Summary of the invention
The invention provides a kind of polychrome carpet jacquard control mechanism, comprise computer, RS485 serial ports, communication module, needle beam moving control mechanism, motor servo driver, servomotor, ethernet communication port, ethernet signal distributor, eight tunnel step motor control drive plates, stepper motor, data storage.Computer connects 1-200 block eight road driving stepper motor control panel by ethernet signal distributor, and Mei Kuai eight road driving stepper motor control panel connects stepper motor;
Computer sends data in order eight road driving stepper motor control panels of every block different IP addresses, and after eight road driving stepper motor control panels receive data, unloading is to data storage;
Computer is connecting communication module also, and communication module connects needle beam moving control mechanism, and needle beam moving control mechanism connects motor servo driver, and motor servo driver connects servomotor;
Be interconnected between needle beam moving control mechanism, eight road driving stepper motor control panels, servo-driver three.
The present invention also provides a kind of Tufting machine with above-mentioned polychrome carpet jacquard control mechanism, for increase selective control yarn or needle tracking placement and density pattern tufted articles can be formed.
Described polychrome carpet jacquard control mechanism is by two needle beam shifting balance axles and displacement screw mandrel composition sight alignment output displacement power, the digital yarn-feeding device of servo or step motor control is coordinated to carry out feeding yarn, realize tufting polychrome carpet manufacture, and can realize polychrome carpet enclose arbitrarily cut with any suede high.Specifically: by one group of data conversion software, servomotor is connected the conventional digital yarn-feeding device in this area and needle beam moving control mechanism, make it precise match, and by yarn color arrangement of threading a needle: as: red (A), yellow (B), blue (C), in vain (D) .... circulation, hide with the low loop pile height of 0.1mm and embody high circle multi-color jacquard effect, and can combine and flat cut flat coil apparatus, make Tufting machine weave the carpet come and reach any loop pile, cut pile and any suede high, largest loop can reach 4 meters of wide cuts, blanket face effect with Wilden or the bright carpets of Acker with, blanket face is more rich and varied, there is multi-level colour solid effect.
The present invention also provides a kind of method preparing multicolor tufted carpet:
The first step: utilize above-mentioned polychrome carpet jacquard control mechanism to utilize computer to be assigned on respective circuit control panel yarn distribution and needle beam displacement data.
Second step: the A that described polychrome carpet jacquard control mechanism utilizes computer to distribute, B, C, D......n chromatism data controls to feed yarn by the yarn-feeding device of Serve Motor Control, the displacement data that needle beam moving control mechanism distributes according to computer moves needle beam, each movement one pin, order is: be moved to the left 1 step; Be moved to the left (color difference number n-4) step, move right (color difference number n-1) step, be moved to the left 1 step, be moved to the left 1 step again and return initial point (meta), every pin needle beam all can move left and right according to pattern, constantly repeats as a circulation (step number is 2* (color difference number n-1)), wherein, the step number of movement is all defined as positive integer, namely when n-4 or n-1 be negative or zero time, be and do not move corresponding step number;
3rd step: after second step is finished, in the present flocked base cloth of pile color table that the multicolour pattern of originally design is become by polychromatic yarn tufting, completes tufting products and produces.
The present invention also provides a kind of Tufting machine being equipped with above-mentioned polychrome carpet jacquard control mechanism; described Tufting machine can comprise usually: tufting machine controller, distributes control system to form desired scan pattern and/or layout for the operation element and operation controlling Tufting machine according to needle tracking of the present invention.This pattern can comprise various expected pattern effect, and the placement of multiple color yarn is to be visible in the position selected over the entire substrate, thus provides the expection density of retaining color/needle tracking per square inch.Such as, pattern can comprise the combination of whole uncut pile pieces, all cut pile pieces and/or cut pile pieces and uncut pile pieces, comprises changeable pile height pieces and other rag or pattern texture effect.
Detailed description of the invention
By best embodiment, the present invention is described in detail below.
Embodiment 1: the composition of polychrome carpet jacquard control mechanism
As shown in Figure 1, polychrome carpet jacquard control mechanism, comprise computer 1, RS485 serial ports 2, connect communication module 3, needle beam moving control mechanism 4, motor servo driver 5, servomotor 6, ethernet communication port 7, ethernet signal distributor 8, eight road driving stepper motor control panel 9, stepper motor 10, data storage 11
Computer 1 connects 10 ethernet signal distributors 8 by ethernet communication port and connects 1-200 eight road driving stepper motor control panel 9, eight road driving stepper motor control panels 9 and connect stepper motor 10;
Computer 1 is given and is sent data to eight road driving stepper motor control panels 9 of the different address of every block in order, and after eight road driving stepper motor control panels 9 receive data, unloading is to data storage 11;
Connecting communication module 3 gone back by computer 1, and communication module 3 connects needle beam moving control mechanism 4, and needle beam moving control mechanism 4 connects motor servo driver 5, and motor servo driver 5 connects servomotor 6;
Be interconnected between needle beam moving control mechanism 4, eight road driving stepper motor control panel 9, servo-driver 5 three.
Specifically, the technological means conventional by this area and manufacture method, the method that those skilled in the art utilize this mechanism to manufacture color tufting product is:
First, pattern is inputted in computer and carry out non-vectored process, calculate position and the gray value of its each pixel; First by pattern scan in computer, then carry out non-Vector operation, being decomposed into some pixels by scanning the pattern that obtains, finally forming coordinate according to the position of each pixel; In this process, in pattern scan to computer, color does not change, and the different gray value of different colors represents;
According to the gray value branch again that each point is different; First scan original pattern the first row, find out the pixel with same grayscale value, by the sequencing scanned stored in a line, will retain the position of this pixel on former columns, all the other positions are the pixel added in pattern simultaneously; And then find out the pixel of another gray value, still press the sequencing of scanning stored in another row, retain the position of this pixel on former columns, all the other positions are the pixel added in pattern; By that analogy, until whole pixels of original pattern the first row have scanned; Repeat said process until till original pattern scan, the pixel originally before branch again in lines after pattern in be defined as: effective pixel points, and in lines after the pixel added in pattern be defined as: inactive pixels point;
Make yarn color to put in order table; Each pin in Tufting machine needle beam penetrates the yarn of required color, the color disposal order of yarn on pin is divided into some groups, on each group pin, the number of color of yarn wants consistent with pattern maximum color number, namely the pin number of each group is pattern maximum color number, the color disposal order of each group yarn, according to regular or No-L aw Order, forms a color alignment table after yarn color arrangement;
Calculate each pin yarn feeding amount in first time tufting process, at first, pattern is contrasted with the color alignment table on corresponding tufting needle according to each effective pixel points in rear this row group formed of different gray value again branch, yarn color gray value on each tufting needle gives a large amount yarn feeding time identical with the gray value of the effective pixel points in this row group, otherwise give lower yarn feeding or not yarn feeding time different from effective pixel points gray value, when upper once tufting, the position of a Tufting machine needle beam lateral displacement pixel or the position of multiple pixel, the yarn feed quantity on each pin is recalculated after movement, by that analogy until needle beam is in the traversing end of this row group, repeat above process until last point of end of line block,
Determine the traversing number of times of tufting needle in tufting process; Get back to original original position at tufting needle after the number of times of regulation is traversing, traversing position location point in each branch's group can not repeat;
Pixel gray value corresponding for pattern after yarn color gray value on pin in needle beam and branch carries out contrasting once by a needle beam often mobile computer;
The result all contrasted and a corresponding needle beam Traverse Displacement Unit colour sequential number order calculate by computer, and export a height control data form;
By height control data form input tufting machine control system; Control system is by the data according to form, export control instruction to digital yarn feeding unit, needle beam moving control mechanism execution yarn feed and needle beam traversing, after being finished, in the present flocked base cloth of pile color table that originally multicolour pattern of design is become by polychromatic yarn tufting, complete jacquard weave tufting products and produce.
Embodiment 2: the Tufting machine being equipped with above-mentioned polychrome carpet jacquard control mechanism
Be that Tufting machine controls the different color yarns such as yarn T1-T6 in Fig. 2-1 to 2-4, arrangement and the jump of battle array distance can form the colour image effect that various smoothness changes.Yarn color placement system maintains has higher or more intensive yarn circle rate than traditional tufting program.By yarn arrange effective coil that system produces be substantially equal to base material feed to and Tufting machine to space the quantity be multiplied by like fixed patterns color and pattern that the requirement drawn specify, also to provide enough density thus those color yarn do not shown hiding simultaneously.Therefore, in the process that pattern coil is formed, needle beam moves according to the cam contour of pattern, and thus, often kind of color will be taken out of or be regained and is hidden in the product that oneself completes.
As shown in Figure 4, the needle beam moving control mechanism used is by needle beam control block (12), needle beam moves bearing (13), needle beam shifting balance axle (14), motor and screw mandrel shaft coupling (15), screw mandrel bearing (16), screw mandrel gearshift (17), displacement screw mandrel (18), needle beam Bit andits control servomotor (19), needle beam screw mandrel displacement fixed mount (20), needle beam and traversing gear connector (21), screw mandrel gearshift power transmission shaft (22) forms, wherein: needle beam control block (12) and needle beam move bearing (13) and needle beam Bit andits control servomotor (19) and screw mandrel bearing (16) and be interconnected, needle beam Bit andits control servomotor (19) is connected with motor and screw mandrel shaft coupling (15), motor is connected with displacement screw mandrel (18) with screw mandrel shaft coupling (15), displacement screw mandrel (18) is connected with needle beam shifting balance axle (14), needle beam shifting balance axle (14) is connected with screw mandrel gearshift (17), screw mandrel gearshift (17) is connected with needle beam screw mandrel displacement fixed mount (20), needle beam screw mandrel displacement fixed mount (20) is connected with needle beam displacement power transmission shaft (22) by needle beam traversing gear connector (21), needle beam Bit andits control servomotor (6) is connected with described motor servo driver 5.Needle beam control block (12) connects Tufting machine (23).This needle beam moving control mechanism utilizes two needle beam shifting balance axles (14) and displacement screw mandrel (18) composition sight alignment output displacement power, reaches adjustment and installation simple and convenient, connects flexibility and reliability, displacement stable output power.
It is high that this needle beam moving control mechanism has needle beam displacement accuracy, and dynamic respond speed is fast, and the code device signal that reading servomotor carries does feedback control signal, overcomes traditional external absolute value encoder and does the large defect of feedback control signal error.
Be the moveable position of needle beam as shown in Figure 3, do meta with 0, left and right directions circulation traversing.
Embodiment 3: the method preparing color tufting product
The first step: the technology of the present invention utilizes polychrome carpet jacquard control system to be distributed by yarn and needle beam displacement data utilizes computer to be assigned on respective circuit control panel.
Second step: the A that polychrome carpet jacquard control system utilizes computer to distribute, B, C, D......n chromatism data controls to feed yarn by the digital yarn-feeding device of Serve Motor Control, needle beam moving control mechanism moves needle beam, moves at every turn and moves a step, and order is: be moved to the left 1 step; Be moved to the left (color difference number n-4) step, move right (color difference number n-1) step, be moved to the left 1 step, be moved to the left 1 step again and return initial point (meta), every pin needle beam all can move left and right according to pattern, constantly repeat as a circulation (step number is 2* (color difference number n-1)), wherein step number is all positive integer;
3rd step: after second step is finished, in the present flocked base cloth of pile color table that the multicolour pattern of originally design is become by polychromatic yarn tufting, completes tufting products and produces.
Wherein, in second step, needle beam moves around utilizing the combination of or multiple jump, the area of the pattern using the quantity of color in pattern and be made up of each specific color, and the initial first step and the step of final step are all repetitions, last alignment circle shown in it is generally the most junior one step that a pattern moves profile circulation, because needle beam transverse shifting base material is carried out according to the actual coil rate of self, so excessive tufting is avoided in multiple mobile combination of jumping.
For three looks, four looks, the five colors, six look jacquard weave tufted carpet preparation methods, described in detail:
The course of work that three look jacquard weave tufted carpets are concrete: the A that polychrome carpet jacquard control system utilizes computer to distribute, B, C tri-chromatism datas control to feed yarn by the digital yarn-feeding device by Serve Motor Control, the displacement data that needle beam moving control mechanism distributes according to computer moves needle beam, move at every turn and move a step, order is: the first pin needle beam is moved to the left a step from initial point (meta), second pin needle beam moves right 1 step, 3rd pin needle beam moves right 1 step, 4th pin needle beam is moved to the left 1 step and comes back to initial point, constantly (as shown in accompanying drawing 2-1) is repeated as a circulation (4 step),
The course of work of four look jacquard weave tufted carpets.The A that polychrome carpet jacquard control system distributes with computer, B, C, D tetra-chromatism datas control to feed yarn by the digital yarn-feeding device of Serve Motor Control, the displacement data that needle beam moving control mechanism distributes according to computer moves needle beam, move at every turn and move a step, order is: the first pin needle beam is moved to the left a step from initial point (meta), second pin needle beam moves right and moves a step, 3rd pin needle beam moves right 1 step, 4th pin needle beam moves right 1 step, 5th pin needle beam is moved to the left a step, 6th pin needle beam is moved to the left a step and comes back to initial point, constantly (as shown in accompanying drawing 2-2) is repeated as a circulation (6 step),
The course of work that five colors jacquard weave tufted carpet is concrete: the A that polychrome carpet jacquard control system utilizes computer to distribute, B, C, D, E five chromatism datas control to feed yarn by the digital yarn-feeding device of Serve Motor Control, the displacement data that needle beam moving control mechanism distributes according to computer moves needle beam, move at every turn and move a step, order is: the first pin needle beam is moved to the left a step from initial point (meta), second pin needle beam is moved to the left a step, 3rd pin needle beam moves right 1 step, 4th pin needle beam moves right 1 step, 5th pin needle beam moves right and moves a step, 6th pin needle beam moves right and moves a step, 7th pin needle beam is moved to the left a step, 8th pin needle beam is moved to the left a step and comes back to initial point, constantly (as illustrated in figs. 2-3) is repeated as a circulation (8 step),
The course of work that six look jacquard weave tufted carpets are concrete: the A that polychrome carpet jacquard control system utilizes computer to distribute, B, C, D, E, F six chromatism datas control to feed yarn by the digital yarn-feeding device of Serve Motor Control, the displacement data that needle beam moving control mechanism distributes according to computer moves needle beam, move at every turn and move a step, order is: the first pin needle beam is moved to the left a step from initial point (meta), second pin needle beam is moved to the left a step, 3rd pin needle beam is moved to the left 1 step, 4th pin needle beam moves right 1 step, 5th pin needle beam moves right and moves a step, 6th pin needle beam moves right and moves a step, 7th pin needle beam moves right and moves a step, 8th pin needle beam moves right and moves a step, nine kinds of needles needle beam is moved to the left a step, tenth pin needle beam is moved to the left a step and comes back to initial point, constantly (as shown in Figure 2-4) is repeated as a circulation (10 step),
Last it is noted that obviously, above-described embodiment is only for example of the present invention is clearly described, and the restriction not to embodiment.For those of ordinary skill in the field, can also make other changes in different forms on the basis of the above description.Here exhaustive without the need to also giving all embodiments.And thus the apparent change of amplifying out or variation be still among protection scope of the present invention.