CN102535059B - Method and device for manufacturing color tufting product - Google Patents
Method and device for manufacturing color tufting product Download PDFInfo
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- CN102535059B CN102535059B CN 201210012340 CN201210012340A CN102535059B CN 102535059 B CN102535059 B CN 102535059B CN 201210012340 CN201210012340 CN 201210012340 CN 201210012340 A CN201210012340 A CN 201210012340A CN 102535059 B CN102535059 B CN 102535059B
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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 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 is inweaved in the base fabric simultaneously by row's pin, the yarn of the different amounts of being controlled by computer control or machinery on each pin of yarn feeding unit feeding.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 linear distribution along flocked base cloth, low feed quantity pile also is linear distribution along flocked base cloth simultaneously, 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 the 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 Tufting machine does not all have the yarn compensation mechanism in addition, and the colored type boundary line of working it out is unintelligible.This is because high pile and the low amount Yarn tuft of feeding of feeding the amount yarn will have certain difference just can make pattern flower type sharpness of border when adjacent abrupt.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 own yarn in addition, the result of yarn feeding can not in time reflect at pin, high feeding measured the pile height that yarn does not reach imagination, and feed the amount yarn and also do not reach due pile minuent at end while.
Therefore, existing tufting loom can only more knitting simple patterns monochromatic or double-colored or three looks, and it is 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, i.e. position and speed that each knitting needle or weave cotton cloth action and desired requirement reaches do not catch up with.Even some high performance loom can be caught up with, but when reaching desired location in required time, length of yarn and Len req are inconsistent when knitting, do not cause according to mobile distance adjustment yarn feeding amount when this is knitting.
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 solution adopted in the present invention 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 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 different colors is represented with different gray values;
Second step: according to the different gray value of each point 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 pattern maximum color number, 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 value 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: determine 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: computer of the every movement of faller gill compares the pixel gray value of faller gill yarn color gray value and branch's back pattern correspondence 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 jacquard weave control data table lattice;
The 8th step: with jacquard weave control data table lattice input Tufting machine control system; 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, finish 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 and to pass number of threads corresponding when single pin is 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 this is organized in lines on traversing number of times and the tufting needle each to organize maximum color number identical.
The displacement number of times was different with each group number of colours on the tufting needle when pin was installed with two one threads of different colours when double pin or single pin.
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 at 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 at 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 at 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 by 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: second 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 by 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, a pair of yarn feeding roller is oppositely arranged before and after becoming, yarn feeding roller one side is gear train, the opposite side of yarn feeding roller is yarn feeding drum group, each yarn feeding roller links to each other by self-corresponding first motor of belt and each respectively, and 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, making each pin on the faller gill is not the position of fixing with corresponding pattern effective pixel points and inactive pixels point, make the high amount pile of feeding feed the amount pile is nonlinear Distribution on the tufting products surface method with hanging down, produce the colored tufting products that high pile covers low pile fully with the method.
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, by being installed in the faller gill Traverse Displacement Unit in the knitting needle mechanism, realize that knitting needle mechanism can move in the horizontal direction fast; By 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; By being installed in the yarn compensation arrangement in the knitting needle mechanism, make the yarn feeding unit accurately provide yarn according to the required length of yarn of reality, make colored tufting products clear patterns, improved tufting products surface jacquard effect; Equipment of the present 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 and device thereof of making colored tufting products of the present invention is described further:
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 faller gill Traverse Displacement Unit control principle schematic diagram;
Fig. 7 is base fabric Traverse Displacement Unit control principle schematic diagram;
Fig. 8 is the shifter structural representation;
Fig. 9 is a kind of method Central Plains layout pixel schematic diagram of making colored tufting products;
Figure 10 be Fig. 9 Central Plains layout pixel again the branch after pattern image vegetarian refreshments schematic diagram.
Among the figure, 1 is yarn feeding device, 2 is knitting mechanism, 3 is the base fabric gathering-device, 4 are the yarn feeding roller, 5 is the roller supporting plate, 6 is first motor, 7 is to be with synchronously, 8 is the guide plate, 9 are the yarn feeding unit, 10 is gear train, 11 are yarn feeding drum group, 12 is yarn, 13 is the yarn compensation arrangement, 14 are the displacement calibrating installation, 15 is first shifter, 16 is the faller gill Traverse Displacement Unit, 17 is the tufting fuselage, 18 is needle beam, 19 is tufting needle, 20 is linear slide block, 21 is Connection Block, 22 is linear slide rail, 23 for connecting slide rail, 24 is roller bearing, 25 is the bearing connecting plate, 26 is first linear bearing, 27 is the first connection push rod, 28 is the ball screw connector, 29 is ball screw nut, 30 is ball screw, 31 is first shaft coupling, 32 is second motor, 33 is absolute encoder, 34 is synchronous pulley, 35 is motor screw mandrel support, 36 is microcomputer, 37 is the Electric Machine Control plate, 38 are the thorn roller mechanism, 39 is the licker-in support, 40 is the second connection push rod, 41 is second linear bearing, 42 is screw mandrel, 43 is the feed screw nut, 44 is the screw mandrel support, 45 is second shaft coupling, 46 is the 3rd motor, 47 is four-sensor, 48 is caltrop, 49 is cloth beam, 50 is flocked base cloth, 51 are the thorn roller shell, 52 are the thorn roll shaft, 53 is first sensor, 54 is second sensor, 55 is the 3rd sensor, 56 is main shaft, 57 is first cam, 58 is second cam, 59 is the 3rd cam, 60 is lever jack, 61 is connecting rod, 62 is performance element, 63 is the motor movement card, 64 is motor driver, 65 is the relative coding device, 66 is the transfer of data communicator, 67 is second shifter, 68 is the triple motion device, 69 is the base fabric Traverse Displacement Unit.
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 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 different colors is represented with different gray values;
Second step: according to the different gray value of each point 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 pattern maximum color number, 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 value 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 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: determine 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 number of times of regulation traversing back 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: computer of the every movement of faller gill compares the pixel gray value of faller gill yarn color gray value and branch's back pattern correspondence 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 jacquard weave control data table lattice;
The 8th step: with jacquard weave control data table lattice input Tufting machine control system; 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, finish 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 and to pass number of threads corresponding when single pin is above.
The displacement number of times was different with each group number of colours on the tufting needle when pin was installed with two one threads of different colours when double pin or single pin.
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 at 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 at 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 at 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) 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 at 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 grouping of pattern, 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 at 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 mobile number of times f (z) in a certain branch group is determined by following functional relation:
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 at this number of times of organizing in lines.
When faller gill has all scanned, the required total mobile number of times ∑ f (z) of pattern after the branch 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 that arranges yarn is when any one-row pixels point of scanning, and every movement once can be the position of a pixel or a plurality of pixels.Mobile from starting point pixel position, must get back to original starting point after mobile f (z) is inferior.
Computer of the every movement of faller gill compares the pixel gray value of faller gill yarn color gray value and branch's back pattern correspondence 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 behind mobile position again, finish the scanning of branch's group after mobile f (z) is inferior.Computer is charged to a sequence number with scanning result.Faller gill carries out the scanning of next branch group again, repeats said process until last that finish 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 by 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: second 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 by 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, yarn feeding roller 4 opposite sides are yarn feeding drum group 11, linking to each other by self-corresponding first motor 6 of belt and each respectively of each yarn feeding roller 4, 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.
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, the first connection 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 by 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, connecting push rod 27 by first also is subjected to displacement bearing connecting plate 25, 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 finished by absolute encoder 33, also can adopt other sensor to finish such as the grating chi.Needle beam 18 moves a distance makes absolute encoder 33 rotate an angle by synchronous pulley 34, and signal of absolute encoder 33 outputs is given microcomputer 36, draws distance and the direction that needle beam 18 moves by microcomputer 36 computings.Microcomputer 36 sends an instruction at first for Electric Machine Control plate 37, needle beam 18 moves according to shift length and the direction of instruction regulation, microcomputer 36 is given displacement calibrating installation 14 input signals by 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 to compensate when being shifted 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 connect 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 by second shaft coupling 45, and then by 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 by 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 be in different positions when height is fed with low feeding by connecting rod 61.
Cloth beam 49 drives flocked base cloth 50 continuously or is interrupted and moves, and cloth beam 49 can be machine driving or pneumatic rotation or hydraulic transmission or servo, the stepper motor transmission.
The operating position of traversing time of the time that needle beam 18 is traversing or thorn roller mechanism 38 with respect to tufting needle 19 is to be determined by first sensor 53, second sensor 54, the 3rd sensor 55.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 by 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 by induction, and comprehensively the induced signal of these three sensors is determined needle beam 18 or stung roller mechanism 38 with respect to traversing time and the locking time of pin 19 operating positions.
At tufting fuselage 17 relative coding device 65 and first sensor 53 are installed, they be transferred to microcomputer 36 on by transfer of data communicator 66 signal of the tufting process sensed and 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 has pulse signal to send, thereby guarantees evenly to feed yarn in a tufting process.
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 position and the gray value of its each pixel; Microcomputer 36 compares the pixel of yarn color permutation table on the tufting faller gill and pattern correspondence, the tufting faller gill moves and carries out to behind a pixel or a plurality of pixels position again and deposit comparing result in, and faller gill is finished once circulation after tufting needle moves regulation to move number of times.Finish after scanning pattern last column 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 by data communication equipment 66.
In the production, color according to product, penetrate the yarn of required color at each pin of Tufting machine, the color alignment of yarn on the pin is divided into some groups in proper order, microcomputer 36 generates the result permutation table of a yarn feeding amount according to the gray scale permutation table that puts in order with obtain through the non-vectorized process contrast of yarn color on the tufting faller gill.
The tufting products that weaves is collected by base fabric gathering-device 3.
Claims (15)
1. method of making colored tufting products is characterized in that according to following step operation:
The first step: pattern imported carry out non-vectorized process in the computer, calculate 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 different colors is represented with different gray values;
Second step: according to the different gray value of each point 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 pattern maximum color number, 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 value 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: determine 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: computer of the every movement of faller gill compares the pixel gray value of faller gill yarn color gray value and branch's back pattern correspondence once;
The 7th step: the result that computer will all contrast and corresponding faller gill Traverse Displacement Unit (6) colour sequential order computation, and export jacquard weave control data table lattice;
The 8th step: with jacquard weave control data table lattice input Tufting machine control system; 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, finish the production of jacquard weave tufting products.
2. according to the method for the colored tufting products of the described 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 described manufacturing of claim 1, it is characterized in that: color alignment form line number and faller gill number and to pass number of threads corresponding when single pin is above.
4. according to the method for the colored tufting products of the described manufacturing of claim 1, it is characterized in that: 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, and tufting needle traversing number of times in this is organized in lines is identical with each group maximum color number on the tufting needle.
5. according to the method for the colored tufting products of the described manufacturing of claim 1, it is characterized in that: when double pin or single pin, a pin is installed with two one threads of different colours, and the traversing number of times of tufting needle is different with each group number of colours on the tufting needle.
6. according to the method for the colored tufting products of the described 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 at this number of times of organizing in lines.
7. according to the method for the colored tufting products of the described 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 at this number of times of organizing in lines.
8. device of realizing the colored tufting products method of the described 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).
9. a kind of device of making colored tufting products according to claim 8, 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).
10. a kind of device of making colored tufting products according to claim 9 is characterized in that: displacement calibrating installation (14) or be absolute encoder, or be the grating chi.
11. a kind of device of making colored tufting products according to claim 8, 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 by 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).
12. a kind of device of making colored tufting products according to claim 11, the structure that it is characterized in that first shifter (15) is: second 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 by Connection Block (21) with the linear slide rail (22) on the needle beam (18).
13. a kind of device of making colored tufting products according to claim 8, 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), the opposite side of yarn feeding roller (4) is yarn feeding drum group (11), each yarn feeding roller (4) links to each other by self-corresponding first motor of belt and each (6) respectively, 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).
14. a kind of device of making colored tufting products according to claim 8 is characterized in that: between yarn feeding device (1) and knitting mechanism (2), be provided with yarn compensation arrangement (13).
15. a kind of device of making colored tufting products according to claim 14, 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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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN103556413B (en) * | 2013-03-08 | 2015-08-05 | 邱家彬 | Polychrome carpet jacquard control mechanism and there is the Tufting machine of this controlling organization |
| CN103469508B (en) * | 2013-09-18 | 2015-04-08 | 邱家彬 | Multi-color carpet jacquard control mechanism and tufting machine with same |
| CN105133174B (en) * | 2015-09-28 | 2017-01-11 | 江苏润源控股集团有限公司 | Warp knitting and embroidering all-in-one machine |
| US9850607B2 (en) * | 2016-03-09 | 2017-12-26 | Interface, Inc. | Balancing yarn use in designing tufted patterns for textiles |
| 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 |
| EP3299502A1 (en) * | 2016-09-22 | 2018-03-28 | NV Michel van de Wiele | Method of preparing a tufting process for tufting a fabric, preferably carpet |
| 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 |
| US10156035B2 (en) | 2017-03-15 | 2018-12-18 | Card-Monroe Corp. | Shift mechanism for a tufting machine |
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| US4991523A (en) * | 1989-06-15 | 1991-02-12 | Textile Corporation Of America | Tufting apparatus |
| US5058518A (en) * | 1989-01-13 | 1991-10-22 | Card-Monroe Corporation | Method and apparatus for producing enhanced graphic appearances in a tufted product and a product produced therefrom |
| US5738030A (en) * | 1996-03-11 | 1998-04-14 | General Design, Inc | Pattern method for multicolor designs |
| US6807917B1 (en) * | 2002-07-03 | 2004-10-26 | Card-Monroe Corp. | Yarn feed system for tufting machines |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| US6834601B2 (en) * | 2002-07-03 | 2004-12-28 | Card-Monroe Corp. | Yarn feed system for tufting machines |
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|---|---|---|---|---|
| US5058518A (en) * | 1989-01-13 | 1991-10-22 | Card-Monroe Corporation | Method and apparatus for producing enhanced graphic appearances in a tufted product and a product produced therefrom |
| US4991523A (en) * | 1989-06-15 | 1991-02-12 | Textile Corporation Of America | Tufting apparatus |
| US5738030A (en) * | 1996-03-11 | 1998-04-14 | General Design, Inc | Pattern method for multicolor designs |
| US6807917B1 (en) * | 2002-07-03 | 2004-10-26 | Card-Monroe Corp. | Yarn feed system for tufting machines |
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| CN101509183A (en) * | 2008-02-15 | 2009-08-19 | 卡德-门罗公司 | Yarn color placement system |
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