A yarn printing and weaving integrated system
By designing an integrated system for warp printing and weaving, continuous and coordinated operation of printing and weaving has been achieved, solving the problems of low efficiency and poor pattern consistency in traditional processes. This enables efficient and precise production of complex artistic patterns, and is suitable for the modern inheritance of intangible cultural heritage products such as Atlas silk.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- DONGHUA UNIV
- Filing Date
- 2026-04-22
- Publication Date
- 2026-07-07
AI Technical Summary
In existing technologies, the warp printing and weaving processes are lengthy and complex, resulting in low production efficiency and poor product quality consistency. Furthermore, uneven tension, yarn damage, and pattern deformation occur during the printing and weaving processes, making it difficult to achieve efficient and precise production of complex artistic patterns.
Design an integrated system for warp printing and weaving, comprising a physical execution subsystem and an integrated control subsystem. Through multi-level active transmission units and high-precision sensors, warp tension and speed are detected. Combined with a reverse mapping compensation algorithm for printing and weaving, continuous and coordinated operation of printing and weaving is achieved, tension and speed matching is precisely controlled, and pattern deformation compensation is performed.
It achieves true integrated continuous production of warp printing and weaving, solving the problems of low efficiency and poor pattern consistency in traditional processes. It ensures the stability of tension in the printing area and the accurate reproduction of patterns, avoiding the generation of defects. It is suitable for the efficient and automated production of complex warp pattern products.
Smart Images
Figure CN122344799A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of textile and dyeing technology, and in particular relates to an integrated system for warp yarn printing and weaving. Background Technology
[0002] Intangible cultural heritage products, such as Atlas silk, which are dyed with warp threads, are highly sought after due to their complex and varied patterns and unique artistic style. However, their traditional production process relies on hand-tied warp dyeing and manual warp arrangement, which suffers from low production efficiency, inconsistent product quality, and a high dependence on the experience of craftsmen. This severely restricts the large-scale, standardized production and modern inheritance of these products.
[0003] In existing technologies, the main process for achieving warp yarn printing followed by weaving is a "pretend weave - printing - weft removal - weaving" route. This process first involves pretending the warp and weft yarns together to form a greige fabric, then printing and finishing the fabric, removing the pretended weft yarns, and finally weaving the printed warp yarns. This method is lengthy and complex, and the pretend weave and weft removal processes are prone to uneven yarn tension, yarn damage, and problems such as pattern deformation and inaccurate pattern positioning, making it difficult to guarantee product quality and production efficiency.
[0004] In recent years, although there have been attempts to print directly on warp yarns on warping or sizing machines before weaving, these techniques mostly involve a simple physical connection between the printing and weaving units. The printing and weaving processes are independent at the control level, failing to achieve continuous and coordinated operation from printing to weaving. During printing, warp yarns experience lateral drift and longitudinal tension deformation, while during weaving, there are significant tension fluctuations and warp and weft shrinkage. When printing and weaving are directly connected, these factors couple, resulting in severe deformation and misalignment of the final fabric pattern compared to the original design, making it impossible to accurately present the intended complex artistic patterns.
[0005] Therefore, how to deeply integrate modern and efficient digital inkjet printing technology with weaving technology, and fundamentally solve the coordination problems of speed matching, tension control, and pattern deformation compensation between printing and weaving from the system control level, while efficiently replacing the manual warp-tying and pattern-arranging process, and perfectly maintaining the artistry of the product pattern, has become a technical bottleneck that urgently needs to be overcome in this field. Summary of the Invention
[0006] The main objective of this invention is to propose an integrated system for warp yarn printing and weaving, which can effectively solve the problems in the background art.
[0007] To achieve the above objectives, the present invention provides the following technical solution:
[0008] An integrated system for warp yarn printing and weaving includes a physical execution subsystem and an integrated control subsystem for controlling the physical execution subsystem;
[0009] The physical execution subsystem, along the warp yarn running direction, includes, in sequence:
[0010] Warp beams loaded with pre-treated warp yarns;
[0011] The back reed used to control the arrangement position and density of the output warp yarns;
[0012] A yarn guide roller is used to actively pull the warp yarn from the warp beam. It is equipped with a pair of clamping rollers for guiding the warp yarn, preventing slippage, and detecting the warp yarn tension and speed.
[0013] The back reed is used to adjust the width and position of the warp yarns;
[0014] A printing machine used to spray patterns onto warp yarns;
[0015] A front telescopic reed used to coordinate with the rear telescopic reed to control the warp position and width of the inkjet printer area;
[0016] The yarn-drawing roller is used to pull the warp yarn out of the inkjet printer area. It is equipped with a pair of clamping rollers for guiding the warp yarn, preventing slippage and detecting the warp yarn tension and speed.
[0017] A width-fixing reed used to control the width of the warp yarns entering the weaving area and to maintain the pattern arrangement order;
[0018] The warp feed shaft is used to control the amount of warp feed and is equipped with a pair of clamping rollers for guiding the warp yarns, preventing slippage, and detecting the warp yarn tension and speed.
[0019] And a loom main unit for performing warp and weft yarn interlacing, the loom main unit including a gas-spring linkage back beam for buffering warp tension fluctuations, an adjustable temperature full-width side support for on-machine color fixing and controlling the fabric width, and a take-up roller for outputting spindle speed signals.
[0020] According to the integrated warp printing and weaving system of the claim, the pre-treated warp yarn loaded on the warp beam has a penetration guiding gradient formed on its surface by a pre-treated slurry, so that the printing ink can quickly penetrate from the printing surface along the circumference of the yarn to achieve consistent color on both sides.
[0021] Preferably, the yarn guide roller, the yarn trailing roller, and the warp feed shaft are all active transmission units equipped with servo motors, and one of the pair of clamping rollers on them integrates a high-precision tension detection sensor, and the other integrates a high-precision linear speed detection sensor.
[0022] Preferably, the rotation angle and lateral position of the reed blades of the rear telescopic reed and the front telescopic reed are adjustable, so as to jointly adjust and lock the width and lateral position of the warp yarns below the inkjet printer.
[0023] Preferably, the integrated control subsystem includes a data integration module and a control integration module;
[0024] The data integration module has a built-in printing and weaving reverse mapping compensation algorithm. This algorithm can automatically retrieve the corresponding shrinkage database to calculate the buckling shrinkage rate when the warp yarns interweave, calculate and generate the distorted printing pattern after compensation and correction, and send it to the printing host based on the input finished product design pattern, the machine parameters of the loom host and the machine parameters of the inkjet host. When the stretched and deformed distorted pattern is printed on the warp yarns and finally interweaves on the loom host and produces warp and weft shrinkage, the finished fabric presents the expected design pattern.
[0025] The control integration module is used to set the take-up roller of the loom as the global main axis, and to coordinate and control the rotation speed of the yarn guide roller, yarn drag roller and warp feed shaft in the integrated printing and weaving system, as well as the reciprocating speed of the printing head and the weft insertion speed of the loom, so as to achieve tension decoupling and speed matching throughout the printing and weaving process.
[0026] Preferably, the control integration module is configured as follows:
[0027] When the main loom is running normally, the yarn feeding roller, yarn guide roller and warp feed beam are controlled to move in sequence to maintain constant warp tension and speed in the printing area;
[0028] When the main loom stops, the warp feeder is controlled to stop feeding yarn and maintain the tension at the weave point. The yarn guide roller and the yarn feed roller are controlled to decelerate synchronously to a stop. The main printer is controlled to enter the breakpoint memory standby state after completing the current scan line.
[0029] Preferably, the air-spring linkage rear beam is used to absorb and buffer the pulse tension fluctuations caused by the opening and weft insertion during the weaving process.
[0030] Preferably, the adjustable temperature full-width edge support can directly fix the ink on the warp yarns using its heat energy while controlling the fabric width. This invention provides an integrated system for warp yarn printing and weaving, which has the following beneficial effects.
[0031] 1. By using the linear layout of the physical execution subsystem and the global coordination of the integrated control subsystem, true integrated continuous production of warp yarns from printing to weaving is achieved, completely solving the problems of low efficiency and poor pattern consistency in traditional processes.
[0032] 2. Through the cooperation of multiple active transmission units such as yarn guide roller, yarn drag roller, and warp feed shaft with sensors, the precise detection and closed-loop control of warp tension and speed are achieved, ensuring the high stability of tension in the printing area.
[0033] 3. By coordinating the adjustment of the rear telescopic reed and the front telescopic reed, the warp width and position of the printing area are precisely controlled, providing a foundation for accurate printing.
[0034] 4. By using the printing and weaving reverse mapping compensation algorithm in the integrated control subsystem, the design pattern is pre-compensated for deformation based on the weaving shrinkage rate, so that the "distorted pattern" printed on the warp yarn can be accurately restored to the expected finished pattern after weaving shrinkage, thus solving the problem of pattern deformation.
[0035] 5. By adopting a coordinated control strategy with the loom take-up roller as the main axis, dynamic matching between printing speed and weaving speed is achieved, as well as orderly linkage during system start-up and shutdown, thus avoiding defects such as horizontal lines and ghosting in the printing.
[0036] 6. Through the improved design of the loom main unit, such as the air-spring linkage back beam and the adjustable temperature full-width side support, the fluctuation of weaving tension is further buffered and on-machine color fixing is achieved, thereby improving the overall stability and efficiency of the system.
[0037] 7. The system of this invention is particularly suitable for replacing the traditional manual production of complex warp pattern products such as Atlas silk, realizing efficient, multi-variety, and highly consistent automated production, which is of great significance for the modern inheritance of intangible cultural heritage. Attached Figure Description
[0038] Figure 1 This is a schematic diagram of the integrated warp yarn printing and weaving system of the present invention.
[0039] The markings in the diagram are: 1. Warp beam; 2. Back reed; 3. Yarn feed roller; 4. Back telescopic reed; 5. Printing machine; 6. Front telescopic reed; 7. Yarn guide roller; 8. Width-fixing reed; 9. Warp feed beam; 10. Loom main unit; 101. Air-spring linkage back beam; 102. Adjustable temperature full-width side support; 103. Take-up roller; 11. Integrated control subsystem. Detailed Implementation
[0040] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.
[0041] like Figure 1As shown, an integrated system for warp yarn printing and weaving includes a physical execution subsystem and an integrated control subsystem 11 for controlling the physical execution subsystem;
[0042] The physical execution subsystem, along the warp yarn running direction, includes, in sequence:
[0043] Warp beam 1 loaded with pretreated warp yarns;
[0044] Back reed 2 is used to control the arrangement position and density of the output warp yarns;
[0045] The yarn guide roller 3 is used to actively draw the warp yarn from the warp beam 1. It is equipped with a pair of clamping rollers for guiding the warp yarn, preventing slippage and detecting the warp yarn tension and speed.
[0046] The back reed 4 is used to adjust the width and position of the warp yarns;
[0047] Printing host 5 for spraying patterns onto warp yarns;
[0048] The front telescopic reed 6 is used to coordinate with the rear telescopic reed 4 to control the warp position and width of the printing host 5 area;
[0049] The drag roller 7 is used to pull the warp yarn from the area of the inkjet printer (5), and is provided with a pair of clamping rollers for guiding the warp yarn, preventing slippage and detecting the warp yarn tension and speed.
[0050] The width-fixing reed 8 is used to control the width of the warp yarns entering the weaving area and to maintain the pattern arrangement order.
[0051] The warp feed shaft 9, which controls the amount of warp feed, is equipped with a pair of clamping rollers for guiding the warp yarns, preventing slippage, and detecting the warp yarn tension and speed.
[0052] And a loom main unit 10 for performing warp and weft yarn interlacing, the loom main unit 10 including a gas-spring linkage back beam 101 for buffering warp yarn tension fluctuations, an adjustable temperature full-width side support 102 for on-machine color fixing and controlling the width of the weave, and a take-up roller 103 for outputting the spindle speed signal.
[0053] The system starts at a warp beam 1 loaded with pre-treated warp yarns. This pre-treatment is not traditional sizing, but rather uses a special sizing agent to treat the warp yarns, creating a penetration-guiding gradient on the yarn surface. This allows the ink for subsequent printing to quickly penetrate the yarn circumferentially from the printed surface, achieving a consistent color on both sides of the fabric and overcoming the limitations of uneven color in traditional printing.
[0054] After the warp yarns are unwound from warp beam 1, they first pass through back reed 2, which initially controls the arrangement and density of the output warp yarns. Subsequently, the warp yarns enter guide rollers 3. Guide rollers 3 are a pair of active rollers driven by servo motors, each equipped with a pair of clamping rollers. These clamping rollers not only guide the warp yarns and prevent them from slipping on the roller surface, but more importantly, one clamping roller integrates a high-precision tension sensor, and the other integrates a high-precision linear velocity sensor. They monitor the initial tension and velocity of the warp yarns in real time, providing crucial feedback for subsequent control and ensuring that the warp yarns are fed into the next stage without slippage and stably.
[0055] The warp yarns then pass through the rear telescopic reed 4. To ensure the warp sheets are flat and uniform during printing and to prevent adjacent yarns from sticking together and mixing colors when ink droplets penetrate, the yarns must pass through the rear telescopic reed 4 before entering the inkjet printer 5. The rotation angle and lateral position of the reed 4 can be adjusted by the control system, thereby changing the width and lateral position of the warp sheets to precisely align them with the printhead array of the inkjet printer 5.
[0056] The warp yarns enter below the inkjet printer 5 and are printed with patterns here. After printing, the warp yarn sheets pass through a pre-drying device (not shown separately in the figure, but can be integrated into the inkjet printer 5) for preliminary drying.
[0057] Next, the warp yarns pass through the front telescopic reed 6. The structure and adjustment method of the front telescopic reed 6 are the same as those of the rear telescopic reed 4. By adjusting the front telescopic reed 6 to keep its setting consistent with that of the rear telescopic reed 4 or by making fine adjustments, the width and lateral position of the warp yarns below the inkjet printer 5 can be locked and stabilized together, ensuring the positioning accuracy of the printed pattern and preventing the pattern from becoming blurry or misaligned due to yarn movement.
[0058] The pre-dried warp yarns are then pulled out by the guide roller 7. The guide roller 7, similar in structure to the lead roller 3, is also a servo motor-driven active roller, equipped with a pair of clamping rollers integrating high-precision tension and linear speed detection sensors. The function of the guide roller 7 is to smoothly pull the warp yarns out of the printing area and to detect the tension and speed at that point again.
[0059] Afterward, the warp yarns pass through the width-fixing reed 8. The main function of the width-fixing reed 8 is to control the absolute width of the warp yarns entering the weaving area and strictly maintain the lateral pattern arrangement order of the warp yarns to prevent errors in subsequent processes. This is one of the key steps to ensure the accurate reproduction of complex patterns.
[0060] The warp yarns then enter the warp feed beam 9. The warp feed beam 9 is also an active control unit equipped with a servo motor and sensor-operated pinch rollers. Its core function is to precisely control the amount of warp yarn fed into the main loom 10 and to smoothly deliver the warp yarns into the weave. More importantly, as an active tension isolation point, the warp feed beam 9 can effectively buffer and isolate severe tension fluctuations from the main loom 10 behind it, ensuring stable tension in the printing area in front of it.
[0061] The warp yarns eventually enter the main loom 10 for warp and weft interlacing. The main loom 10 integrates three key components: a pneumatic-spring linked back beam 101, an adjustable-temperature full-width selvedge support 102, and a take-up roller 103. The pneumatic-spring linked back beam 101 can efficiently absorb and buffer the pulse tension fluctuations caused by the shedding and weft insertion actions, protecting the warp yarns and stabilizing the weaving process. The adjustable-temperature full-width selvedge support 102, while controlling the fabric width and preventing fabric shrinkage, also has a heating function that can directly fix the printed warp yarns on the machine, eliminating the need for a separate fixing process. The take-up roller 103 not only completes the fabric take-up, but the speed signal generated by its spindle encoder is the main speed reference (global spindle) for the entire integrated control subsystem 11.
[0062] The integrated control subsystem 11 is the brain that enables the "deep integration of software and hardware" in this invention. It includes a data integration module and a control integration module.
[0063] The data integration module has a built-in printing and weaving reverse mapping compensation algorithm. This algorithm can automatically retrieve the corresponding shrinkage database to calculate the buckling shrinkage rate when the warp yarns interweave, calculate and generate the distorted printing pattern after compensation and correction, and send it to the printing host 5 based on the input finished product design pattern, the machine parameters of the loom host 10 and the machine parameters of the inkjet host 5. When the stretched and deformed distorted pattern is printed on the warp yarns and finally interweaves on the loom host 10 and produces warp and weft shrinkage, the finished fabric presents the expected design pattern, realizing the accurate reproduction and online switching of complex artistic patterns.
[0064] The control integration module is responsible for the motion coordination of the entire system. It is used to set the take-up roller 103 of the loom host 10 as the global main axis, and to coordinate and control the rotation speed of the yarn guide roller 3, the yarn drag roller 7 and the warp feed shaft 9 in the integrated printing and weaving system, as well as the reciprocating speed of the printing head and the weft insertion speed of the loom, so as to achieve tension decoupling and speed matching throughout the printing and weaving process;
[0065] The control logic is as follows: When the loom host 10 is running normally, the control module controls the yarn feed roller 3, the yarn guide roller 7, and the warp feed shaft 9 to follow the rhythm of the take-up roller 103, maintaining a constant tension and speed in the printing area between the yarn feed roller 3 and the yarn guide roller 7, creating a stable environment for high-quality printing. When the loom stops for any reason, the control module immediately executes the linkage shutdown procedure: the warp feed shaft 9 stops feeding yarn but maintains the weft tension; the yarn guide roller 7 and the yarn feed roller 3 decelerate synchronously until they stop; the printing host 5 enters the breakpoint memory standby state after completing the current printing scan line. This collaborative control strategy fundamentally avoids printing horizontal lines and ghosting defects caused by the start and stop of the loom, achieving truly continuous high-quality production.
[0066] In summary, this invention, through the deep integration of innovative mechanical layout and intelligent control software, constructs a complete closed-loop production system encompassing pattern design, warp printing, and weaving. It not only automates the traditional manual warp-tying and pattern arrangement process but also solves the core bottleneck of direct linkage between printing and weaving through precise tension control, speed matching, and pattern deformation compensation technologies. This provides an efficient, precise, and flexible modern solution for producing high-value-added textiles with complex warp patterns.
[0067] 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 the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.
Claims
1. An integrated system for warp yarn printing and weaving, characterized in that, It includes a physical execution subsystem and an integrated control subsystem for controlling the physical execution subsystem (11); The physical execution subsystem, along the warp yarn running direction, includes, in sequence: Warp beam loaded with pretreated warp yarns (1); The back reed (2) is used to control the arrangement position and density of the output warp yarns. A yarn guide roller (3) is used to actively pull the warp yarn from the warp beam (1), and a pair of clamping rollers are provided on it to guide the warp yarn, prevent slippage and detect the warp yarn tension and speed. (4) is a back stretch reed used to adjust the width and position of the warp yarn. Printing host (5) for spraying patterns onto warp yarns; The front telescopic reed (6) is used to coordinate with the rear telescopic reed (4) to control the warp position and width of the printing host (5) area. A drag roller (7) for pulling warp yarns out of the area of the inkjet printer (5) is provided with a pair of clamping rollers for guiding the warp yarns, preventing slippage and detecting warp yarn tension and speed. A fixed-width reed (8) used to control the width of the warp yarns entering the weaving area and to maintain the pattern arrangement order. The warp feed shaft (9) is used to control the amount of warp feed, and is equipped with a pair of clamping rollers for guiding the warp yarn, preventing slippage and detecting the warp yarn tension and speed. And the main loom (10) for performing warp and weft yarn interlacing, the main loom (10) includes a gas spring linkage back beam (101) for buffering warp tension fluctuations, an adjustable temperature full width side support (102) for on-machine color fixing and controlling the width of the weave, and a take-up roller (103) for outputting the spindle speed signal.
2. The integrated warp yarn printing and weaving system according to claim 1, characterized in that, The pretreated warp yarns loaded on the warp beam (1) have a penetration guide gradient formed on their surface by the pretreated slurry, so that the inkjet ink can quickly penetrate from the printing surface along the circumference of the yarn to achieve consistent color on both sides.
3. The integrated warp yarn printing and weaving system according to claim 1, characterized in that, The yarn guide roller (3), the yarn drag roller (7), and the warp feed shaft (9) are all active transmission units equipped with servo motors. One of the pair of clamping rollers on them integrates a high-precision tension detection sensor, and the other integrates a high-precision linear speed detection sensor.
4. The integrated warp yarn printing and weaving system according to claim 1, characterized in that, The rotation angle and lateral position of the reeds of the rear telescopic reed (4) and the front telescopic reed (6) are adjustable, which are used to jointly adjust and lock the width and lateral position of the warp yarns below the inkjet printer (5).
5. The integrated warp yarn printing and weaving system according to claim 1, characterized in that, The integrated control subsystem (11) includes a data integration module and a control integration module; The data integration module has a built-in printing and weaving reverse mapping compensation algorithm. This algorithm can automatically retrieve the corresponding shrinkage database to calculate the buckling shrinkage rate when the warp yarns interweave, calculate and generate the distorted printing pattern after compensation and correction, and send it to the printing host (5) according to the input finished product design pattern, the machine parameters of the loom host (10) and the machine parameters of the inkjet host (5). When the distorted pattern of stretching deformation is printed on the warp yarns and finally interweaves on the loom host (10) and generates warp and weft shrinkage, the finished fabric presents the expected design pattern. The control integration module is used to set the take-up roller (103) of the loom host (10) as the global main shaft, and coordinate the rotation speed of the yarn guide roller (3), the yarn drag roller (7) and the warp feed shaft (9) in the integrated printing and weaving system, as well as the reciprocating speed of the inkjet head and the weft insertion speed of the loom, so as to achieve tension decoupling and speed matching of the entire printing and weaving process.
6. The integrated warp yarn printing and weaving system according to claim 5, characterized in that, The control integration module is configured as follows: When the main loom (10) is running normally, the yarn guide roller (3), yarn drag roller (7) and warp feed shaft (9) are controlled to move in sequence to maintain the constant warp tension and speed in the printing area; When the loom host (10) stops, control the warp feed shaft (9) to stop feeding yarn and maintain the weaving tension, control the yarn guide roller (7) and the yarn feed roller (3) to decelerate synchronously to stop, and control the inkjet printer host (5) to enter the breakpoint memory standby state after completing the current scan line.
7. The integrated warp yarn printing and weaving system according to claim 1, characterized in that, The air-spring linkage rear beam (101) is used to absorb and buffer the pulse tension fluctuations caused by the opening and weft insertion during the weaving process.
8. The integrated warp yarn printing and weaving system according to claim 1, characterized in that, The adjustable temperature full-width side support (102) can directly fix the ink on the warp yarns with its heat energy while controlling the width of the weave.