0039] A weft insertion switching device 6 is installed on the outer side of the frame 1. The weft insertion switching device 6 includes a bracket 61. Two parallel sliding grooves 611 are opened in the front-back direction on the top of the bracket 61, and a slider 612 is slidably fitted in each groove 611. A movable plate 62 is fixedly connected to the two sliders 612 and can move back and forth along the sliding grooves 611. A strip-shaped opening 613 is opened in the middle of the top of the bracket 61. A connecting block 6131 passes through the strip-shaped opening 613, with its upper end fixed to the bottom of the movable plate 62 and its lower end fixed to the telescopic end of an electric push rod 614 installed on the inner top wall of the bracket 61. When the electric push rod 614 extends or retracts, it drives the movable plate 62 to move, realizing lateral feed.

[0040] The movable plate 62 is equipped with a rapier weft insertion mechanism 7, an air-jet weft insertion mechanism 8, and a water-jet weft insertion mechanism 9. Specifically:

[0041] like Figure 4 As shown, the rapier weft insertion mechanism 7 includes a housing 71. A rapier wheel 72 is rotatably mounted inside the housing 71 via bearings. A flexible rapier belt 73 is wound around the rapier wheel 72, and a rapier head 74 is fixed to the free end of the flexible rapier belt 73. A limiting block 75 is also provided inside the housing 71 to guide the flexible rapier belt 73 smoothly in and out. A motor 76 (preferably a servo motor) is fixedly mounted on the outer wall of the housing 71. The output shaft of the motor 76 extends into the housing 71 and is fixedly connected to the rapier wheel 72, providing power to the rapier wheel. In rapier weft insertion mode, the motor 76 drives the rapier wheel 72 to rotate forward and backward, causing the rapier head 74 to reciprocate, completing the action of clamping the weft yarn and introducing it into the shed.

[0042] like Figure 3 As shown, a rotating mechanism 63 is provided on the movable plate 62, the air-jet weft insertion mechanism 8 includes an air jet head 83, and the water-jet weft insertion mechanism 9 includes a water jet head 94. The rotating mechanism 63 includes a support plate 631 vertically fixed on the movable plate 62, a servo rotary motor 632 fixed on the support plate 631, the output shaft of which is connected to the rotating shaft 633 via a coupling, and a disc-shaped rotating plate 634 fixed to the end of the rotating shaft 633. Both the air jet head 83 and the water jet head 94 are mounted on the movable plate 62.

[0043] The air-jet weft insertion mechanism 8 also includes an air pump 81 and an air pipe 82. The air pump 81 is installed on the inner bottom of the support 61, and one end of the air pipe 82 is connected to the air outlet of the air pump 81, while the other end is connected to the air jet head 83. The water-jet weft insertion mechanism 9 also includes a water tank 91, a water pump 92, and a water supply pipe 93. The water tank 91 is fixed to the rear side of the support 61, the water pump 92 is installed on the top of the water tank 91, the water inlet pipe 95 extends into the bottom of the water tank 91, and one end of the water supply pipe 93 is connected to the water outlet of the water pump 92, while the other end is connected to the water jet head 94. Both the air pipe 82 and the water supply pipe 93 are sufficiently long flexible hoses (such as rubber hoses) to accommodate the movement of the movable plate 62. In addition, the water tank 91 can also be equipped with a liquid level sensor and connected to the controller 10, which will issue an alarm or automatically replenish clean water when the water level is too low.

[0044] Furthermore, a through hole 621 is provided on the movable plate 62, and a clearance opening 615 is provided at the corresponding position on the top of the bracket 61. After the air pipe 82 and the water pipe 93 come out from the jet head 83 / water spray head 94, they pass through the through hole 621 and the clearance opening 615 in sequence, and then connect to the air pump 81 and the water pump 92.

[0045] The system also includes a controller 10, which uses a PLC or a microcontroller. The controller 10 is electrically connected to the position sensor 102, the electric actuator 614, the servo rotary motor 632, the motor 76, the air pump 81, the water pump 92, etc. The controller 10 is also connected to a touch-screen operation panel for users to select the weft insertion mode.

[0046] It should be noted that a water tank 11 is provided at the bottom of the frame 1. The water tank 11 has a certain inclination angle and is used to collect the water flowing down during the weft insertion. A return water pipe 12 is provided on the frame 1. One end of the return water pipe 12 is connected to the water tank 11 and the other end is connected to the water tank 91. A filter screen is provided at the end of the return water pipe 12 located in the water tank 11, which can filter out impurities such as fiber debris in the recycled water and return it to the water tank 91, so as to realize the recycling of water resources.

[0047] Working principle:

[0048] Rapier weft insertion pattern: such as Figure 1 As shown, the system is in rapier weft insertion mode, with the movable plate 62 in the rear position (electric push rod 614 in the extended state), the rapier head 74 aligned with the weft insertion opening 101, and the air jet head 83 and water jet head 94 on the rotating plate 634 in the non-working position. The motor 76 drives the rapier wheel 72 to rotate forward and backward, causing the rapier head 74 to reciprocate, completing the action of clamping the weft yarn and introducing it into the shed.

[0049] Jet Mode: When the user selects "Jet Mode" via the control panel, the controller 10, upon receiving the command, first exits the rapier mode by stopping the motor 76, ensuring the rapier head 74 retracts into the housing 71. Then, the controller 10 controls the electric push rod 614 to retract, moving the movable plate 62 forward, causing the entire rapier weft insertion mechanism 7 to leave the weft insertion port 101 area. The position sensor 102 detects the departure of the rapier head 74 and sends a feedback signal.

[0050] Next, the system switches to jet head 83. Controller 10 controls servo rotary motor 632 to rotate at a preset angle (e.g., 60° or 90°, depending on the installation orientation), causing jet head 83 on rotary plate 634 to rotate forward and align with weft insertion port 101. Position sensor 102 checks again whether jet head 83 is in position; upon confirmation, controller 10 stops servo rotary motor 632.

[0051] Finally, the jet weft insertion is initiated: controller 10 starts air pump 81, compressed air is ejected from jet head 83 through air pipe 82, carrying the weft yarn into the shed, and the beat-up mechanism 4 operates synchronously to complete the weaving. In this mode, water pump 92 does not work, and water tank 11 and return water pipe 12 are idle.

[0052] like Figure 2 As shown, when switching from jet mode to water spray mode, controller 10 first stops air pump 81, then controls servo rotary motor 632 to continue rotating by a fixed angle, so that water nozzle 94 replaces jet nozzle 83 and aligns with weft insertion port 101. Finally, water pump 92 is started, and water pump 92 draws water from water tank 91 through water pipe 93 and delivers it to water nozzle 94. The high-pressure water flow carries the weft yarn through the shed. The sprayed water falls into water tank 11 at the bottom of frame 1 under gravity. Water tank 11 has a certain inclination angle, so that water automatically flows to the inlet end of return water pipe 12. A filter screen is installed at the inlet end of return water pipe 12 to intercept solid impurities such as fiber debris and dust in the water. The filtered water flows back to water tank 91 through return water pipe 12.

[0053] After the water spraying mode ends, the controller 10 can control the electric push rod 614 and the servo rotary motor 632 to reset the water spray head 94 and turn off the water pump 92.

[0054] Example 2

[0055] like Figure 5 As shown, this embodiment is a further improvement based on Embodiment 1. Compared with Embodiment 1, since different yarns have different requirements for air or water spray parameters (such as air pressure, water pressure, spray angle, and nozzle diameter), both the air jet head 83 and the water spray head 94 in this invention are designed as detachable structures. Specifically:

[0056] The outer edge of the rotating plate 634 has two notched arcs 635, which are used to accommodate the jet head 83 and the water spray head 94, respectively. Each notched arc 635 has a slot 636. Insert blocks 637 are fixed to the surfaces of the jet head 83 and the water spray head 94. After the insert blocks 637 are inserted into the slots 636, they are screwed in and locked from the side of the rotating plate 634 by screws 638. The operator can replace nozzles with different orifice diameters or spray characteristics simply by loosening the screws 638 and pulling the insert blocks 637 out of the slots 636.

[0057] The above description is merely a preferred embodiment of the present invention; however, the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and its improved concepts, should be covered within the scope of protection of the present invention.

Claims

1. A modular weaving system compatible with rapier, air jet and water jet weft insertion modes, comprising a machine frame (1) provided with a warp let-off mechanism (2), a heald frame mechanism (3), a beat-up mechanism (4), a take-up mechanism (5) and a weft bobbin (13), characterized in that: A weft insertion port (101) is provided on one side of the frame (1) corresponding to the weft insertion side of the loom, and a position sensor (102) is provided inside the frame (1) at a position corresponding to the weft insertion port (101). The frame (1) is provided with a weft insertion switching device (6) on its outer side. The weft insertion switching device (6) is provided with a rapier weft insertion mechanism (7), an air jet weft insertion mechanism (8) and a water jet weft insertion mechanism (9). The weft insertion switching device (6) includes a bracket (61), a movable plate (62) is slidably connected on the bracket (61), the rapier weft insertion mechanism (7) is installed on the movable plate (62), and a rotating mechanism (63) is provided on the movable plate (62). The jet weft insertion mechanism (8) includes a jet head (83), and the water jet weft insertion mechanism (9) includes a water jet head (94). Both the jet head (83) and the water jet head (94) are mounted on the rotating mechanism (63). The system also includes a controller (10), which is electrically connected to a position sensor (102), a weft insertion switching device (6), a rapier weft insertion mechanism (7), an air jet weft insertion mechanism (8), and a water jet weft insertion mechanism (9).

2. The modular weaving system compatible with rapier, air-jet, and water-jet weft insertion modes according to claim 1, characterized in that: The top of the bracket (61) is provided with a sliding groove (611), and a slider (612) is slidably connected in the sliding groove (611). The slider (612) is fixedly connected to the bottom of the movable plate (62). The top of the bracket (61) is also provided with a strip-shaped opening (613), and a connecting block (6131) is inserted in the strip-shaped opening (613). An electric push rod (614) is fixedly connected to the inner top wall of the bracket (61). The telescopic end of the electric push rod (614) is fixedly connected to the connecting block (6131). The electric push rod (614) drives the movable plate (62) to move back and forth along the sliding groove (611).

3. The modular weaving system compatible with rapier, air-jet, and water-jet weft insertion modes according to claim 1, characterized in that: The rotating mechanism (63) includes a support plate (631) fixedly mounted on the movable plate (62), a servo rotary motor (632) fixedly mounted on the support plate (631), a rotating shaft (633) fixedly connected to the output shaft of the servo rotary motor (632), a rotating plate (634) fixedly connected to the rotating shaft (633), and the jet head (83) and the water spray head (94) detachably mounted on the rotating plate (634).

4. A modular weaving system compatible with rapier, air-jet, and water-jet weft insertion modes according to claim 3, characterized in that: The outer circumference of the rotating plate (634) is provided with a notch arc (635) adapted to the shape of the jet head (83) and the water spray head (94). A slot (636) is provided on the rotating plate (634) and located in the notch arc (635). The jet head (83) and the water spray head (94) are respectively fixedly connected with a plug (637) adapted to the slot (636). The plug (637) is inserted into the slot (636) and locked by a screw (638).

5. A modular weaving system compatible with rapier, air-jet, and water-jet weft insertion modes according to claim 1, characterized in that: The rapier weft insertion mechanism (7) includes a housing (71), a rapier wheel (72) is rotatably connected inside the housing (71), a flexible rapier belt (73) is wound around the rapier wheel (72), and a rapier head (74) is connected to the extended end of the flexible rapier belt (73). A limit block (75) is also provided inside the housing (71) for limiting and guiding the flexible rapier belt (73). A motor (76) is fixedly installed on the outer wall of the housing (71), and the output shaft of the motor (76) extends into the housing (71) and is fixedly connected to the rapier wheel (72).

6. A modular weaving system compatible with rapier, air-jet, and water-jet weft insertion modes according to claim 1, characterized in that: The jet weft insertion mechanism (8) also includes an air pump (81) and an air pipe (82). The air pump (81) is installed in the bracket (61), and the air pipe (82) connects the air pump (81) and the jet head (83). The air pipe (82) is a flexible hose.

7. A modular weaving system compatible with rapier, air-jet, and water-jet weft insertion modes according to claim 6, characterized in that: The water spraying weft insertion mechanism (9) also includes a water tank (91), a water pump (92) and a water delivery pipe (93). The water tank (91) is mounted on a bracket (61), and the water pump (92) is mounted on the water tank (91). The inlet of the water pump (92) is connected to an inlet pipe (95), which extends into the interior of the water tank (91). The water delivery pipe (93) connects the outlet of the water pump (92) to the spray head (94). The water delivery pipe (93) is a flexible hose.

8. A modular weaving system compatible with rapier, air-jet, and water-jet weft insertion modes according to claim 7, characterized in that: The movable plate (62) has a through hole (621), and the top of the bracket (61) has a clearance opening (615). The air pipe (82) and the water pipe (93) pass through the through hole (621) and the clearance opening (615) in sequence and are connected to the air pump (81) and the water pump (92) respectively.

9. A modular weaving system compatible with rapier, air-jet, and water-jet weft insertion modes according to claim 7, characterized in that: The bottom of the frame (1) is provided with a water tank (11), and a return water pipe (12) is provided on the frame (1). One end of the return water pipe (12) is connected to the water tank (11), and the other end is connected to the water tank (91). A filter screen is provided at the end of the return water pipe (12) located in the water tank (11).

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