KR100593072B1 - Process for preparing a patterned fabric - Google Patents

Abstract

A method of manufacturing a cut-pile-shaped pattern fabric using a general loom, the method comprising: (a) selecting a pattern image; (b) dividing the selected pattern image into unit cells; (c) designing one long rectangular yarn having all the colors of each cell sequentially by connecting all the cells of the divided pattern image; (d) preparing a yarn as designed above; And (e) characterized in that it comprises the step of weaving the fabric with the selected pattern image by weaving into a fabric using the fabric weaving.

Cut-pile, glyph fabric, loom, CAD program

Description

Process for preparing a patterned fabric

1 is a view showing an embodiment of a pattern fabric manufacturing method according to the present invention.

2 is a performance screen of the design CAD program according to an embodiment of the present invention.

3 is an example of a glyph image bitmap.

4 is an example of a glyph image bitmap with color adjustment according to one embodiment of the invention.

5 is an example of a pattern of incorrect repeating unit.

6 is a method of defining a repeating unit according to an embodiment of the present invention.

7 is an example of a pattern in which repeating units are correctly defined in accordance with one embodiment of the present invention.

8 is an example of a cell segmented glyph image in accordance with an embodiment of the present invention.

9 is a diagram illustrating an automatic update of a cell by a user input according to an embodiment of the present invention.

10 is a screen for inputting parameters for the direct design according to an embodiment of the present invention.

Figure 11 is a direct production simulation screen in accordance with an embodiment of the present invention.

12 is a production simulation screen of the pattern fabric according to an embodiment of the present invention.

Figure 13 is an example of the production simulation of various patterns of fabric according to an embodiment of the present invention.

Figure 14 is an appearance photograph of a LabJack U12 USB controller (top) and a relay board (bottom) used in one embodiment of the present invention.

15 is a conceptual diagram of a solenoid valve control using a computer according to an embodiment of the present invention.

Figure 16 is a controller wiring picture according to an embodiment of the present invention.

17 is a loom controller setting screen according to an embodiment of the present invention.

18 is a picture of the weft selection device of the loom used in one embodiment of the present invention.

19 is an example of a weaving unit process definition in accordance with an embodiment of the present invention.

20 is an example of a fabric weaving unit process according to an embodiment of the present invention.

21 is a user interface for weaving process control according to an embodiment of the present invention.

22 is a message box for the control of the weaving process according to an embodiment of the present invention.

Figure 23 is a flow chart showing one embodiment of a pattern fabric manufacturing method according to the present invention.

The present invention relates to a method of manufacturing a patterned fabric, and more particularly, to a method of manufacturing a multi-colored patterned fabric in the form of a cut-pile using a general loom.

As a method of manufacturing a multicolored pattern fabric, there is generally a method of printing a pattern by printing, or a fabric using a special opening device such as jacquard or dobby. However, the pattern fabric produced by printing has the disadvantage that the pattern appears only on one side of the fabric, and the pattern fabric manufactured by using a device such as jacquard or dobby is a so-called uncut-pile type fabric. Colors of the patterns on both sides of the fabric are opposite to each other or the material of the patterns on either side of the coarse or rough appearance is a disadvantage. Therefore, with these conventional methods, it was impossible to produce a cut-pile pattern fabric in which a pattern of the same color and the same material appeared on both sides of the fabric.

Meanwhile, the conventional cut-pile pattern fabric is a product that is manufactured by considering a pattern designed with a dyed yarn and then weaved and sold by hand, which is a very expensive fabric produced only in a part of Japan. Therefore, if the industrial mass production of such cut-pile pattern fabrics is possible, this will not only result in a breakthrough for the existing textile production system but also become a very high value-added industry.

Disclosure of the Invention It is an object of the present invention to provide a method for industrially manufacturing a multi-colored pattern fabric in a cut-pile form using a general loom without using a special device such as a jacquard or dobby. Doing.

In order to achieve the above object, the present invention comprises the steps of (a) selecting a glyph image; (b) dividing the selected pattern image into unit cells; (c) designing one long rectangular yarn having all the colors of each cell sequentially by connecting all the cells of the divided pattern image; (d) preparing a yarn as designed above; And (e) weaving a fabric having the selected pattern image by weaving into the fabric using the manufactured weaving yarn as the weft yarn.

Hereinafter, with reference to the drawings will be described in more detail the configuration of the present invention.

1. Outline of Method for Manufacturing Patterned Fabric According to the Present Invention

The outline of the method of the present invention for constructing a multicolored pattern fabric with a weaving yarn made using a general loom without using a special opening device such as a jacquard or dobby is shown in FIG. Hereinafter, a description will be given with reference to FIG. 1.

① Selection of pattern image to weave and adjustment of color

First, we select the image of the pattern we want to weave. When selecting a pattern image, since weaving of the fabric has a limitation on the type of replaceable weft for the general loom, it is most preferable to have the number of colors within the range of the number of weft that can be replaced in the loom. If not, it is desirable to have a color within the number of weft by appropriately adjusting the color of the pattern image.

② Split unit cell of image

After adjusting the color of the image pattern, the image of the pattern should be divided into small cell elements. At this time, the size of the cell is determined in consideration of the thickness of the weft yarn to be used for direct weaving. For example, when the thickness of the weft yarn is about 2mm, the pattern image is divided into cells having a width × length of 2 × 2 mm.

③ Design and manufacture of direct company

Subsequently, each cell of the divided glyph image is connected to design one long rectangular yarn having the colors of each cell sequentially. The connection of each cell connects, for example, the right end of each row of the split glyph image and the left end of the next row, and the image is composed of one long thread (direct yarn).

Then, in order to actually produce a single long weave designed with the colors of the divided cells of the pattern image, weaving the fabric by matching the color order of the wefts that are sequentially in turn with the colors of each cell of the image. Using a knife, cut between each warp of this fabric. In this case, a plurality of long straight yarns having a color of each unit cell of the image can be produced at once.

④ Weaving fabrics

Next, when weaving the fabric using the weft yarn designed and manufactured above, it is possible to obtain a cut-pile-shaped pattern of the same shape as the original image.

2. Program the manufacturing method of the pattern fabric according to the present invention

As described above, in order to weave a multi-colored pattern fabric with a general loom, we need to manufacture a weaving yarn in which image patterns are divided into unit cells and then all cells are connected into one. By the way, in the manufacturing process of the weaving yarn, we need to replace the weft yarn from dozens of simple patterns to thousands of complicated patterns, and it is almost impossible to determine the order of the weft entry by hand. Therefore, it is essential to develop software that can perform color control of pattern images, cell decomposition of images, and automatic generation of weft replacement sequences.

In the present invention, as an example of such software, a CAD (Computer Added Design) program as in Example 1 below is created. The execution screen of the design CAD program developed in the present invention is as shown in FIG. The program is written in C ++ and is intended to run on PCs running Windows 98 or later.

<Example 1>

1. Selection of the pattern image to be weaved

In theory, there is no limitation on the size of the pattern image or the number of colors that can be produced. However, in the case of general looms, the width of the loom is fixed and the types of wefts that can be replaced are limited. Therefore, it is necessary to adjust the image of the pattern appropriately in consideration of this. This can be done by the following process.

① Import Glyph Images

Bitmap data to be used as a glyph image can be created using a deck style card, a scanner, or a digital camera, and the CAD system developed in the present invention supports the most widely used BMP and JPG image file formats. . An example of a glyph image is shown in FIG. 3.

② Adjust the number of colors

Because there is a limit to the number of wefts that can be replaced in the loom, it is not possible to directly use images of various colors as shown above. Therefore, it is necessary to group a large number of colors in an image into several colors using a technique such as color quantization. There are several methods of color quantization such as optimized octree, through space distance, nearest color, error diffusion, etc. Since there are 8 weft exchangers of the rapier loom used in the present invention, the color existing in the image by the optimized octree method is maximum 8 Dogs were adjusted. An example of an image in which the number of colors is adjusted is as shown in FIG. 4. It is considered suitable for weaving because the image quality does not deteriorate even if the color is adjusted. Therefore, when the color is significantly different from the original after the color adjustment, the weft replacement device needs to be improved.

③ Setting of repeat unit

In the case of continuous patterns, good results are difficult to achieve if the repeating unit is incomplete. In the example shown in FIG. 4, since each pattern does not represent a complete unit of repetition, the result as shown in FIG.

Therefore, in order to obtain good results, it is necessary to precisely define the repeating unit. In the present invention, the user can redefine the repeating unit in real time while watching the repeated pattern. When the glyph image is loaded, the glyphs appear continuously in all directions, and as shown in FIG. 6, the user moves four controllers on the glyph boundary to newly designate a repeating unit.

An example of a pattern in which a repeating unit is correctly defined is shown in FIG. 7.

2. Cell division step of glyph image

To make the fabric in a direct weave, the image of the pattern must be divided into small cell elements of solid color with the same width and width as the weft thickness used in the weaving. In the CAD program, when the user inputs the actual size and the weft thickness of the glyph image, the image is automatically divided into cells accordingly. An example of the cell-divided image is shown in FIG. 8. In addition, the size of the repeating unit pattern, the size of the cell, and the weft color table are displayed on the left side of the cell-divided image to facilitate the weft preparation.

Meanwhile, as shown in FIG. 9, the cell is automatically updated when the user changes the image size and the weft thickness as shown in FIG. 9 so that various conditions can be taken to obtain an optimal result. In addition, if the parameters such as the size of the entire pattern is adjusted, all calculations are immediately updated so that they can be visually displayed in real time.

3. Direct design and manufacturing simulation stage

After cell division of the glyph image is completed, each row of the image can be concatenated to design a long yarn. That is, the designed directivity includes all the color information of each cell of the pattern image.

Next, a step of manufacturing the designed yarns is involved. The program of the present invention is configured to allow manufacturing simulations before actual fabrication of designed yarns. To this end, the user first inputs the width of the fabric cloth to be weaved for weaving the yarn, the amount of edges or blanks to be placed on the left and right sides of the pattern, as shown in FIG. It will automatically generate weft inversion sequences for. Once the parameters have been entered, the system will show the process of creating dozens or even hundreds of weaving yarns simultaneously. In the actual process, weaving the fabric by first matching the color order of the wefts which are sequentially in turn with the color of each cell of the image, and then cutting with a knife between each warp of the fabric to make dozens or hundreds of weaving yarns. In this case, increasing the number of inclinations can make more weaving yarns with one weaving, and as a result, more patterns can be made. 11 shows an example of such a fabrication simulation. The user can use the scroll bar to check any part of the direct sunlight. In addition, the indentation sequence thus made can be output in the form of a text file, so even in the case of a loom that cannot be automatically controlled, this can be used to manually manufacture the weaving yarn required for weaving multicolor fabrics.

4. Weaving simulation step of pattern fabric

Subsequently, the weaving process is completed using the designed weaving yarn as the weft, and the pattern fabric is completed. The program of the present invention is configured to simulate the shape of the finished fabric. To this end, we simulated the fabric process using a weaving yarn just like the actual weaving process and added a little noise and shade to each color of the cell to have a slightly three-dimensional shape as shown in FIG.

In addition, since the fabric image can be enlarged or reduced freely, the user will be able to test in advance what the appearance will look like if the original image is divided into cell weaving, and it is expected to be applicable to design changes.

3. Preparation of a yarn designed according to the method of the present invention

According to the method of the present invention, after dividing the cells of the patterned image, each row of the image is connected to design a single yarn, and a process of actually manufacturing the designed yarn using a loom is performed.

In Examples 2 to 4 of the present invention, a weaving yarn designed according to the method of the present invention was actually manufactured using a loom. At this time, the specifications of the loom used for the weaving and weaving are shown in Table 1.

Specifications of the loom used in the experiment Heald count 20 Replaceable Weft Count 8 How to enter Rapier Control method PLC based pneumatic cylinder control method

Generally looms are controlled by a programmable logic controller (PLC). When the user operates the control panel and inputs various parameters necessary for weaving, the PLC stores these commands, interprets them, and moves the solenoid valves installed in each part of the loom such as heald, rapier and weft selector. At this time, the compressed air supplied from the external compressor is controlled by the solenoid valve to control the movement of the loom in such a way that it is transmitted to the pneumatic cylinders installed in the respective driving units.

This control method is effective when weaving simple tissue fabrics, but it is not suitable for weaving a patterned fabric in the same manner as in the present invention. Due to the characteristics of the invention, such a task is not possible with a storage capacity of a general PLC.

Accordingly, in order to weave a patterned fabric by the method of the present invention, a loom controller having a capacity capable of executing a patterned fabric manufacturing program according to the method of the present invention should be provided.

 To this end, in the embodiment of the present invention, a hardware (controller) that allows the control of the loom using a computer was manufactured.

<Example 2>

Production of a controller capable of controlling the loom according to the method of the present invention

In order to manufacture a controller that can control a loom according to a pattern fabric manufacturing program according to the present invention, first, it was necessary to know how a conventional loom controller controls solenoids of each loom. Each solenoid of each loom has two wires. Several experiments show that the valve opens when the 24V power is applied between black and red, and the valve is closed when the power is cut off. Thus, if a computer was used to create hardware that could supply and release 24V power to multiple channels, the loom could be controlled by the computer.

However, it was found that the let-off motion of the warp beam and the take-up motion of the fabric in the loom are not controlled by the computer in the weaving process because the speed is determined by the servo motor mounted on the loom. Thus, the factors that need to be controlled for weaving weaving and weaving can be summarized as heald, weft selector, body, and rapier. In the present invention, since it is necessary to control up to six healds, eight wefts, bodies, and rapiers, it is possible to solve the loom control problem by manufacturing a 16-channel controller.

In general, there are many ways to control an external device using a computer, but in the present invention, a control device using a USB which has recently achieved a trend of automatic control in consideration of the scalability of the system is used. The USB port eliminates the need to add external power to the controller, allows access to any type of computer, including notebook PCs, and allows multiple looms (up to 127) to be connected and controlled simultaneously. There are advantages. In the present invention, a controller can be made by combining a LabJack U12 USB controller and a 16 channel relay board as shown in FIG. In this case, the relay board is a board for installing a relay that operates according to a signal sent from a controller. In the present invention, a 16-channel RB-16 board is used. When the RB-16 board is used, the input / output of the signal can be performed through the I / O module as shown in the original figure, but the present invention does not use the I / O module because only the output of the signal is used.

Meanwhile, the signal from the computer to the relay board through the USB controller is 5V. This is because the controller is powered through the USB port without using a separate power source.The solenoid valves of the loom require 24V voltage and a minimum current of 1A, so the relay board alone cannot control the loom. Therefore, the present invention uses a method of opening and closing the circuit for supplying the external power of 24V, 1A to the solenoid by using a solid state relay (SSR) operating at 5V, the schematic diagram of which is shown in FIG.

SSR used in the controller manufactured in the present invention is operated at 5V and the operating load was 120V, 3A maximum. In addition, since the input and output parts are electrically insulated, the stability of the system can be guaranteed and the operation status can be confirmed by the LED attached to the upper part.

In the present invention, a USB loom, a relay board, a power supply, and various cable connectors are configured in one case to produce a computer loom controller.

The wiring of the controller is as shown in FIG. 220V power, solenoid wiring, and USB cable from the left. The solenoid connection wire is 20 strands. Connect black to the positive pole of all solenoids and the rest of the colors to the negative pole of each solenoid. The number of SSRs assigned to each wiring is shown in Table 2.

Color palette of wiring assigned to each SSR One blue 9 White 2 Red 10 Blue + white 3 Yellow 11 Red + black 4 green 12 Green + white 5 orange color 13 Brown + white 6 purple 14 Yellow + black 7 Brown 15 Orange + black 8 grey 16 Brown + white

<Example 3>

Production of hardware control software

In the present invention, using the controller produced as described above, a software module for allowing a computer to directly control a conventional loom loom based on a PLC control was developed and integrated into a design CAD system. Since the LabJack U12 controller can be controlled natively using the C language, it can be integrated seamlessly into a glyph CAD system and can control 16 channels of digital out ports for loom control. The controller setting screen is as shown in FIG.

Detailed descriptions of the contents that can be operated by the user in the setting screen are as follows.

① Allocate an arbitrary SSR to each drive of the loom.

On the left side of the controller screen is a list of 16 drive units on the computer-controlled loom and the number of SSRs assigned to each. 'Weft 1 to 8' represent the weft yarns 1 to 8 of the weft selector as shown in FIG. 18, and 'Rapier', 'Body', and 'Harness 1 to 6' respectively represent the rapier head, body, and heald. Indicates. In the loom used in the present invention, 20 healds are installed, but in the process of weaving weaving, such as weaving weaving, it is necessary to weave fabrics, so no matter how high the density, up to 6 healds are sufficient for 6 healds. Only control was performed.

The user can select the driver to which the SSR is to be allocated from the list, select the appropriate number from the 'Switch Number' on the right side and press the 'Set' button to allocate the SSR. This is made to solve this by software when inevitable wiring cannot be done in order to make work easier during the wiring process of the system, and the user can have more flexibility in wiring.

Once all 16 SSRs have been allocated to all drives, this combination allows the user to automatically control different weaving processes.

② Test drive

Pressing the 'Initialize' button turns all SSRs off so that the heald falls and the rapier, weft selector and body retreat. To test a particular drive, select it from the list (multiple choices) and then press the 'On' and 'Off' buttons to see the result. The LED on top of the SSR on the controller's relay board indicates that the signal transmission is correct. If the driver does not work even though the LED is blinking, check the wiring.

③ Definition of Weaving Unit Process

The feeding and winding motions of the rapier loom used in the present invention are excluded from the control range by the computer because they are controlled by a servo motor moving at a predetermined speed. Therefore, only vertical light, body needle and weft selection motion of heald can be used to define the weaving unit process. In addition, since the looms are designed to occur independently of each other, the other movement starts after one movement is finished. However, weaving speed was relatively not so fast, but sequential control was possible. The weaving unit process results in the indentation of one weft yarn, and the combination of unit motions for this is infinite. For example, the simplest fabric is as follows.

a) opening and closing of heald

For basic fabrics, the warp is divided into two healds (defined as 1 and 2). Since the rapier loom used in the present invention uses the upper opening movement, the first heald rises and the second heald stops. To express this opening motion, first select Harness 1 from the combo box labeled 'Choose Type' as shown in FIG.

Then, in the radio button on the bottom, select ‘On’ and then press ‘Add’ and the 'Harness 1 On' will appear in the list on the right. Then, in the same way, select 'Harness 2', check the 'Off' button, and then 'Add' the 'Harness 2 Off' item. Therefore, if these two items are executed during actual weaving, heald will rise 1 and 2 will be fixed, resulting in an opening.

b) time delay

In a conventional loom, the timing of the indentation after the opening motion is controlled by crank timing or the like, but in the case of a computer-controlled loom, a certain time delay can be defined to precisely control this action. To delay the time, select 'Delay' in the 'Choose Type' combo box, enter the required delay time in the edit box located below the 'On' button, and press the 'Add' button. 'Is added, and weaving is delayed by the specified time before the next exercise is performed. At this time, the unit of delay time is set to millisecond (1/1000 second).

c) selection of wefts

To import the wefts according to the indentation sequence created in the design CAD program, select 'Weft Selector', check the 'On' button, and press the 'Add' button. This adds the ‘Weft Selector On’ item to the list on the right and automatically selects the appropriate weft and delivers it to the rapier head when weaving. For each operation, an appropriate delay time must be defined.

d) stomach movement

If you select 'Rapier' and check 'On' and 'Add', if 'Rapier On' item is added, rapier is inserted into the opening while weaving the weft. After that, give the appropriate delay time and define the 'Rapier Off' item again. Then add the 'Weft Selector Off' item in a similar way as in c). Again, adequate time delay is essential for each step.

e) opening and closing of healds

After the incidence, the opening and closing state of the heald is reversed before, during and after the body needle. This can be done by defining an appropriate delay time. The opening and closing of the heald can be defined in the opposite manner as in a). The heald is lowered and the second is raised.

f) body needles

Body needle movement can be done by adding the 'Body On' and 'Body Off' items and defining the appropriate time delay.

g) management of unit movement lists;

To delete all the contents of the list, press the 'Clear' button. To delete an item from the list, select the item and press the 'Delete' button. In addition, when you want to edit an item, select the item and then press the 'Edit' button to change the item to a newly defined item. For example, if you select 'Harness 1 On' item, check 'Off' button and press 'Edit' button, it will be changed to 'Harness 1 Off'. And when you want to insert another item between two items, select the item just below the position you want to insert, define the item and press the 'Add' button to insert the new item above the item. In this way, each item can be entered, modified, inserted, or deleted.

An example of the weaving unit process of the fabric defined as described above is shown in FIG.

④ Testing of Weaving Unit Process

After defining the unit process, you can test the enumeration process by pressing the ‘Test One Step’ button. This process ensures that each part of the loom is moving properly and determines the appropriate delay time.

<Example 4>

Weaving and weaving Weaving Process  control

When the enameling process is performed without any abnormality, weaving of the weaving yarn and the pattern fabric can be performed, and a user interface for this is shown in FIG.

① Production of direct weaving

Weaving can be done in the 'Weave Yarn' section. After deciding how many times to repeat the pattern in the inclined direction, we enter in Repeat and press the 'Start' button to start weaving. The upper of the two progress bars represents the progress of the repeating unit, and the lower one represents the weft state of the wefts required to form a unit. The user can stop by pressing the 'ESC' key if a problem occurs during the intrusion. If the process is stopped as shown in Figure 22 after the problem solving whether we continue or stop weaving by answering this can be stopped or continue the process.

② Weaving of Patterned Fabrics

The weaving fabric can be weaved with the weaving yarn made previously. If you press Start in the Weave fabric section, you can weave the fabric because weaving the fabric using only weft 1 when selecting the weft. In the second stage, improvements will be made to optimize the pattern considering the linear axis, and to automatically detect whether or not weft misses or wefts are properly entered. In addition, to solve the problems that may occur during weaving of warp yarn or weft thread, and to check the weaving conditions of pattern fabrics that can be woven in actual rapier looms, we have established a system that can weave double-sided pile pattern fabrics without having a jacquard device. I would like to.

A block diagram of a pattern fabric manufacturing program including a hardware control module developed in accordance with the present invention is shown in FIG.

As described above, according to the present invention, it is possible to industrialize a pattern fabric in the form of a cut pile that cannot be woven in the existing production system. Therefore, the industrialization of the manufacture of such a patterned fabric by the present invention can bring a breakthrough turning point for the current fabric production system.

Claims (10)

(a) selecting a glyph image; (b) dividing the selected pattern image into unit cells; (c) designing one long rectangular yarn having all the colors of each cell sequentially by connecting all the cells of the divided pattern image; (d) preparing a yarn as designed above; And (e) weaving a patterned fabric having the selected pattern image by weaving into a woven fabric using the fabric weaving as a weft. The method of claim 1, wherein step (d) (d1) sequentially fabricating a weft yarn in the color order of the connected cells to manufacture a fabric; And (d2) a method of manufacturing a patterned fabric comprising cutting a plurality of inclined yarns of each of the fabrics to produce a plurality of long straight yarns sequentially having the color of each cell as a whole. The process of claim 1 or 2, wherein step (a) And controlling the number of colors of the pattern image within the number of replaceable weft yarns in the loom used in the manufacture of the weaving yarn. The method of manufacturing a patterned fabric according to claim 1 or 2, wherein the size of the cell in step (b) is equal to the thickness of the weft yarn to be used in the subsequent weaving. The method according to claim 1 or 2, wherein the connecting of each cell in step (c) is made by connecting the right end of each row of the divided image and the left end of the next row. The method according to claim 1 or 2, further comprising the step of simulating the manufacture of a weaving yarn as designed as described above after step (c) and before step (d). Method for producing a patterned fabric further comprising. (a) selecting a glyph image; (b) dividing the selected pattern image into unit cells; (c) designing one long rectangular yarn having all the colors of each cell sequentially by connecting all the cells of the divided pattern image; (d) preparing a yarn as designed above; And (e) a computer-readable recording medium having recorded thereon a program which performs a step of completing a patterned fabric having the selected patterned image by weaving into a fabric using the manufactured weaving yarn as a weft yarn. 8. The method of claim 7, wherein step (d) (d1) sequentially fabricating a weft yarn in the color order of the connected cells to manufacture a fabric; And (d2) a computer-readable recording medium having recorded thereon a program comprising cutting a plurality of warp yarns of each of said fabrics to produce a plurality of elongated yarns sequentially having the color of each cell as a whole. The method of claim 7 or 8, wherein step (a) A computer-readable recording medium having recorded thereon a program comprising adjusting the number of colors of a glyph image within the number of replaceable wefts in a loom used in the manufacture of a weaving yarn. Patterned fabric prepared by the method of claim 1.

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