Method of knitting plush yarn on a warp knitting machine

Abstract

This invention provides a method for weaving plush yarn on a warp knitting machine, belonging to the field of warp knitting technology. This method uses polyester multifilament DTY yarn or functional multifilament yarn to weave a double-sided structure, forming a double-sided rope. Utilizing the flexible yarn feeding characteristics of the machine, it can adapt to plush yarns of different thicknesses, materials, and colors. Combined with the adjustable double-sided opening of the warp knitting machine, the fluffiness of the rope can be flexibly controlled by precisely controlling the opening size. Simultaneously, by combining a multi-speed warp feeding mechanism or Jacquard knitting technology, the length and discontinuous distribution of the plush can be precisely controlled. Structural design is performed based on the color attributes of different plush fibers, ultimately weaving a customized plush rope that combines functionality and aesthetics. This invention achieves integrated weaving and forming, eliminating the need for additional finishing processes, saving production time and reducing production costs, while also achieving green, environmentally friendly, and pollution-free production, aligning with the development trend of low-carbon industries.

Description

Technical Field

[0001] This invention relates to the field of warp knitting technology, specifically to a method for weaving plush yarn on a warp knitting machine. Background Technology

[0002] In the current textile industry, yarn is the core basic raw material, and its production mainly relies on traditional spinning and spun yarn processes. For special categories such as plush yarn and fancy yarn, secondary processing is required through weaving machines to form the desired plush texture or diverse patterns.

[0003] Currently, the production of plush yarns on the market (such as wool, cashmere, mohair, acrylic plush, etc.) mainly relies on coarse and fine wool spinning processes, or auxiliary processes such as spraying and brushing. The core goal is to make the fibers fluffy and napped and then spin them into yarn. However, this type of production process has the following drawbacks: 1. This type of process starts with loose fibers and requires multiple pretreatments such as wool selection, wool washing, and loose fiber dyeing. The process is lengthy, and the wool washing and loose fiber dyeing processes generate wastewater, resulting in a heavy environmental burden.

[0004] 2. In traditional processes, the fineness, fluffiness, length, and color of the plush are fixed during the spinning stage, and only simple shaping can be achieved during the weaving stage; if the plush pattern needs to be changed, the machine must be stopped to change the yarn and the raw materials. Summary of the Invention

[0005] This invention provides a method for weaving plush yarn on a warp knitting machine to solve at least one of the technical problems mentioned in the background art.

[0006] To solve the above-mentioned technical problems, the present invention discloses a method for weaving plush yarn on a warp knitting machine, comprising: S1: Ingredients: Select multifilament yarn as the middle layer material, and combine it with plush yarn of different denier specifications and different luster types; S2: The weaving pattern is adopted, with the front needle bed of the double needle bed weaving the front plush braided layer of the rope and the back needle bed weaving the bottom plush braided layer of the rope; the middle layer uses the multifilament yarn, and through the repeated weaving or intermittent weaving process of the front and back needle beds, a three-layer double-sided rope base material consisting of the front plush braided layer, the middle layer and the bottom plush braided layer is woven into one piece. S3: The thickness, width and visual specifications of the pile are adjusted by using the open-thread yarn method; Differentiated weaving includes two paths: Path 1, using the same open-thread process with pile yarns of different deniers; Path 2, using the same pile yarns of different deniers with different open-thread processes. S4: By adjusting the double-sided opening size of the double needle bed warp knitting equipment, the spread of the pile on both sides is adjusted to control the fluffiness of the pile; a multi-channel parallel synchronous weaving mode is adopted to simultaneously weave multiple specifications and batches of ropes. S5: Customized weaving based on plush length and distribution pattern: S5.1: Adjust the needle arrangement in the knitting area to control the length of the finished pile; S5.2: Configure a multi-speed warp feed mechanism or jacquard weaving device to implement intermittent weaving of the intermediate layer, control the spacing and distribution pattern of the pile, and complete the zonal structured color matching according to the color of the pile yarn.

[0007] Preferably, the denier specifications of the plush yarn include 30D, 40D, 50D, 75D, 100D, 150D, 200D, and 300D.

[0008] Preferably, the gloss types include semi-gloss, glossy, and matte.

[0009] Preferably, the multifilament yarn is polyester DTY multifilament or functional multifilament yarn.

[0010] Preferably, the functional multifilament yarn includes at least one of the following: moisture-wicking yarn, antibacterial yarn, UV-protective yarn, antistatic yarn, odor-resistant yarn, warmth-retaining yarn, and heat-generating yarn.

[0011] Preferably, the air-penetration process includes: 1-penetration-1-air, 2-penetration-2-air, and 3-penetration-3-air.

[0012] Preferably, the plush length described in S5.1 is 0.1cm to 4cm.

[0013] Preferably, during the execution of S2, a splitting shear is simultaneously set on the warp knitting equipment; when the knitting operation is in progress, the splitting shear is used to split and decompose each pile yarn, so that a single pile yarn is split into two pile yarns.

[0014] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments.

[0015] Compared with the prior art, the present invention has the following beneficial effects: Leveraging the unique advantages of double-needle bed warp knitting equipment, this method achieves integrated weaving of the fabric body, breaking the limitations of traditional rope-making processes and balancing production efficiency, product diversity, and customization needs. This method uses polyester multifilament DTY yarn or functional multifilament yarn to weave a double-sided structure, fully utilizing the special advantages of double-sided weaving on warp knitting machines. It can not only weave double-sided ropes but also adapt to different thicknesses, materials, and colors of plush yarns through the flexible yarn feeding characteristics of the equipment. Combined with the adjustable double-sided opening of the warp knitting equipment, the fluffiness of the rope can be flexibly controlled by precisely controlling the opening size. Simultaneously, by combining a multi-speed warp feeding mechanism or Jacquard weaving technology, the length and discontinuous distribution of the plush can be precisely controlled. Structural design is carried out according to the color attributes of different plush fibers, ultimately weaving customized plush ropes that combine functionality and aesthetics. Furthermore, this method utilizes warp knitting equipment, allowing for the use of low-cost synthetic multifilament yarns as raw materials. It also places lower demands on the quality of the yarn fibers and eliminates the need for complex pre-treatment processes. The entire process is a single, integrated knitting process, requiring no additional finishing steps. This saves on production time and costs while achieving green, environmentally friendly, and pollution-free production, aligning with the low-carbon industry trend. Simultaneously, the resulting pile yarn, due to the integrated knitting process, exhibits extremely high pile structure stability, minimizing shedding and effectively extending the lifespan of the yarn and braided rope products. Moreover, this braided rope has wide downstream applications, suitable for various textile equipment, enabling the weaving of various high-end fabrics and accessories on looms. Attached Figure Description

[0016] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings: Figure 1 This is a schematic diagram of the process of the present invention; Figure 2 This is a structural diagram of the yarn of the present invention on the sewing machine of a warp knitting equipment; Figure 3 This is an anatomical diagram of the yarn structure of the present invention; Figure 4 This is a diagram of the actual yarn used in the production of this invention. Detailed Implementation

[0017] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0018] Furthermore, in this invention, the use of terms such as "first" and "second" is for descriptive purposes only and does not specifically refer to any order or sequence, nor is it intended to limit the invention. They are merely used to distinguish components or operations described using the same technical terms and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the technical solutions and features of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. If a combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0019] The present invention provides the following embodiments: This invention provides a method for weaving plush yarn on a warp knitting machine, such as... Figures 1-4 As shown, it includes: S1: Ingredients: Select multifilament yarn as the middle layer material, and combine it with plush yarn of different denier specifications and different luster types; S2: The weaving pattern is adopted, with the front needle bed of the double needle bed weaving the front plush braided layer of the rope and the back needle bed weaving the bottom plush braided layer of the rope; the middle layer uses the multifilament yarn, and through the repeated weaving or intermittent weaving process of the front and back needle beds, a three-layer double-sided rope base material consisting of the front plush braided layer, the middle layer and the bottom plush braided layer is woven into one piece. S3: The thickness, width and visual specifications of the pile are adjusted by using the open-thread yarn method; Differentiated weaving includes two paths: Path 1, using the same open-thread process with pile yarns of different deniers; Path 2, using the same pile yarns of different deniers with different open-thread processes. S4: By adjusting the double-sided opening size of the double-needle bed warp knitting equipment (a double-needle bed warp knitting machine has two sets of needle beds, front and back, respectively knitting the front and bottom pile layers; the lateral distance between the front and back needle beds is the double-sided opening size; pile spread: after the yarn is knitted into loops to form pile, the distance between the two needle beds will spread and disperse the vertical pile fibers laterally to both sides, and the lateral width of the spread is the spread), the pile spread on both sides can be adjusted to control the pile fluffiness; a multi-channel parallel synchronous weaving mode is adopted (a wide-width whole-machine synchronous weaving structure is adopted, and multiple independently adjustable weaving channels are set within the width) to simultaneously weave multiple specifications and batches of ropes; Using a wide-width double-needle bed warp knitting main unit as the carrier, the main shaft, tensioning, and warp feeding systems of the whole machine operate synchronously to maintain the basic characteristics of synchronous material output in wide-width weaving. At the same time, multiple independent weaving channels are divided along the transverse width of the equipment. Each channel is equipped with an independent open threading, opening, and yarn feeding adjustment mechanism. Weaving process parameters can be set for each channel separately. Therefore, it is possible to simultaneously complete the weaving of various specifications and different batches of ropes within the same width.

[0020] S5: Customized weaving based on plush length and distribution pattern: S5.1: Adjust the needle arrangement in the knitting area to control the length of the finished pile; S5.2: Configure a multi-speed warp feed mechanism or jacquard weaving device to implement intermittent weaving of the intermediate layer, control the spacing and distribution pattern of the pile, and complete the zonal structured color matching according to the color of the pile yarn.

[0021] Normal weaving section: The multi-speed warp feed mechanism continuously feeds the multifilament intermediate yarn at a set speed, and the front and rear needle beds knit synchronously, forming a complete three-layer structure. This section will generate raised pile. Intermittent openwork section: The controller sends a signal, and the multi-speed warp feed mechanism briefly slows down / pauses to feed multifilament yarn. At this time, the pile yarn on both sides continues to be woven, and there is no multifilament support in the middle, forming openwork gaps in the fabric. Resumption weaving section: The multi-speed warp feed mechanism resumes the set yarn feeding speed, the intermediate layer multifilament yarn is reconnected, and the three-layer structure is formed again.

[0022] There are two ways to control the spacing between pile intervals: The first relies on a multi-speed warp feeding mechanism. The equipment controller sends timing signals to control the feeding time of the intermediate multifilament yarn. The longer the multifilament yarn is stopped, the longer the length of the open section without lining yarn support, and the wider the gap between the piles. Conversely, the gap shrinks. At the same time, the multifilament yarn can be fed at a reduced speed for a short time to create narrow and shallow micro-intervals. The second relies on a Jacquard weaving device. The program controls the duration for which the guide needle carrying the intermediate multifilament yarn is lifted and detached from the weaving. The lifting time of the guide needle directly corresponds to the length of the open gap. By modifying the lifting time, the width of each pile interval can be precisely adjusted to achieve an interval spacing of any size.

[0023] Both devices can achieve sequential arrangement of the overall pile distribution pattern: When using a multi-speed warp feed mechanism, multiple combinations of "pile segments + gaps" of varying lengths can be continuously arranged within the equipment program. The arrangement cycle can be freely set to uniform and equidistant, dense in the middle and sparse at both ends, or alternating density. The entire sequence will repeat continuously with the weaving to form a fixed pile distribution pattern. When using a Jacquard weaving device, independent guide needle on / off sequences can be set for different length sections of the rope. The front, middle, and rear sections of the same rope can use completely different pile interval combinations to achieve segmented differentiated distribution and meet the complex pile arrangement requirements such as staggered, gradual, and locally dense.

[0024] The zoned structured color matching is mainly achieved by the jacquard weaving device. First, the pile yarns of different colors are threaded into the independent guide needle group of the jacquard. Then, the entire weaving width and length are divided into multiple independent weaving blocks. During the weaving process, the equipment drives the guide needles of the corresponding color pile yarn in the target block to participate in the weaving according to the preset color matching scheme. The guide needles of other colors are raised and do not participate in the weaving, so that different blocks are woven with different colors of pile, forming a structured color with clear boundaries and regular blocks. If a multi-speed warp feed mechanism is selected, the multi-color pile yarns can be threaded in sections in advance, and the supply of different colored yarns can be switched in sections during weaving to achieve zoned color matching simultaneously. Preferably, the denier specifications of the plush yarn include 30D, 40D, 50D, 75D, 100D, 150D, 200D, and 300D.

[0025] Preferably, the gloss types include semi-gloss, glossy, and matte.

[0026] Preferably, the multifilament yarn is polyester DTY multifilament or functional multifilament yarn.

[0027] Preferably, the functional multifilament yarn includes at least one of the following: moisture-wicking yarn, antibacterial yarn, UV-protective yarn, antistatic yarn, odor-resistant yarn, warmth-retaining yarn, and heat-generating yarn.

[0028] Preferably, the air-penetration process includes: 1-penetration-1-air, 2-penetration-2-air, and 3-penetration-3-air.

[0029] Preferably, the plush length described in S5.1 is 0.1cm to 4cm.

[0030] Preferably, during the execution of S2, a splitting shear is simultaneously set on the warp knitting equipment; when the knitting operation is in progress, the splitting shear is used to split and decompose each pile yarn, so that a single pile yarn is split into two pile yarns.

[0031] Case 1: Ordinary warp knitting double-sided warp knitting machine, single-needle double-bed: GB4: Warped multifilament yarn P-DTY150D / 48F semi-dull low-elasticity lightweight mesh with 6 heads and 520 yarns. GB4 yarn is threaded on the machine in a full-thread manner, with a warp feed of 1850MM / lactate and a padding number of 0-0 / 0-1 / 1-1 / / 1-0 / ; GB refers to a ground comb (ground comb). GB5: Warped multifilament yarn P-DTY150D / 48F semi-dull low elasticity light mesh with 6 heads and 520 yarns. GB5 yarn is threaded on the machine in a full-thread manner, with a warp feed of 6000MM / lactate and a padding number of 1-0 / 1-0 / 0-1 / 0-1 / / . Note: GB5's digital yarn padding allows for 4-needle, 3-needle, and 2-needle double-needle knitting structures, controlling the density of yarn, rope, and pile; the length of the pile is controlled by the size of the double-sided opening of the warp knitting equipment. GB6: Warped multifilament yarn P-DTY150D / 48F semi-dull low elasticity light mesh with 6 heads and 520 yarns. GB6 yarn is threaded on the machine in a full-thread manner, with a warp feed of 1850MM / lactate and a padding number of 1-1 / / 1-0 / 0-0 / 0-1 / . Note: Different thicknesses and deniers of yarn can also be used to weave plush ropes of different thicknesses to suit a variety of application scenarios.

[0032] Case 2: Ordinary warp knitting double-sided warp knitting machine, with both handles absorbing the pile: GB3: Warped multifilament yarn P-DTY150D / 48F semi-dull low elasticity light mesh with 6 heads and 520 yarns. GB3 yarn is threaded on the machine in a full-thread manner, with a warp feed of 1850MM / lactate and a padding number of 1-0 / 0-0 / 0-1 / 1-1 / / . GB4: Warped multifilament yarn P-DTY100D / 96F semi-dull low elasticity light mesh with 6 heads and 520 yarns. GB4 yarn is threaded on the machine in a full-thread manner, with a warp feed of 4300MM / lactate and a padding number of 1-0 / 0-0 / 0-1 / / 1-0 / . GB5: Warped multifilament yarn P-DTY100D / 96F semi-dull low elasticity light mesh with 6 heads and 520 yarns. GB5 yarn is threaded on the machine in a full-thread manner, with a warp feed of 4300MM / lactate and a padding number of 1-0 / 1-0 / 0-0 / 1-1 / / . Note: GB4 and GB5 are interconnected, and can also control the 4-needle, 3-needle, and 2-needle digital padding of GB4, and the reciprocating double needle knitting yarn of GB5 with 4-needle, 3-needle, and 2-needle padding, to control the density of the plush texture. GB6: Warped multifilament yarn P-DTY150D / 48F semi-dull low elasticity light mesh with 6 heads and 520 yarns. GB6 yarn is threaded on the machine in a full-threading manner, with a warp feed of 1850MM / lactate and a padding number of 1-1 / 1-0 / 0-0 / 0-1 / . Note: Various functional yarns can be used to give the yarn moisture-wicking properties, enhanced warmth retention, heat generation, etc. Case 3: Warp knitting machine for double-sided jacquard yarn: GB2: Warping P-DTY150D / 48F semi-glossy environmentally friendly low-elasticity lightweight net (recycle) 6 heads 520 yarns, GB2 yarn is threaded on the machine in a full-threading manner, the warp feed is 1700MM / lact, and the padding yarn number is: 1-0 / 0-0 / 0-1 / 1-1 / / . JB1.1: P-DTY150D / 48F semi-glossy environmentally friendly low-elasticity micro-mesh (twist-free) yarn creel with 1536 yarns. JB1.1 yarns are threaded on the machine using a 1-thread-1-empty-thread method, with a warp feed of 6800mm / lactate. The yarn padding code is: 0-0 / 0-0 / 0-0 / 0-0 / / . JB1.2: P-DTY150D / 48F semi-glossy environmentally friendly low-elasticity micro-mesh (twist-free), 1536 yarns on the yarn creel. JB1.2 yarns are threaded on the machine using a 1-thread-1-blank threading method, with a warp feed of 6800mm / lactate. The yarn padding code is: 0-0 / 0-0 / 0-0 / 0-0 / / . Note: JB1.1 and JB1.2 Jacquard yarns form the middle pile through back-and-forth knitting on the front and back sewing machines. Due to the flexibility of Jacquard CAD drawing and the warp feed rate with the yarn frame, variations in pile yarn length, intermittent pile, and pile density can be achieved on the same pile rope, allowing for customization. This results in a rich and distinctive design. GB6: Warped multifilament yarn P-DTY150D / 48F semi-dull low elasticity light mesh with 6 heads and 520 yarns. GB6 yarn is threaded on the machine in a full-thread manner, with a warp feed of 1700MM / lactate and a padding number of 1-1 / 1-0 / 0-0 / 0-1 / . The above method involves using a pile-splitting shear on the warp knitting equipment while weaving the rope to dissect each pile rope and yarn, thus turning one yarn into two pile yarns. The beneficial effects of the above technical solution are as follows: Relying on the double-sided structure of warp knitting double needle bed equipment, various machine sizes can be flexibly selected and a zoned weaving mode can be adopted. One side is woven into the front of the rope, and the other side is woven into the bottom of the rope. The middle layer uses polyester multifilament DTY yarn or functional yarn and yarns with different luster (different thicknesses of yarn, such as 30D, 40D, 50D, 75D, 100D, 150D, 200D, 300D with different lusters of semi-gloss, gloss, and full matte) as the core weaving material. Through repeated weaving or intermittent weaving process of the front and rear needle beds, a double-sided rope base material with a three-layer structure is formed, laying the foundation for the structural stability and functionality of the rope.

[0033] By fully utilizing the flexibility of warp knitting equipment in threading yarn, and designing diverse open-thread yarn methods, the thickness and width of the rope can be flexibly adjusted. For example, by using open-thread techniques such as 1 thread 1 open, 2 thread 2 open, and 3 thread 3 open, plush ropes of different widths can be woven. Alternatively, the same open-thread method (such as 1 thread 1 open) can be used with yarns of different denier (D) to weave plush ropes of different thicknesses, adapting to diverse application scenarios.

[0034] Leveraging the core advantage of wide-width weaving in warp knitting equipment, simultaneous weaving of multiple specifications and batches of ropes can be achieved, significantly improving production efficiency and effectively saving labor input and production costs. At the same time, warp knitting equipment can simultaneously weave hundreds or even thousands of yarns. In addition, the equipment itself has the characteristics of fast weaving speed and high operational stability, which further enhances production efficiency and solves the pain points of low efficiency and high labor costs in traditional rope weaving processes.

[0035] The length of the plush in the rope weaving area can be flexibly adjusted as needed, with the finished product having a plush length of approximately 0.1CM-4CM.

[0036] Combining the advantages of the warp feeding mechanism and the flexible organizational structure design of warp knitting equipment, the middle layer uses polyester multifilament DTY yarn for intermittent weaving, which can achieve intermittent distribution of plush, and the interval and distribution pattern can be precisely controlled, realizing the customized design of rope plush, meeting the appearance and functional requirements of different scenarios, and enriching the diversity of rope products.

[0037] Leveraging the unique advantages of double-needle bed warp knitting equipment, this method achieves integrated weaving of the fabric body, breaking the limitations of traditional rope-making processes and balancing production efficiency, product diversity, and customization needs. This method uses polyester multifilament DTY yarn or functional multifilament yarn to weave a double-sided structure, fully utilizing the special advantages of double-sided weaving on warp knitting machines. It can not only weave double-sided ropes but also adapt to different thicknesses, materials, and colors of plush yarns through the flexible yarn feeding characteristics of the equipment. Combined with the adjustable double-sided opening of the warp knitting equipment, the fluffiness of the rope can be flexibly controlled by precisely controlling the opening size. Simultaneously, by combining a multi-speed warp feeding mechanism or Jacquard weaving technology, the length and discontinuous distribution of the plush can be precisely controlled. Structural design is carried out according to the color attributes of different plush fibers, ultimately weaving customized plush ropes that combine functionality and aesthetics. Furthermore, this method utilizes warp knitting equipment, allowing for the use of low-cost synthetic multifilament yarns as raw materials. It also places lower demands on the quality of the yarn fibers and eliminates the need for complex pre-treatment processes. The entire process is a single, integrated knitting process, requiring no additional finishing steps. This saves on production time and costs while achieving green, environmentally friendly, and pollution-free production, aligning with the low-carbon industry trend. Simultaneously, the resulting pile yarn, due to the integrated knitting process, exhibits extremely high pile structure stability, minimizing shedding and effectively extending the lifespan of the yarn and braided rope products. Moreover, this braided rope has wide downstream applications, suitable for various textile equipment, enabling the weaving of various high-end fabrics and accessories on looms.

[0038] In an optional embodiment, a tension control auxiliary process is further included, which includes: a1: Get the preset tension control range for the yarns of the front plush braided layer, middle layer, and bottom plush braided layer corresponding to the current batch of weaving; a2: Based on the preset tension control range corresponding to a1, the current batch weaving is executed, and the yarn tension corresponding to the front pile layer, middle layer, and bottom pile layer is detected multiple times during the weaving process; A tension state matrix is ​​constructed based on the tension detection results. Columns 1-7 of the tension state matrix represent the detection time, state feature number, yarn tension detection value of the front plush layer, yarn tension detection value of the middle layer, yarn tension detection value of the bottom plush layer, tension difference between the front and middle layers (yarn tension detection value of the front plush layer minus yarn tension detection value of the middle layer), and tension difference between the bottom and middle layers (yarn tension detection value of the bottom plush layer minus yarn tension detection value of the middle layer). When the yarn tension detection value of the intermediate layer is within the theoretical yarn tension range of the intermediate layer in the intermittent weaving (i.e., the intermittent hollow section) corresponding to the current batch weaving, the state feature number is 1. When the yarn tension detection value of the intermediate layer is within the theoretical yarn tension range of the intermediate layer in the continuous plush forming weaving (i.e., normal weaving section) corresponding to the current batch weaving, the state characteristic number is 2. The tension of the three layers of yarn is collected synchronously. At the same detection time, the tension values ​​of the three layers are read synchronously and the tension difference between the layers is calculated. The values ​​are then uniformly filled into the same row of the matrix. Furthermore, the tension state matrix is ​​fixed with two reference rows, namely the intermittent weaving reference row and the continuous plush forming reference row. The two types of reference rows are stored separately. After the most recent yarn tension adjustment is qualified (the detection values ​​of all tension columns and difference columns in the row fall within the qualified tension range of the corresponding working condition), the synchronous detection data at the corresponding detection time under each working condition is stored. During operation, only the reference row that matches the current state feature number is retrieved to perform double comparison and deviation calculation.

[0039] The tension state matrix adopts a fixed-row sliding window caching mechanism. The tension state matrix stores the synchronous detection data of the most recent M groups (8 to 15 groups, preferably 10 groups) of non-baseline rows. The number of stored rows is fixed. When the collected data reaches the maximum number of stored rows, the earliest written row (non-baseline row) of data is automatically removed. When the equipment is powered on for the first time and switches to a certain working condition where there is no corresponding baseline, it automatically generates the initial baseline for that working condition by collecting three consecutive sets of synchronous data in which all indicators are qualified. a3: Tension control of three-layer yarns based on tension state matrix: a31: Based on the state feature sequence number in the matrix, retrieve the preset tension control range of the three layers of yarn under the corresponding segment working condition (the preset tension control range corresponding to the yarn of the front plush braided layer, the middle layer, and the bottom plush braided layer), and the preset allowable range of the tension difference between the two layers. This range is calibrated by batch gradient trial weaving.

[0040] a32: Synchronously collect data by traversing the M groups of non-baseline rows in the sliding window; perform double comparison on each row: First step: The three-layer tension column and the two sets of interlayer difference columns in this row are matched against the corresponding preset allowable ranges for comparison; The second step involves calculating the deviation of all indicators in the row from the fixed baseline row of the matrix with the same state feature number; when the window is full, the earliest written non-baseline row is automatically removed.

[0041] For example, the deviation in the i-th column of the matrix (i is greater than or equal to 2): |Detection value in the i-th column of the current row - Detection value in the i-th column of the benchmark row for matching the state feature number of the current row | ÷ Detection value in the i-th column of the benchmark row for matching the state feature number of the current row; a33: The output torque of the yarn feeding motor is the adjustment target, and a fixed small gradient is used for gradual correction. The single torque adjustment gradient is 2% to 5% of the total torque range (i.e., the rated torque of the yarn feeding motor), preferably 3%. 1) Instantaneous Exceedance: If any layer of yarn tension value or any set of interlayer tension difference exceeds the "preset tension control range of three layers of yarn and the preset allowable range of two sets of interlayer tension difference under the corresponding segmented working condition" in any row of collected data within the sliding window, it is judged as an instantaneous exceedance. In each round, only a single gradient torque correction is applied, and multiple iterations are performed until the index returns to the range (i.e., the tension value of any layer of yarn and any set of interlayer tension difference are within the "preset tension control range of three layers of yarn and the preset allowable range of two sets of interlayer tension difference under the corresponding segmented working condition"). 2) Gradual drift: Within the window, ≥3 consecutive sets of data with the same state feature number continuously shift in one direction (continuously increasing or decreasing) relative to the original baseline row corresponding to the same state feature number, and the single relative deviation is >5%. For mild drift (5% < single relative deviation ≤ 10%), apply single gradient torque in advance for each round; for severe drift (single relative deviation > 10%), apply double gradient torque in advance for each round. If the drift cannot be suppressed after 5 consecutive iterations of adjustment, a fault shutdown is triggered.

[0042] a34: Synchronous acquisition and update matrix after adjustment; only when all tensions and differences in this row fall within the preset tension control range of the three-layer yarn retrieved by the corresponding state feature number, the preset allowable range of tension difference between the two sets of layers, and the relative deviations of all indicators in this row relative to the "original reference row corresponding to the same state feature number" are less than 5%, the synchronous detection data of this row will replace the original reference row of the corresponding working condition and become the new reference row of this working condition; when changing batch processes, clear all non-reference rows in the sliding window and simultaneously clear the original reference rows corresponding to the two sets of working conditions.

[0043] The single instantaneous out-of-tolerance adjustment can be iterated for a maximum of 5 rounds. If the index still cannot return to the preset range after 5 consecutive iterations, or if the cumulative torque of a single motor reaches 80% of the total torque range but still fails to meet the standard, or if the tension of any layer of yarn exceeds the limit tension threshold of that layer, the equipment will be directly interlocked to stop and the fault tension data will be recorded. In this embodiment, tension adjustment is a prior art technique. Specifically, the tension can be corrected by conventional methods such as adjusting the output torque of the yarn feeding motor, changing the yarn path damping resistance, and adjusting the conveying speed of the warp roller. The above-mentioned basic tension adjustment methods are all well-known in the art and will not be described in detail in this application.

[0044] In this embodiment, the preset tension control range is a stable process range that is determined and screened by the multi-condition gradient trial weaving test in the early stage and adapted to the current batch weaving; each batch weaving has a corresponding stable process range for batch weaving determined by the test; during the test, gradient tension weaving test is carried out for the same raw material specifications, open path, double-sided opening size and target pile length as the current batch, the tension is adjusted step by step and the finished product is inspected, and the tension values ​​that are prone to yarn breakage, delamination of three-layer substrate, rope size deviation, pile flattening and reduction of tensile strength of finished product are eliminated. Only the tension range that does not damage the appearance, internal composite structure and mechanical properties of the product with small tension fluctuations is retained as the exclusive stable process range for this set of working conditions; By comprehensively combining raw material information (including yarn denier and luster), looping path, double-sided opening size, and target pile length, the tension control range is determined. For fine denier yarn, large opening, high loft, and long pile conditions, a lower tension is matched; for coarse denier yarn, small opening, and tight short pile conditions, a moderate tension is matched. The front pile layer, middle layer, and bottom pile layer are each configured with an independent tension range to ensure uniform coil formation in the current batch weaving and reduce quality defects such as yarn breakage, pile flattening, and delamination of the three-layer substrate.

[0045] In this embodiment, tension detection points are respectively arranged in the yarn path section between the warp feed beam of the front pile yarn, the middle multifilament yarn, and the bottom pile yarn and the double needle bed weaving area. Tension sensors are independently configured for the three layers of yarn path, and the tension of each layer of yarn is collected separately in real time. The beneficial effects of the above technical solution are as follows: This solution distinguishes between two working conditions: intermittent openwork weaving and continuous plush forming. Each condition has its own dedicated reference line. During operation, only the reference line matching the current working condition is called to calculate the relative tension deviation, completely avoiding drift misjudgment and repeated motor misadjustment caused by mixing tension standards for different weaving working conditions. At the same time, it limits the generation / update of the corresponding working condition reference to only continuous multi-set grid sampling data, ensuring that the tension benchmark is always the standard state of stable forming under the current process, reducing batch quality defects such as plush flattening, delamination of three-layer substrate, and uneven coil forming.

[0046] Three-layer synchronous acquisition + multi-dimensional dual comparison to predict gradual tension drift in advance and reduce yarn breakage: A standardized tension state matrix with 7 columns containing three independent layers of tension and two sets of inter-layer differences is constructed. The three layers of yarn data are collected synchronously at the same time and archived uniformly. Each row of data is subjected to dual comparison of "interval range matching + same baseline row deviation verification". Gradient pre-adjustment is performed in advance for gradual drift with continuous unidirectional offset within the window. Differentiated torque adjustment amplitude is used to distinguish between light and heavy drift. Correction can be completed in the stage of small tension offset, avoiding tension from continuously offset to the limit and causing yarn breakage, reducing raw material loss and downtime rework frequency.

[0047] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A method for weaving plush yarn on a warp knitting machine, characterized in that: include: S1: Ingredients: Select multifilament yarn as the middle layer material, and combine it with plush yarn of different denier specifications and different luster types; S2: The weaving pattern is adopted, with the front needle bed of the double needle bed weaving the front plush braided layer of the rope and the back needle bed weaving the bottom plush braided layer of the rope; the middle layer uses the multifilament yarn, and through the repeated weaving or intermittent weaving process of the front and back needle beds, a three-layer double-sided rope base material consisting of the front plush braided layer, the middle layer and the bottom plush braided layer is woven into one piece. S3: The thickness, width and visual specifications of the pile are adjusted by using the open-thread yarn method; Differentiated weaving includes two paths: Path 1, using the same open-thread process with pile yarns of different deniers; Path 2, using the same pile yarns of different deniers with different open-thread processes. S4: By adjusting the double-sided opening size of the double needle bed warp knitting equipment, the spread of the pile on both sides is adjusted to control the fluffiness of the pile; a multi-channel parallel synchronous weaving mode is adopted to simultaneously weave multiple specifications and batches of ropes. S5: Customized weaving based on plush length and distribution pattern: S5.1: Adjust the needle arrangement in the knitting area to control the length of the finished pile; S5.2: Configure a multi-speed warp feed mechanism or jacquard weaving device to implement intermittent weaving of the intermediate layer, control the spacing and distribution pattern of the pile, and complete the zonal structured color matching according to the color of the pile yarn.

2. The method for weaving plush yarn on a warp knitting machine according to claim 1, characterized in that: The denier specifications of the plush yarn include 30D, 40D, 50D, 75D, 100D, 150D, 200D, and 300D.

3. The method for weaving plush yarn on a warp knitting machine according to claim 1, characterized in that: Gloss types include semi-gloss, glossy, and matte.

4. The method for weaving plush yarn on a warp knitting machine according to claim 1, characterized in that: The multifilament yarn is polyester DTY multifilament or functional multifilament yarn.

5. The method for weaving plush yarn on a warp knitting machine according to claim 1, characterized in that: Functional multifilament yarns include at least one of the following: moisture-wicking yarn, antibacterial yarn, UV-protective yarn, antistatic yarn, odor-resistant yarn, warmth-retaining yarn, and heat-generating yarn.

6. The method for weaving plush yarn on a warp knitting machine according to claim 1, characterized in that: The air-piercing process includes: 1-piercing-1-air, 2-piercing-2-air, and 3-piercing-3-air.

7. The method for weaving plush yarn on a warp knitting machine according to claim 1, characterized in that: The plush length described in S5.1 is 0.1cm to 4cm.

8. The method for weaving plush yarn on a warp knitting machine according to claim 1, characterized in that: During the execution of S2, a splitting shear is simultaneously set on the warp knitting equipment; as the knitting operation proceeds, the splitting shear is used to split and decompose each pile yarn, so that a single pile yarn is split into two pile yarns.

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