CN102535059A - Method and device for manufacturing color tufting product - Google Patents
Method and device for manufacturing color tufting product Download PDFInfo
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- CN102535059A CN102535059A CN2012100123407A CN201210012340A CN102535059A CN 102535059 A CN102535059 A CN 102535059A CN 2012100123407 A CN2012100123407 A CN 2012100123407A CN 201210012340 A CN201210012340 A CN 201210012340A CN 102535059 A CN102535059 A CN 102535059A
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Abstract
The invention relates to a method and a device for manufacturing a color tufting product, belonging to the technical field for manufacturing the color tufting product. The solved technical problem in the invention is to provide the method and the device for manufacturing the tufting product with colorful jacquards, wherein high piles of the tufting product completely cover low piles; the technical scheme for solving the technical problem is as follows: a non-vector pattern is adopted and a tufting faller or a tufting base cloth is scanned line by line according to pattern pixel points rearranged in rows when at different positions, each tufting faller corresponds to effective pixel points and invalid pixel points at different positions in each tufting process, so that high-feed piles and low-feed piles are in non-linear distribution on the surface of the tufting product; and the method and the device are mainly used for manufacturing the color tufting product.
Description
Technical field
The present invention relates to a kind of method and device thereof of making colored tufting products, belong to and make colored tufting products technical field.
Background technology
Making colored tufting products method commonly used is: each pin of tufting loom keeps the fixed position with respect to each pixel of layout, and high and low pile is a linear distribution along flocked base cloth, and high pile covers low pile can only accomplish half covering.
Simultaneously, the pattern that scanning obtains does not come branch again according to gray values of pixel points, and there is the effective pixel points of gray value more than a kind in each provisional capital in the pattern, so prior art can only be produced a kind of comparatively simple jacquard weave tufting products.
Tufting loom on the market mainly is to utilize high and low pile structure to reach the effect of jacquard weave now, and this kind loom inweaves in the base fabric by arranging pin simultaneously, perhaps feeds the different yarns of measuring in the yarn feeding unit of machinery control by computer control on each pin.The pile that the yarn of a large amount feeding forms will partly cover low amount feeding pile on the tufting products surface and form pattern.Each pin keeps the fixed position with respect to each pixel of layout.Because the pile of high feed quantity is a linear distribution along flocked base cloth, low simultaneously feed quantity pile also is a linear distribution along flocked base cloth, can only be half covering so high pile covers low pile.All produce such loom such as Britain Cobble company and U.S. Tuftco company.
Britain Cobble company also produces the colored Tufting machine of a kind of colortech of being called, and the mode that this machine utilization selects tufting needle to take turns to operate reaches jacquard effect, and color on the working needle of choosing and pattern color coincide.So operating efficiency is lower because all pins can not be worked simultaneously.
Also has a kind of Tufting machine on the market; Needle beam also can be traversing during work; The pattern that it uses does not come branch again according to gray values of pixel points, and there is the effective pixel points of gray value more than a kind in each provisional capital in the pattern, so produce a kind of comparatively simple jacquard weave tufting products.
Existing in addition Tufting machine does not all have the yarn compensation mechanism, and the colored type boundary line of working it out is unintelligible.This is because high pile of feeding the amount yarn will have certain difference just can make pattern flower type sharpness of border when adjacent abrupt with the low amount Yarn tuft of feeding.Such as low pile of tufting high pile of tufting more and then at once behind high pile of tufting; Because the position of tufting yarn feeding device and pin is far away; The flexible contraction of in addition yarn own; The result of yarn feeding can not in time reflect on pin, and high feeding measured the pile height that yarn does not reach imagination, and it is low that end while hello amount yarn does not reach due pile yet.
Therefore; Existing tufting loom can only more knitting simple patterns monochromatic or double-colored or three looks; And comparatively complicated for those patterns, during the bigger product of change color, just can not be knitting; Cause can not knitting complex pattern product reason existing loom can not be fast and accurately change the yarn that matches with pattern color when main, promptly each knitting needle or weave cotton cloth action with hope that position and speed that requirement reaches do not catch up with.Even some high performance loom can be caught up with, but when in required time, reaching desired location, length of yarn and Len req are inconsistent when knitting, and this does not have when being knitting to cause according to the distance adjustment yarn feeding amount that moves.
Summary of the invention
The present invention overcomes the shortcoming that prior art exists, and technical problem to be solved provides a kind ofly can produce method and the device thereof that polychrome jacquard weave, high pile cover low pile tufting products fully.
For solving the problems of the technologies described above, the technical scheme that the present invention adopted is: a kind of method and device thereof of making colored tufting products, undertaken by following step:
The first step: pattern imported carry out non-vectorized process in the computer, calculate the position and the gray value of its each pixel; Earlier pattern is scanned in the computer, carry out non-vector then and calculate, the pattern that scanning is obtained is decomposed into some pixels, and the position according to each pixel forms coordinate at last; Pattern scans that color does not change in the computer in this process, and various colors is represented with different gray values;
Second step: according to each point different gray values branch again; Scanning original pattern first row is found out the pixel with same grayscale value earlier, deposits delegation in by the sequencing that scans, and will keep the position of this pixel on former columns simultaneously, and all the other positions are the pixel that adds in the pattern; And then find out the pixel of another gray value, and still the sequencing by scanning deposits another row in, keeps the position of this pixel on former columns, and all the other positions are the pixel that adds in the pattern; By that analogy, the whole pixels up to original pattern first row have scanned; Repeat said process until till original pattern scan, originally the preceding pixel of branch is being defined as in the pattern after in lines again: effective pixel points, and the pixel that adds in the pattern in lines is defined as: the inactive pixels point;
The 3rd step: make the yarn color table that puts in order; Penetrate the yarn of required color on each pin in the Tufting machine faller gill; The color alignment of yarn on the pin is divided into some groups in proper order; The number of color of yarn wants consistent with pattern maximum color number on each group pin; Just the pin number of each group is a pattern maximum color number, and the color alignment order of each group yarn is according to regular or irregular arrangement, and yarn color is arranged the back that finishes and formed a color alignment table;
The 4th step: calculate each pin yarn feeding amount in first time tufting process; Each effective pixel points in first this row group that pattern is formed according to different gray values branch back again compares with the color alignment table on the corresponding tufting needle; The gray value of the effective pixel points in the yarn color gray value on each tufting needle and this row group gives a large amount yarn feeding when identical, otherwise does not give lower yarn feeding or not yarn feeding simultaneously with the effective pixel points gray value.When tufting next time; The tufting needle horizontal row is to the position of a pixel of displacement or the position of a plurality of pixels; Recomputate the yarn feed quantity on each pin behind mobile the finishing; By that analogy until faller gill, repeats above process in the traversing end of this row group until last organizes end in lines;
The 5th step: confirm the traversing number of times of tufting needle in the tufting process; Tufting needle is once traversing in tufting process each time, is getting back to original original position through the traversing back of the number of times of regulation tufting needle, and traversing position location point in each is organized in lines can not repeat;
The 6th step: faller gill whenever moves a computer faller gill yarn color gray value and branch's corresponding pixel gray value of back pattern is compared once;
The 7th step: the result that computer will all contrast and corresponding faller gill Traverse Displacement Unit be according to the colour sequential order computation, and export a jacquard weave control data form;
The 8th step: with jacquard weave control data form input Tufting machine control system; The control system will be according to the data of form, and the output control instruction arrives the yarn feeding unit, the faller gill Traverse Displacement Unit is carried out, and on the present flocked base cloth of pile color table of the multicolour pattern that will design originally after being finished with yarn tufting one-tenth, accomplish the production of jacquard weave tufting products.
Each pin of single pin passes 1 one thread, and then the color alignment form is 1 row; Each pin of single pin passes 2 one threads, and then the color alignment form is 2 row.
Color alignment form line number and faller gill number were with to pass number of threads corresponding when single pin was above.
In a certain branch group 1 row pixel or the capable pixel of pattern maximum color number arranged, each pin only passes under the situation of an one thread when single pin, tufting needle in this is organized in lines on traversing number of times and the tufting needle each to organize maximum color number identical.
When pin is installed with two one threads of different colours when double pin or single pin on displacement number of times and the tufting needle each to organize number of colours different.
When a certain branch group had only 1 row pixel or the capable pixel of pattern maximum color number, faller gill is traversing should to be pattern maximum color number to this number of times of organizing in lines.
Each pinprick passes the yarn of two kinds of different colours during single pin, and the yarn of each color is to control the yarn feeding amount separately, and faller gill is traversing should to be 1/2nd of pattern maximum color number to this number of times of organizing in lines.
Each pin of double pin passes an one thread, calculates the yarn feeding amount of each color in the tufting process on each pin, and faller gill is traversing should to be 1/2nd of pattern maximum color number to this number of times of organizing in lines.
A kind of device of realizing making colored tufting products method; Comprise: be arranged on tufting fuselage top yarn feeding device, be arranged on knitting mechanism on the tufting fuselage work top, be arranged on the base fabric gathering-device of tufting Lower Mid Fuselage; Knitting mechanism and base fabric gathering-device are parallel to each other, and the structure of wherein said knitting mechanism is: knitting mechanism is provided with and can makes the reciprocating faller gill Traverse Displacement Unit in the knitting mechanism left and right sides.
Tufting machine be provided with on one's body can surveyingpin horizontal row moving device real time position the displacement calibrating installation.
Displacement calibrating installation or be absolute encoder, or be the grating chi.
The structure of faller gill Traverse Displacement Unit is: needle beam links to each other with the tufting fuselage with linear slide block through the linear slide rail that at least two groups complement one another, needle beam be fixed on Tufting machine first shifter on one's body and link to each other.
The structure of first shifter is: the second device motor is connected with synchronous pulley, first shaft coupling, ball-screw, ball screw nut, ball-screw connector from right to left in turn and is connected push rod with first, and first connects the flexible end of push rod links to each other through Connection Block with linear slide rail on the needle beam.
Described yarn feeding device comprises at least one group of yarn feeding unit; The structure of every group of yarn feeding unit is: a pair of intermeshing yarn feeding roller is positioned at the left end of roller supporting plate, and a pair of yarn feeding roller is oppositely arranged before and after becoming, and yarn feeding roller one side is a gear train; The opposite side of yarn feeding roller is a yarn feeding drum group; Linking to each other with each self-corresponding first motor through belt respectively of each yarn feeding roller, first motor is arranged on the right side of roller supporting plate, and the upper end that is positioned at the roller supporting plate is provided with the guide plate.
Between yarn feeding device and knitting mechanism, be provided with the yarn compensation arrangement.
Yarn passes yarn feeding device, knitting mechanism and base fabric gathering-device from top to bottom successively in the yarn compensation arrangement, and second shifter is identical with the structure of first shifter with the triple motion device.
The present invention compared with prior art has following beneficial effect.
1, the present invention adopts a kind of pattern of non-vector quantization and tufting row pin is lined by line scan according to the pattern image vegetarian refreshments after the branch again; Make that each pin is not the position of fixing with corresponding pattern effective pixel points and inactive pixels point on the faller gill; Make the high amount pile of feeding feed the amount pile is nonlinear Distribution on the tufting products surface method, produce the colored tufting products that high pile covers low pile fully with the method with hanging down.
2, the pattern that obtains of the present invention scanning comes branch again according to gray values of pixel points, and each provisional capital has only the effective pixel points of a kind of gray value in the pattern, can produce polychrome jacquard weave tufting products.
3,, realize that knitting needle mechanism can move in the horizontal direction fast through being installed in the faller gill Traverse Displacement Unit in the knitting needle mechanism; Through being installed in the displacement calibrating installation in the knitting needle mechanism, guarantee that the displacement of knitting mechanism horizontal direction and vertical direction is accurate; Through being installed in the yarn compensation arrangement in the knitting needle mechanism, make the yarn feeding unit yarn accurately is provided according to the required length of yarn of reality, make colored tufting products clear patterns, improved tufting products surface jacquard effect; Equipment according to the invention, mechanism is simple, and high efficiency can be produced polychrome jacquard weave tufting products.
Description of drawings
Below in conjunction with accompanying drawing a kind of method of making colored tufting products of the present invention and device thereof are done and to be further described:
Fig. 1 is a kind of perspective view of making the equipment of colored tufting products;
Fig. 2 is a kind of lateral plan of making the equipment of colored tufting products;
Fig. 3 is a kind of rear view of making the equipment of colored tufting products;
Fig. 4 is the front view of yarn feeding device;
Fig. 5 is the perspective view of yarn feeding device;
Fig. 6 is a faller gill Traverse Displacement Unit control principle sketch map;
Fig. 7 is a base fabric Traverse Displacement Unit control principle sketch map;
Fig. 8 is the shifter structural representation;
Fig. 9 is a kind of method Central Plains layout pixel sketch map of making colored tufting products;
Figure 10 be Fig. 9 Central Plains layout pixel again the branch after pattern image vegetarian refreshments sketch map.
Among the figure, 1 for yarn feeding device, 2 for knitting mechanism, 3 for the bottom gathering-device, 4 for the yarn feeding roller, 5 for roller supporting plate, 6 be first motor, 7 for synchronous band, 8 for the guide plate, 9 for the yarn feeding unit, 10 for gear train, 11 for yarn feeding drum group, 12 for yarn, 13 for the yarn compensation arrangement, 14 for displacement calibrating installation, 15 be first shifter, 16 for the faller gill Traverse Displacement Unit, 17 for the tufting fuselage, 18 for needle beam, 19 for tufting needle, 20 for linear slide block, 21 for Connection Block, 22 for linear slide rail, 23 for connect slide rail, 24 for roller bearing, 25 for bearing connecting plate, 26 be first linear bearing, 27 be first connect push rod, 28 for the ball screw connector, 29 for ball screw nut, 30 for ball screw, 31 be first shaft coupling, 32 be second motor, 33 for absolute encoder, 34 for synchronous pulley, 35 for motor screw mandrel support, 36 for microcomputer, 37 for the Electric Machine Control plate, 38 for the thorn roller mechanism, 39 for licker-in support, 40 be second connect push rod, 41 be second linear bearing, 42 for screw mandrel, 43 for the feed screw nut, 44 for screw mandrel support, 45 be second shaft coupling, 46 be the 3rd motor, 47 be four-sensor, 48 for caltrop, 49 for cloth beam, 50 for flocked base cloth, 51 for the thorn roller shell, 52 for the thorn roll shaft, 53 for first sensor, 54 be that second sensor, 55 is that the 3rd sensor, 56 is that first cam, 58 is that second cam, 59 is that the 3rd cam, 60 is that second shifter, 68 be triple motion device, 69 for base fabric Traverse Displacement Unit for relative coding device, 66 for transfer of data communicator, 67 for motor driver, 65 on motor movement card, 64 for performance element, 63 for connecting rod, 62 for lever jack, 61 on main shaft, 57.
The specific embodiment
A kind of method of making colored tufting products of the present invention, undertaken by following step:
The first step: pattern imported carry out non-vectorized process in the computer, calculate the position and the gray value of its each pixel; Earlier pattern is scanned in the computer, carry out non-vector then and calculate, the pattern that scanning is obtained is decomposed into some pixels, and the position according to each pixel forms coordinate at last; Pattern scans that color does not change in the computer in this process, and various colors is represented with different gray values;
Second step: according to each point different gray values branch again; Scanning original pattern first row is found out the pixel with same grayscale value earlier, deposits delegation in by the sequencing that scans, and will keep the position of this pixel on former columns simultaneously, and all the other positions are the pixel that adds in the pattern; And then find out the pixel of another gray value, and still the sequencing by scanning deposits another row in, keeps the position of this pixel on former columns, and all the other positions are the pixel that adds in the pattern; By that analogy, the whole pixels up to original pattern first row have scanned; Repeat said process until till original pattern scan, originally the preceding pixel of branch is being defined as in the pattern after in lines again: effective pixel points, and the pixel that adds in the pattern in lines is defined as: the inactive pixels point;
The 3rd step: make the yarn color table that puts in order; Penetrate the yarn of required color on each pin in the Tufting machine faller gill; The color alignment of yarn on the pin is divided into some groups in proper order; The number of color of yarn wants consistent with pattern maximum color number on each group pin; Just the pin number of each group is a pattern maximum color number, and the color alignment order of each group yarn is according to regular or irregular arrangement, and yarn color is arranged the back that finishes and formed a color alignment table;
The 4th step: calculate each pin yarn feeding amount in first time tufting process; Each effective pixel points in first this row group that pattern is formed according to different gray values branch back again compares with the color alignment table on the corresponding tufting needle; The gray value of the effective pixel points in the yarn color gray value on each tufting needle and this row group gives a large amount yarn feeding when identical, otherwise does not give lower yarn feeding or not yarn feeding simultaneously with the effective pixel points gray value.When tufting next time; The position of a tufting faller gill or a pixel of flocked base cloth lateral displacement or the position of a plurality of pixels; Recomputate the yarn feed quantity on each pin behind mobile the finishing; By that analogy until faller gill, repeats above process in the traversing end of this row group until last organizes end in lines;
The 5th step: confirm tufting needle 19 or flocked base cloth 50 traversing number of times in the tufting process; Tufting needle 19 or flocked base cloth 50 are once traversing in tufting process each time, are getting back to original original position through the traversing back of the number of times of regulation tufting needle 19 or flocked base cloth 50, and traversing position location point in each is organized in lines can not repeat;
The 6th step: faller gill whenever moves a computer faller gill yarn color gray value and branch's corresponding pixel gray value of back pattern is compared once;
The 7th step: the result that computer will all contrast and corresponding faller gill Traverse Displacement Unit 16 or base fabric Traverse Displacement Unit 69 be according to the colour sequential order computation, and export a jacquard weave control data form;
The 8th step: with jacquard weave control data form input Tufting machine control system; The control system will be according to the data of form; The output control instruction arrives yarn feeding unit 9, faller gill Traverse Displacement Unit 16 or base fabric Traverse Displacement Unit 69 and carries out; On the present flocked base cloth of pile color table of the multicolour pattern that will design originally after being finished with yarn tufting one-tenth, accomplish the production of jacquard weave tufting products.
Each pin of single pin passes 1 one thread, and then the color alignment form is 1 row; Each pin of single pin pass 2 one thread colors then arrange form be 2 the row.
Color alignment form line number and faller gill number were with to pass number of threads corresponding when single pin was above.
In a certain branch group 1 row pixel or the capable pixel of pattern maximum color number arranged, each pin only passes under the situation of an one thread when single pin, tufting needle in this is organized in lines on traversing number of times and the tufting needle each to organize maximum color number identical.
When pin is installed with two one threads of different colours when double pin or single pin on displacement number of times and the tufting needle each to organize number of colours different.
When a certain branch group had only 1 row pixel or the capable pixel of pattern maximum color number, the traversing or flocked base cloth of faller gill is traversing should to be pattern maximum color number to this number of times of organizing in lines.
Each pinprick passes the yarn of two kinds of different colours during single pin, and the yarn of each color is to control the yarn feeding amount separately, and the traversing or flocked base cloth of faller gill is traversing should to be 1/2nd of pattern maximum color number to this number of times of organizing in lines.
Each pin of double pin passes an one thread, calculates the yarn feeding amount of each color in the tufting process on each pin, and the traversing or flocked base cloth of faller gill is traversing should to be 1/2nd of pattern maximum color number to this number of times of organizing in lines.
When carrying out above-mentioned steps, microcomputer relates to the following functional relation:
The pattern maximum color is counted on m and the faller gill yarn color and is counted f (x) and concern just like minor function:
f(x)=km (1)
Wherein
F (x): yarn color is counted f (x)>1
M: the whole number of colours m of pattern>1
K: pass number of yarns on each pin.
Secondly when k=1, total radical that yarn is arranged on faller gill is defined as St, if total radical of pin is defined as D on the faller gill, then has:
St=D
The total radical St of yarn on the faller gill is pressed the whole number of colours m of pattern divides into groups, following functional relation is arranged:
p=St/m (2)
P: the total radical of yarn is by the packet count of color;
The number of threads of each group can be expressed as: Si=St/p, i=1 wherein, 2,3...p;
Number of threads Si according to yarn packet count p and each group arranges out yarn color gray value permutation table on faller gill.
Pressing surface function when arranging yarn carries out:
Si=m (3)
Just the number of threads of each group is consistent with whole number of colours.
Faller gill or base fabric move number of times f (z) and are confirmed by following functional relation in a certain branch group:
Single needle row single thread f (z)=m (4)
Perhaps
Crosspointer row single thread f (z)=m/2 (5)
Might be 1 row pixel or multirow or the capable pixel of m in a certain branch group, should be m or m/2 no matter there is the traversing or flocked base cloth of how many row pixel faller gills traversing in this branch's group to this number of times of organizing in lines.
When faller gill has all scanned, required total of the pattern after the branch moves number of times ∑ f (z) and equals each f that organizes in lines (z) and multiply by the total line number i of former layout again.
∑f(z)=i*f(z) (6)
Perhaps
∑f(z)=i*m (7)
Secondly, the faller gill of having arranged yarn is when any one-row pixels point of scanning, and whenever mobile once can be the position of a pixel or a plurality of pixels.Move and to begin, move f (z) and must get back to original starting point after inferior from starting point pixel position.
Faller gill whenever moves a computer faller gill yarn color gray value and branch's corresponding pixel gray value of back pattern is compared according to following functional relation:
F (y)=faller gill yarn color gray value/corresponding pattern pixel gray scale (8)
When f (y)=1 computer-chronograph deposits a useful signal in, when f (y) ≠ 1 computer-chronograph deposits an invalid signals in.
Faller gill or base fabric repeat above-mentioned contrast after moving a position again, move the scanning that branch's group is accomplished in the inferior back of f (z).Computer is charged to a sequence number with scanning result.Faller gill carries out the scanning of next one branch group again, repeats said process until last of completion pattern organized end in lines.
A kind of device of making colored tufting products that the present invention relates to; Comprise: be arranged on tufting fuselage 17 tops yarn feeding device 1, be arranged on knitting mechanism 2 on tufting fuselage 17 work tops, be arranged on the base fabric gathering-device 3 of tufting fuselage 17 middle and lower parts; Knitting mechanism 2 is parallel to each other with base fabric gathering-device 3, and the structure of wherein said knitting mechanism 2 is: knitting mechanism 2 is provided with and can makes the reciprocating faller gill Traverse Displacement Unit 16 in knitting mechanism 2 left and right sides.
Tufting fuselage 17 be provided with can surveyingpin horizontal row moving device 16 real time positions displacement calibrating installation 14.
The structure of faller gill Traverse Displacement Unit 16 is: needle beam 18 links to each other with tufting fuselage 17 with linear slide block 20 through the linear slide rail 22 that at least two groups complement one another, and needle beam 18 links to each other with first shifter 15 on being fixed on tufting fuselage 17.
The structure of first shifter 15 is: the second device motor 32 is connected with synchronous pulley 34, first shaft coupling 31, ball-screw 30, ball screw nut 29, ball-screw connector 28 from right to left in turn and is connected push rod 27, the first with first and connects the flexible end of push rods 27 and link to each other through Connection Block 21 with linear slide rail 22 on the needle beam 18.
Described yarn feeding device 1 comprises at least one group of yarn feeding unit 9; The structure of every group of yarn feeding unit 9 is: a pair of intermeshing yarn feeding roller 4 is positioned at the left end of roller supporting plate 5; 4 one-tenth front and back of a pair of yarn feeding roller are oppositely arranged; Yarn feeding roller 4 one sides are gear train 10, and the opposite side of yarn feeding roller 4 is a yarn feeding drum group 11, and the belt that passes through respectively of each yarn feeding roller 4 links to each other with each self-corresponding first motor 6; First motor 6 is arranged on the right side of roller supporting plate 5, and the upper end that is positioned at roller supporting plate 5 is provided with guide plate 8.
Between yarn feeding device 1 and knitting mechanism 2, be provided with yarn compensation arrangement 13.
Yarn passes yarn feeding device 1 from top to bottom successively in the yarn compensation arrangement 13, knitting mechanism 2 is identical with the structure of first shifter 15 with triple motion device 68 with base fabric gathering-device 3, the second shifters 67.
Apparatus of the present invention mainly are made up of following four parts: yarn feeding device 1, faller gill Traverse Displacement Unit 2, base fabric Traverse Displacement Unit 16 and control system.Wherein,
Yarn feeding device also can comprise yarn feeding unit 9, and yarn feeding unit 9 comprises yarn feeding roller 4, roller supporting plate 5, first motor 6, guide plate 8 again.Yarn feeding roller 4 is directly driven by first motor 6.
Yarn feeding unit 9 is installed on the roller supporting plate 5, and the quantity of the yarn feeding unit on the roller supporting plate 5 and arrangement mode are according to the arranging density and the quantity decision that can control yarn 12 on the tufting needle 19 of the pin on the needle beam 18 in the Tufting machine 17 19.
Tufting needle horizontal row moving device 16 comprises tufting needle 19, linear slide block 20, Connection Block 21, linear slide rail 22, needle beam 18, connects slide rail 23, roller bearing 24, bearing connecting plate 25, first linear bearing 26, first connect push rod 27, ball-screw connector 28, ball-screw nut 29, ball-screw 30, first shaft coupling 31, second motor 32, absolute encoder 33, synchronous pulley 34, motor leading screw support 35.Second motor 32 rotates corresponding angle according to different yarn feeding amounts; Make ball-screw 30 also rotate corresponding angle through shaft coupling 31 connections; Thereby promote ball-screw nut 29 and produce displacement, ball-screw nut 29 is installed on the ball-screw connector 28, connects push rod 27 through first bearing connecting plate 25 also is subjected to displacement; Roller bearing 24 on the bearing connecting plate 25 promotes to connect slide rails 23, is fixed on and makes needle beam 18 also produce a displacement on the needle beam 18 thereby connect slide rail 23.
The detection of needle beam 18 displacements is accomplished by absolute encoder 33, also can adopt other sensor to accomplish such as the grating chi.Needle beam 18 moves a distance makes absolute encoder 33 rotate an angle through synchronous pulley 34, and signal of absolute encoder 33 outputs is given microcomputer 36, draws distance and the direction that needle beam 18 moves through microcomputer 36 computings.Microcomputer 36 sends an instruction at first for Electric Machine Control plate 37; Needle beam 18 moves according to the shift length and the direction of instruction regulation; Microcomputer 36 is given displacement calibrating installation 14 input signals through absolute encoder 33 behind the mobile end, and whether displacement calibrating installation 14 can calculate needle beam 18 according to the correct displacement of instruction.If displacement has deviation computer when being shifted, to compensate next time, displacement each time all will be carried out position and direction and detect.
Base fabric Traverse Displacement Unit 69 comprises that thorn roller mechanism 38, licker-in support 39, second connects push rod 40, second linear bearing 41, leading screw 42, feed screw nut 43, leading screw support 44, second shaft coupling 45, the 3rd motor 46, four-sensor 47.The 3rd motor 46 rotates an angle makes leading screw 42 rotate and promote feed screw nut 43 displacements through second shaft coupling 45, and then through the second connection push rod 40 thorn rod mechanism 38 also is subjected to displacement.Thorn roller shell 51 surfaces are implanted with caltrop 48, and caltrop 48 is installed between tufting fuselage 17 and the cloth beam 49, and caltrop 48 thrusts flocked base cloth 50.Caltrop 48 drives flocked base cloth 50 when traversing traversing together.Thorn roller mechanism 38 is made up of thorn roller shell 51 and thorn roll shaft 52, connects with bearing between them.Also with Tufting machine cloth beam 49 continuously or be interrupted mobilely, thorn roller shell 51 surperficial caltrops 48 thrust flocked base cloth 50 to flocked base cloth 50, thorn roller shell 51 also with flocked base cloth 50 same moved further.
Between yarn feeding unit 9 and tufting needle 19, install a yarn compensation arrangement 13 additional; Yarn compensation arrangement 13 comprises lever jack 60, connecting rod 61, performance element 62; Yarn 12 is through the performance element 62 on the yarn compensation arrangement 13, the high amount of feeding convert to low when feeding amount lever jack 60 lift a position a part of yarn be pulled up; Otherwise when the low amount of feeding converted height hello amount to, lever jack 60 put down this part yarn is released.Performance element 62 is received microcomputer 36 instruction backs and is moved, and makes lever jack 60 when height is fed with low feeding, be in different positions through connecting rod 61.
Cloth beam 49 drive flocked base cloth 50 perhaps are interrupted mobile continuously, and cloth beam 49 can be machine driving or pneumatic rotation or hydraulic transmission or servo, the stepper motor transmission.
Times that needle beam 18 is traversing or to sting the traversing time of roller mechanism 38 be to be confirmed by first sensor 53, second sensor 54, the 3rd sensor 55 with respect to the operating position of tufting needle 19.First sensor 53 is contained in the signal of the rotating cycle of first cam, the 57 detection main shafts 56 on the Tufting machine main shaft 56 through induction; Second sensor 54 and the 3 55 is contained in second cam 58 and the 3rd cam 59 output one group coding signal on the main shaft 56 through induction, and comprehensively the induced signal of these three sensors is confirmed needle beam 18 or stung traversing time and the locking time of roller mechanism 38 with respect to pin 19 operating positions.
Relative coding device 65 and first sensor 53 are installed on tufting fuselage 17; They with the signal of the tufting process of sensing through transfer of data communicator 66 be transferred on the microcomputer 36 with motor movement card 63 on; Then trigger motor movement card 63 and send pulse signal to motor driver 64, motor driver 64 drives first motor 7 again and reaches yarn feeding.Relative coding device 65 is divided into some steps with a tufting process, and each step motor movement card 63 all has pulse signal to send, thereby guarantees in a tufting process, evenly to feed yarn.
The control system comprises microcomputer 36, transfer of data communicator 66, motor movement card 63, motor driver 64, absolute encoder 33, relative coding device 65, first sensor sensor 53, second sensor 54, the 3rd sensor 55.Pattern is imported microcomputer 36 carry out non-vector processing, calculate the position and the gray value of its each pixel; The pixel that microcomputer 36 is corresponding with yarn color permutation table and pattern on the tufting faller gill compares; The tufting faller gill move carry out again behind a pixel or a plurality of pixels position to and deposit comparing result in, faller gill is accomplished once circulation after tufting needle moves regulation to move number of times.After scanning pattern last column, finish by that analogy, computer generates the permutation table of a yarn feeding amount with the result, each line data representative corresponding motor yarn feeding amount when carrying out this row pattern in the table.Computer will decompose the yarn feeding amount of each yarn feeding unit, and the result is transferred on the corresponding motor movement card 63 through data communication equipment 66.
In the production; Color according to product; On each pin of Tufting machine, penetrate the yarn of required color; The color alignment of yarn on the pin is divided into some groups in proper order, and microcomputer 36 generates the result permutation table of a yarn feeding amount according to the gray scale permutation table contrast that puts in order with obtain through non-vectorized process of yarn color on the tufting faller gill.
The tufting products that weaves is collected by bottom gathering-device 3.
Claims (16)
1. method of making colored tufting products is characterized in that according to following procedure:
The first step: pattern imported carry out non-vectorized process in the computer, calculate the position and the gray value of its each pixel; Earlier pattern is scanned in the computer, carry out non-vector then and calculate, the pattern that scanning is obtained is decomposed into some pixels, and the position according to each pixel forms coordinate at last; Pattern scans that color does not change in the computer in this process, and various colors is represented with different gray values;
Second step: according to each point different gray values branch again; Scanning original pattern first row is found out the pixel with same grayscale value earlier, deposits delegation in by the sequencing that scans, and will keep the position of this pixel on former columns simultaneously, and all the other positions are the pixel that adds in the pattern; And then find out the pixel of another gray value, and still the sequencing by scanning deposits another row in, keeps the position of this pixel on former columns, and all the other positions are the pixel that adds in the pattern; By that analogy, the whole pixels up to original pattern first row have scanned; Repeat said process until till original pattern scan, originally the preceding pixel of branch is being defined as in the pattern after in lines again: effective pixel points, and the pixel that adds in the pattern in lines is defined as: the inactive pixels point;
The 3rd step: make the yarn color table that puts in order; Penetrate the yarn of required color on each pin in the Tufting machine faller gill; The color alignment of yarn on the pin is divided into some groups in proper order; The number of color of yarn wants consistent with pattern maximum color number on each group pin; Just the pin number of each group is a pattern maximum color number, and the color alignment order of each group yarn is according to regular or irregular arrangement, and yarn color is arranged the back that finishes and formed a color alignment table;
The 4th step: calculate each pin yarn feeding amount in first time tufting process; Each effective pixel points in first this row group that pattern is formed according to different gray values branch back again compares with the color alignment table on the corresponding tufting needle; The gray value of the effective pixel points in the yarn color gray value on each tufting needle and this row group gives a large amount yarn feeding when identical; Otherwise do not give lower yarn feeding or not yarn feeding simultaneously with the effective pixel points gray value; When tufting next time; The tufting needle horizontal row is to the position of a pixel of displacement or the position of a plurality of pixels; Recomputate the yarn feed quantity on each pin behind mobile the finishing, by that analogy until faller gill, repeats above process in the traversing end of this row group until last organizes end in lines;
The 5th step: confirm the traversing number of times of tufting needle in the tufting process (19); Tufting needle (19) is once traversing in tufting process each time, is getting back to original original position through the number of times of regulation traversing back tufting needle (19), and traversing position location point in each is organized in lines can not repeat;
The 6th step: faller gill whenever moves a computer faller gill yarn color gray value and branch's corresponding pixel gray value of back pattern is compared once;
The 7th step: result that computer will all contrast and corresponding faller gill Traverse Displacement Unit (6) colour sequential order computation, and export a jacquard weave control data form;
The 8th step: with jacquard weave control data form input Tufting machine control system; The control system will be according to the data of form; The output control instruction arrives yarn feeding unit (9), faller gill Traverse Displacement Unit (16) is carried out; On the present flocked base cloth of pile color table of the multicolour pattern that will design originally after being finished with yarn tufting one-tenth, accomplish the production of jacquard weave tufting products.
2. according to the method for the colored tufting products of the said manufacturing of claim 1, it is characterized in that: each pin of single pin passes 1 one thread, and then the color alignment form is 1 row; Each pin of single pin passes 2 one threads, and then the color alignment form is 2 row.
3. according to the method for the colored tufting products of the said manufacturing of claim 1, it is characterized in that: color alignment form line number and faller gill number were with to pass number of threads corresponding when single pin was above.
4. according to the method for the colored tufting products of the said manufacturing of claim 1; It is characterized in that: 1 row pixel or the capable pixel of pattern maximum color number arranged in a certain branch group; Each pin only passes under the situation of an one thread when single pin, tufting needle in this is organized in lines on traversing number of times and the tufting needle each group maximum color number identical.
5. according to the method for the colored tufting products of the said manufacturing of claim 1, it is characterized in that: when a pin is installed with two one threads of different colours when double pin or single pin, on displacement number of times and the tufting needle each to organize number of colours different.
6. the method for the colored tufting products of manufacturing according to claim 1; It is characterized in that: when a certain branch group had only 1 row pixel or the capable pixel of pattern maximum color number, faller gill is traversing should to be pattern maximum color number to this number of times of organizing in lines.
7. according to the method for the colored tufting products of the said manufacturing of claim 1; It is characterized in that: each pinprick passes the yarn of two kinds of different colours during single pin; The yarn of each color is to control the yarn feeding amount separately, and faller gill is traversing should to be 1/2nd of pattern maximum color number to this number of times of organizing in lines.
8. according to the method for the colored tufting products of the said manufacturing of claim 1; It is characterized in that: each pin of double pin passes an one thread; Calculate the yarn feeding amount of each color in the tufting process on each pin, faller gill is traversing should to be 1/2nd of pattern maximum color number to this number of times of organizing in lines.
9. device of realizing the colored tufting products method of the said manufacturing of claim 1; Comprise: be arranged on tufting fuselage (17) top yarn feeding device (1), be arranged on knitting mechanism (2) on tufting fuselage (17) work top, be arranged on the base fabric gathering-device (3) of tufting fuselage (17) middle and lower part; Knitting mechanism (2) is parallel to each other with base fabric gathering-device (3), and it is characterized in that the structure of described knitting mechanism (2) is: knitting mechanism (2) is provided with and can makes knitting mechanism (2) the reciprocating faller gill Traverse Displacement Unit in the left and right sides (16).
10. a kind of device of making colored tufting products according to claim 9, it is characterized in that tufting fuselage (17) be provided with can surveyingpin horizontal row moving device (16) real time position displacement calibrating installation (14).
11. a kind of device of making colored tufting products according to claim 10 is characterized in that: displacement calibrating installation (14) or for absolute encoder, or be the grating chi.
12. a kind of device of making colored tufting products according to claim 9; The structure that it is characterized in that faller gill Traverse Displacement Unit (16) is: the linear slide rail (22) that needle beam (18) complements one another through at least two groups links to each other with tufting fuselage (17) with linear slide block (20), and needle beam (18) links to each other with first shifter (15) on being fixed on tufting fuselage (17).
13. a kind of device of making colored tufting products according to claim 12; The structure that it is characterized in that first shifter (15) is: the second device motor (32) is connected with synchronous pulley (34), first shaft coupling (31), ball-screw (30), ball screw nut (29), ball-screw connector (28) from right to left in turn and is connected push rod (27) with first, and the flexible end of the first connection push rod (27) links to each other through Connection Block (21) with the linear slide rail (22) on the needle beam (18).
14. a kind of device of making colored tufting products according to claim 9; It is characterized in that: described yarn feeding device (1) comprises at least one group of yarn feeding unit (9); The structure of every group of yarn feeding unit (9) is: a pair of intermeshing yarn feeding roller (4) is positioned at the left end of roller supporting plate (5); A pair of yarn feeding roller (4) is oppositely arranged before and after becoming; Yarn feeding roller (4) one sides are gear train (10), and the opposite side of yarn feeding roller (4) is a yarn feeding drum group (11), and the belt that passes through respectively of each yarn feeding roller (4) links to each other with each self-corresponding first motor (6); First motor (6) is arranged on the right side of roller supporting plate (5), and the upper end that is positioned at roller supporting plate (5) is provided with guide plate (8).
15. a kind of device of making colored tufting products according to claim 9 is characterized in that: between yarn feeding device (1) and knitting mechanism (2), be provided with yarn compensation arrangement (13).
16. a kind of device of making colored tufting products according to claim 15; It is characterized in that: yarn passes yarn feeding device (1), knitting mechanism (2) and base fabric gathering-device (3) from top to bottom successively in the yarn compensation arrangement (13), and second shifter (67) is identical with the structure of first shifter (15) with triple motion device (68).
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| CN103556413A (en) * | 2013-03-08 | 2014-02-05 | 邱家彬 | Multi-color carpet jacquard control mechanism and tufting machine having multi-color carpet jacquard control mechanism |
| CN105133174A (en) * | 2015-09-28 | 2015-12-09 | 江苏润源控股集团有限公司 | Warp knitting and embroidering all-in-one machine |
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| CN107305652A (en) * | 2016-04-22 | 2017-10-31 | 郭保卫 | The system and method that a kind of tufted carpet production process is accurately controlled |
| CN109154119A (en) * | 2016-03-09 | 2019-01-04 | 因特菲斯有限公司 | The balanced yarn dosage in the tufted pattern of design textile |
| CN109642380A (en) * | 2016-09-22 | 2019-04-16 | 米歇尔·范德威尔公司 | Preparation method for the braiding process woven to fabric (preferably carpet) |
| CN110382762A (en) * | 2017-03-15 | 2019-10-25 | 卡蒙罗公司 | Shift mechanism for tufting machine |
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| CN106757889A (en) * | 2017-01-11 | 2017-05-31 | 常州武鼎地毯机械有限公司 | The tufting device of polychrome complete alternation carpet pattern effecting method and application the method |
| CN106757889B (en) * | 2017-01-11 | 2024-02-06 | 常州武鼎地毯机械有限公司 | Multicolor full-circulation carpet jacquard method and tufting device applying same |
| CN110382762A (en) * | 2017-03-15 | 2019-10-25 | 卡蒙罗公司 | Shift mechanism for tufting machine |
| CN110382762B (en) * | 2017-03-15 | 2022-03-22 | 卡蒙罗公司 | Shifting mechanism for tufting machine |
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