Weaving Pattern Data Sets for Effect Thread Control
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Solution Overview
Problem
Existing methods for generating data sets for weaving patterns with additional weft effects do not adequately control guide means for effect threads in both the weft and vertical directions, limiting the complexity and precision of fabric designs.
Innovation Solution
A method that generates data sets by defining a fabric area with multiple data values for each position of binding points, including shot sequence numbers and additional shot effects, which are stored in a weaving machine's control device to control the vertical and horizontal movement of effect threads, allowing for precise positioning and movement of effect threads relative to weft and warp threads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additional weft effects are achieved by positioning effect threads above or below weft threads using guide means, then fabric design complexity and versatility are improved, but the complexity of controlling guide means in both vertical and weft directions increases
Solution Approach 1:
The control of guide means is segmented into two independent directions: vertical positioning controlled by shedding means and weft-direction positioning controlled by displacement device. This segmentation allows each control system to focus on one dimension, reducing overall control complexity while enabling complex fabric designs through coordinated operation of both systems
Solution Approach 2:
The patent adds a new dimension of control by introducing displacement device that moves guide means in the weft direction, complementing the existing vertical control. This dimensional expansion transforms the control system from one-dimensional (vertical only) to two-dimensional (vertical + weft direction), enabling sophisticated effect thread positioning without overwhelming complexity
2Shape
If effect threads are positioned above weft threads to emerge from reed gaps, then weft effect visibility and fabric aesthetic quality are improved, but the precision required for positioning effect threads increases
Solution Approach 1:
The shedding means positions effect threads in the correct vertical position (above or below weft threads) in advance of weft insertion, ensuring proper emergence from reed gaps. This preliminary positioning action eliminates the need for complex real-time adjustments during weft insertion, maintaining high visibility while managing precision requirements through advance preparation
Solution Approach 2:
The guide means acts as an intermediary device that facilitates precise positioning of effect threads. By providing a dedicated guiding mechanism, the system achieves accurate positioning without requiring the entire weaving system to operate at high precision, distributing the precision requirement to a specialized component
3Productivity
If data sets for weaving patterns include information for controlling guide means in both vertical and weft directions, then production efficiency and automation are improved, but the complexity of data generation and processing increases
Solution Approach 1:
The data set is segmented into distinct components: vertical positioning data for shedding means and weft-direction positioning data for displacement device. This segmentation allows each control system to process independent data streams, improving automation and production efficiency while making data generation more systematic and manageable through modular approach
Solution Approach 2:
The control system is designed to handle multiple functions through a unified data set structure that accommodates both shedding control and displacement control. This multi-functionality improves productivity by integrating both control aspects into one automated system, while the standardized data format reduces generation complexity through reusability and consistency
Data Source
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Figure 2.1~2.2
Figure 3.1
AI summary
For weaving pattern formation of a woven fabric having weft threads (3), warp threads (1) and effect threads (2), data sets (20) are generated according to a method, in which data values of weft numbers (30) and of positions of weave points (P) of an effect thread (2) with the weft threads (3) in the pattern repeat (29) are derived. Said data sets (20) are supplemented by further data values (31, 32, 33, 34) which are derived from the weaving pattern, in such a way that they form a point paper design (28) for a weaving pattern with additional weft effects. In a weaving machine having devices for displacing effect threads (2) in the weft direction (12), the weaving pattern formation is derived from the data sets (20) of said point paper design (28).