WO2016155163A1 - 四组份异步牵伸动态配置纱线线密度和混纺比的方法及装置 - Google Patents
四组份异步牵伸动态配置纱线线密度和混纺比的方法及装置 Download PDFInfo
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- WO2016155163A1 WO2016155163A1 PCT/CN2015/085214 CN2015085214W WO2016155163A1 WO 2016155163 A1 WO2016155163 A1 WO 2016155163A1 CN 2015085214 W CN2015085214 W CN 2015085214W WO 2016155163 A1 WO2016155163 A1 WO 2016155163A1
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- rear roller
- yarn
- roller
- roving
- component
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01H—SPINNING OR TWISTING
- D01H5/00—Drafting machines or arrangements ; Threading of roving into drafting machine
- D01H5/18—Drafting machines or arrangements without fallers or like pinned bars
- D01H5/32—Regulating or varying draft
- D01H5/36—Regulating or varying draft according to a pre-arranged pattern, e.g. to produce slubs
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01H—SPINNING OR TWISTING
- D01H5/00—Drafting machines or arrangements ; Threading of roving into drafting machine
- D01H5/18—Drafting machines or arrangements without fallers or like pinned bars
- D01H5/70—Constructional features of drafting elements
- D01H5/74—Rollers or roller bearings
Definitions
- the invention relates to the field of ring spinning in the textile industry, in particular to a method and a device for dynamically configuring a linear density and a blending ratio of a four-component asynchronous drafting.
- the yarn is an elongated fiber assembly formed by twisting the fibers in parallel orientation.
- the characteristic parameters of the yarn generally include fineness (linear density), twist, blend ratio (mixing ratio), and the like.
- the characteristic parameters of the yarn are important features that need to be controlled during the forming process.
- a yarn having a constant linear density and a blending ratio such as a linear density yarn having a gradation color or a segmented color
- Blended yarn or mixed color yarn which does not change in linear density and blending ratio, but is blended in any ratio.
- a yarn having a constant linear density and a blending ratio (or color mixing ratio) can be conceived as a linear density yarn having a gradation color or a segmented color.
- a blending ratio or color mixing ratio
- the existing method for producing a linear density yarn by ring spinning uses a middle and a rear roller to feed a roving, and intermittently spinning through the uneven feeding of the rear roller to produce a variable linear density yarn.
- an intermittent spinning process and its yarn (authorization number ZL01126398.9), its principle is to feed a staple yarn B from the back roller, through the uneven draft of the middle and rear rollers Then, it is merged with another main yarn strip A fed from the middle roller and then into the front drafting zone.
- the main yarn strand is evenly thinned to a certain linear density under the action of the main drafting ratio in the front zone, and the auxiliary yarn strand is attached to the main yarn.
- a discontinuous uneven linear density distribution is formed on the yarn batt.
- the roller is unevenly fed to the amount of the auxiliary yarn fluctuation amount, and finally, different effects such as a little yarn, a slub yarn, and a big belly yarn can be formed on the yarn.
- the disadvantage of this method is that the main and auxiliary yarns cannot be exchanged, and the variation of the thickness of the bamboo section is limited.
- the current method is to mix two or more different kinds of raw materials through a pre-spinning process to obtain a roving of a certain blending ratio, and then the roving is spun into a spun yarn in a spinning process to obtain a linear density and a blended yarn.
- Traditional processes can only achieve several more conventional ratios, such as 50:50, 65:35, 60:40.
- the main problems are that one cannot be blended at any ratio, and the second cannot achieve blending of two or more fibers in any ratio in one step.
- the object of the present invention is to provide a four-component hetero-synchronized secondary draft fiber strand, which is then combined and twisted to form a yarn, which can arbitrarily control the linear density and blending of the ring-spun yarn. ratio.
- the invention can simultaneously change the density of the spun yarn and the blending ratio, and breaks through the limitation that the existing spinning method cannot adjust the characteristic parameters of the yarn on-line, and produces the above four types of yarns.
- a method for dynamically configuring a linear density and a blending ratio of a four-component asynchronous drafting specifically includes:
- the actuator mainly comprises a four-component split-type hetero-synchronous secondary drafting mechanism, a twisting mechanism and a winding forming mechanism, and the four-component split-type asynchronous secondary drafting mechanism includes a first-stage drafting provided before and after Unit, secondary drafting unit;
- the first stage drafting unit comprises a combined rear roller and a middle roller; the combined rear roller has four rotational degrees of freedom, and includes a first rear roller, a second rear roller, and a third side arranged side by side on the same rear roller shaft.
- the secondary synchronous drafting unit includes a front roller and the middle roller; the front roller rotates at a surface linear velocity V q ;
- the yarn density of the yarn Y obtained by drawing and twisting the front roller is ⁇ y ,
- the blending ratios k 1 , k 2 , k 3 and k 4 of the first roving component, the second roving component, the third roving component and the fourth roving component are expressed as follows:
- On-line dynamic adjustment of the yarn Y-line density or/and blending ratio is achieved by adjusting the rotational speeds of the first rear roller, the second rear roller, the third rear roller, and the fourth rear roller.
- the first rear roller and the second are derived.
- ⁇ 1 , ⁇ 2 , ⁇ 3 , ⁇ 4 , V q are constants, and K i and ⁇ y are functions as a function of time t.
- ⁇ y is the amount of linear density change of the yarn Y
- ⁇ V h1 , ⁇ V h2 , ⁇ V h3 and ⁇ V h4 are the speed changes of the first, second, third and fourth rear rollers
- the adjustment process is such that the speed of any of the rear rollers is zero, and the speeds of the other three rear rollers are not zero.
- the discontinuity of the roving component drawn by any one of the back rollers in the yarn Y is realized, and the other three roving components are continuous, and the adjusted linear density ⁇ ' y of the yarn Y is:
- T 1 and T 2 are two consecutive time points, and t is a time variable.
- the adjustment process is such that the speed of any two rear rollers is zero, and the speeds of the other two rear rollers are not Zero, the discontinuity of the roving component drawn by any two of the back rollers in the yarn Y is achieved, while the other two roving components are continuous, and the adjusted linear density ⁇ ' y of the yarn Y is:
- T 1 and T 2 are two consecutive time points, t is a time variable; i ⁇ j, and i, j ⁇ (1, 2, 3, 4).
- the adjustment process is such that the speed of any three rear rollers is zero, and the speeds of the other rear rollers are not zero. Then, the discontinuity of the roving component drawn by any three of the rear rollers in the yarn Y is realized, while the other roving components are continuous, and the adjusted linear density ⁇ ' y of the yarn Y is:
- T 1 and T 2 are two consecutive time points, t is a time variable; j ⁇ (1, 2, 3, 4).
- the adjustment process is performed such that the speeds of the two rear rollers are sequentially adjusted to zero, and the speeds of the other rear rollers are not Zero, the roving component stretched by the two rear rollers in the yarn Y is successively interrupted, while the other roving components are continuous, and the adjusted linear density ⁇ ' y of the yarn Y is:
- T 1 , T 2 and T 3 are three time points, and t is a time variable
- the adjustment process is performed to adjust the speeds of the three rear rollers to zero, and the speeds of the other rear rollers are not Zero, the roving component stretched by the three rear rollers in the yarn Y is successively interrupted, while the other roving components are continuous, and the adjusted linear density ⁇ ' y of the yarn Y is:
- T 1 , T 2 , T 3 and T 4 are four time points, and t is a time variable
- V h1 * ⁇ 1 +V h2 * ⁇ 2 +V h3 * ⁇ 3 +V h4 * ⁇ 4 constant
- the yarn Y is divided into n segments, and the linear density and the blending ratio of each yarn Y are the same, and the linear density or the blending ratio of the adjacent two segments is different;
- the linear velocities of the first rear roller, the second rear roller, the third rear roller and the fourth rear roller are V h1i , V h2i , V h3i and V h4i , respectively , where i ⁇ ( 1,2,...,n); after the i-th yarn Y of the first roving component, the second roving component, the third roving component and the fourth roving component formed by two-stage drafting and twisting
- the blending ratios k 1i , k 2i , k 3i and k 4i can be expressed as follows:
- the linear density of the yarn of the i-th segment is:
- the reference line segment the reference line density of the segment is ⁇ 0
- the first rear roller, the second rear roller, the third rear roller and the first segment of the segment The reference line speeds of the four rear rollers are V h10 , V h20 , V h30 and V h40 respectively ; the reference blend of the first roving component, the second roving component, the third roving component and the fourth roving component of the segment
- the ratios are k 10 , k 20 , k 30 and k 40 , respectively.
- V z V h10 +V h20 +V h30 +V h40 (7);
- the reference speeds V h10 , V h20 , V h30 and V h40 of the first rear roller, the second rear roller, the third rear roller and the fourth rear roller are based on the first roving component, the second roving component, and the first
- the material of the three roving components and the fourth roving component, the reference line density ⁇ 0 and the reference blending ratios k 10 , k 20 , k 30 and k 40 are set in advance;
- equation (6) is simplified as:
- the linear density of the yarn Y increases the dynamic increment ⁇ yi based on the reference line density, that is, the thickness change ⁇ yi ;
- the linear velocities of the first rear roller, the second rear roller, the third rear roller, and the fourth rear roller respectively increase in accordance with the reference linear velocity, that is, (V h10 +V h20 +V h30 +V h40 ) ⁇ (V h10 + ⁇ V h1i +V h20 + ⁇ V h2i +V h30 + ⁇ V h3i +V h40 + ⁇ V h4i ), the increment of yarn Y-line density is:
- the linear density variation of the yarn Y is achieved by controlling the sum of the linear velocity increments ⁇ V i of the first rear roller, the second rear roller, the third rear roller, and the fourth rear roller.
- Adjusting the blending ratio of the yarn Y by controlling the linear velocity increments of the first rear roller, the second rear roller, the third rear roller, and the fourth rear roller;
- ⁇ V h4i k 4i *(V z + ⁇ V i )-V h40 .
- V h1i , V h2i , V h3i and V h4i are zero, and the others are not zero, then 1-3 kinds of roving components in the yarn i of the i-th segment are realized. continuous.
- first rear roller, the second rear roller, the third rear roller, and the fourth rear roller are respectively drawn with yellow, magenta, cyan, and black yarns; the front roller speed V q is kept constant, and the first adjustment is performed.
- the speed of the rear roller, the second rear roller, the third rear roller and the fourth rear roller achieves the color matching of the yarn; when the color is mixed, the black yarn is used to adjust the color depth or saturation of the color spinning.
- the color mixing ratio is incremented by 10% as the minimum increment, and the color matching can form the following color mixing:
- the patent of the present invention selects a gradient mixed color matching with 0.1 as a gradient, and according to the above statistics, according to the four primary color rovings (four colors)
- the roving is coupled to draw, cross-change, and twist, and finally 248 colors can be formed to form a segment color yarn having 248 color distributions.
- the yellow, magenta and cyan primary color yarns have various defects in the material itself and in the manufacturing process, which brings about the theoretical color effect when the three primary colors are mixed, in the color depth. Different from the theoretical color, the present invention compensates for the above defects by introducing black and using black yarn to adjust the color depth of the final yarn, thereby obtaining an ideal color effect.
- a four-component isochronous drafting device for controlling yarn linear density and blending ratio, comprising a control system and an actuator, the actuator comprising a four-component split-type hetero-synchronous secondary drafting mechanism, twisting mechanism and winding a molding mechanism;
- the secondary drafting mechanism comprises a primary drafting unit and a secondary drafting unit;
- the primary drafting unit comprises a combined rear roller and a middle roller;
- the combined rear roller has four rotational degrees of freedom, including the same a first rear roller, a second rear roller, a third rear roller, and a fourth rear roller disposed side by side on the root roller shaft;
- the secondary drafting unit includes a front roller and the middle roller.
- control system mainly includes a PLC programmable controller, a servo driver, a servo motor, and the like.
- any one of the first rear roller, the second rear roller, the third rear roller, and the fourth rear roller is fixedly disposed on the rear roller shaft, and the other three rear rollers are disposed independently of each other on the rear roller shaft on.
- the third rear roller is fixedly disposed on the rear roller shaft, and the other three rear rollers are disposed on the rear roller shaft independently of each other; the second rear roller is disposed to be connected to the driving mechanism
- the sleeve is sleeved on the rear roller shaft, and the first rear roller is rotatably fitted outside the sleeve.
- the speed of the middle roller is fixed and not greater than the sum of the speeds of the first rear roller, the second rear roller, the third rear roller, and the fourth rear roller.
- the method of the invention changes the conventional four-component front and rear zone synchronous drafting into four-component separated asynchronous drawing (hereinafter referred to as first-order asynchronous drawing) and four-component combined synchronous drawing (hereinafter referred to as secondary synchronous drawing)
- the first step of the asynchronous drafting is used to control the dynamic variation of the mixing ratio of the four components and the linear density of the yarn, and the level of the baseline density of the yarn is controlled by the two-stage simultaneous drafting.
- the spinning device and the process of the four-component split-type hetero-synchronous second-stage drafting and the twisting and twisting yarn of the invention can realize the random online dynamic control of the change of the linear density and the blending ratio of the spun yarn, and break through the original bamboo.
- Three technical bottlenecks in the spinning process 1 can only adjust the linear density change, can not adjust its blending ratio change (or color change); 2 bamboo yarn pattern is single; 3 bamboo pattern is poorly reproducible .
- Total equivalent draw ratio It is a very important parameter in spinning, which is the product of the draft ratio of the front zone and the draw ratio of the back zone.
- the rovings ⁇ 1 , ⁇ 2 , ⁇ 3 and ⁇ 4 are subjected to the asynchronous drafting of the rear zone and the synchronous drafting of the front zone, and then merged and twisted to form a yarn, the blending ratio k 1 , k 2 , k 3 , k 4 can be expressed as follows:
- the blending ratio of the four components in the yarn and the rotational speed of the rear roller surface V h1 , V h2 , V h3 , V h4 and the four coarse yarn densities ⁇ 1 , ⁇ 2 , ⁇ 3 , ⁇ 4 are related.
- the values of ⁇ 1 , ⁇ 2 , ⁇ 3 , and ⁇ 4 are constant regardless of time, and V h1 , V h2 , V h3 , and V h4 are related to the spindle speed set by the spinning machine, because the spindle speed is related to the spinning machine. Production, different spindle speeds are used in different companies, spinning different raw materials and product specifications.
- the yarn density is:
- the linear density of the yarn is related to the movement speeds V h1 , V h2 , V h3 , V h4 of the rear roller and the four coarse yarn densities ⁇ 1 , ⁇ 2 , ⁇ 3 , and ⁇ 4 .
- the values of ⁇ 1 , ⁇ 2 , ⁇ 3 , and ⁇ 4 are constant regardless of time, while V h1 , V h2 , V h3 , and V h4 are related to the spindle speed set by the spinning machine, and the spindle speed is related to the spinning.
- Machine output, different spindle speeds are used in different companies, spinning different raw materials and product specifications.
- the linear density determined by the equation (8) causes V h1 , V h2 , V h3 , and V h4 to change due to changes in the spindle speed even if the values of the rovings ⁇ 1 , ⁇ 2 , ⁇ 3 , and ⁇ 4 are constant. This leads to uncertainty in line density.
- V h1 +V h2 +V h3 +V h4 V z , that is, the sum of the speeds of the four rear rollers is equal to the linear velocity of the middle roller, so the above four formulas can be simplified to :
- the blending ratio of the four components ⁇ 1 , ⁇ 2 , ⁇ 3 and ⁇ 4 in the yarn is equal to the reciprocal of their respective draw ratios in the primary draw zone.
- k 2 0.7,0.6,0.5,0.4,0,3,0,2,0.1,0,0.1,0.1,0
- k 3 0.2, 0.2, 0.2, 0.2, 0.2, 0.2, 0.2, 0.2, 0, 2, 0.1, 0, 0
- k 3 0.1, 0.1, 0.1, 0.1, 0.1, 0.1, 0.1, 0, 1, 0, 0, 0
- Figure 1 is a schematic view of the principle of a secondary draft spinning device
- Figure 2 is a schematic view of the combined rear roller structure
- Figure 3 is a side view showing the structure of the secondary draft spinning device
- Figure 4 is a travel path diagram of the yarn in the secondary drawing in the embodiment
- Figure 5 is a schematic diagram of the structure of the control system.
- a method for dynamically configuring a linear density and a blend ratio of a four-component asynchronous drafting specifically includes:
- the drafting and twisting system includes a first-stage drafting unit and a second-stage drafting unit disposed before and after;
- the first stage drafting unit comprises a combined rear roller and a middle roller 3; the combined rear roller has four rotational degrees of freedom, including a first rear roller 6 and a second rear roller 8 and a third side arranged side by side on the same rear roller shaft.
- the rear roller 10 and the fourth rear roller 12; the secondary drafting unit includes a front roller 1 and a middle roller 3.
- 4 is a top roller corresponding to the middle roller 3, and 5, 7, 9, and 11 are four corresponding to the four rear rollers.
- a top roller. 2 is a top roller corresponding to the front roller 1.
- O 1 O' 1 , O 2 O' 2 , and O 3 O' 3 represent the axial lines of the back roller, the middle roller, and the front roller, respectively.
- the middle roller and the rear roller constitute a first-level draft, and the front roller and the middle roller constitute a secondary draft.
- 15 is a winding forming mechanism
- 14 is a guide roller
- 16 is a yarn Y.
- the four-degree-of-freedom combined rear roller with four nestings, six, eight, ten and twelve active roller covers are on the same mandrel, and are respectively driven by pulleys 20, 24, 30, 32. drive.
- the first rear roller, the second rear roller, the third rear roller, and the fourth rear roller move at speeds V h1 , V h2 , V h3 , and V h4 , respectively ;
- the middle roller rotates at a speed of V z ;
- the unit includes a front roller and a middle roller; the front roller rotates at a surface linear velocity V q ; the first roving component, the second rear roller, the third rear roller, and the fourth rear roller are drawn, and the second
- the linear density of the roving component, the third roving component and the fourth roving component are ⁇ 1 , ⁇ 2 , ⁇ 3 and ⁇ 4 , respectively, and the linear density of the yarn Y obtained by the front roller after drawing is ⁇ y .
- the four coaxial outer diameter outer rear rollers respectively correspond to four coaxial outer diameter outer rear upper rollers, and the rear regions are arranged in four parallel rows, and the upper and lower corresponding upper and lower aprons respectively hold four rovings.
- the four roving strips are positioned by the yarn guide bar and the bell mouth during the drafting and twisting process, so that they follow the path shown in FIG.
- the four rovings ⁇ 1 , ⁇ 2 , ⁇ 3 , ⁇ 4 are fed into the primary drafting zone by the rear roller jaws a 1 , a 2 , a 3 , a 4 at different speeds, parallel movement to the middle roller holding point b 1 , b 2 , b 3 , b 4 are taken out at a speed V z , and the three strands are subjected to asynchronous drafting, respectively, and the strand density is ⁇ 1 ', ⁇ 2 ', ⁇ 3 ' and ⁇ 4 ', respectively, and then Entering the secondary drafting zone and meeting the front roller holding point c, the linear density of the three whiskers becomes ⁇ 1 ′′, ⁇ 1 ′′, ⁇ 3 ′′ and ⁇ under the synchronous drafting of the front roller surface velocity V q 4 ", the four whiskers are joined to the front roller jaw c and then twisted coaxially to form the yarn Y.
- the secondary drafting unit includes a front roller and the middle roller; the front roller moves at a speed V q ;
- the yarn density of the yarn Y obtained by drawing and twisting the front roller is ⁇ y ,
- ⁇ y is the amount of linear density change of the yarn Y
- ⁇ V h1 , ⁇ V h2 , ⁇ V h3 and ⁇ V h4 are the speed changes of the first, second, third and fourth rear rollers
- the adjustment process is such that the speed of any of the rear rollers is zero, and the speeds of the other three rear rollers are not zero.
- the discontinuity of the roving component drawn by any one of the back rollers in the yarn Y is realized, and the other three roving components are continuous, and the adjusted linear density ⁇ ' y of the yarn Y is:
- T 1 and T 2 are two consecutive time points, and t is a time variable.
- the adjustment process is such that the speed of any two rear rollers is zero, and the speeds of the other two rear rollers are not Zero, the discontinuity of the roving component drawn by the two rear rollers in the yarn Y is achieved, while the other two roving components are continuous, and the adjusted linear density ⁇ ' y of the yarn Y is:
- T 1 and T 2 are two consecutive time points, t is a time variable; i ⁇ j, and i, j ⁇ (1, 2, 3, 4).
- the adjustment process is such that the speed of any three rear rollers is zero, and the speeds of the other rear rollers are not zero. Then, the discontinuity of the roving component drawn by any three rear rollers in the yarn Y is realized, while the other roving components are continuous, and the adjusted linear density ⁇ ' y of the yarn Y is:
- T 1 and T 2 are two consecutive time points, t is a time variable; j ⁇ (1, 2, 3, 4).
- the adjustment process is such that the speeds of the two rear rollers are adjusted to zero, and the speeds of the other rear rollers are not Zero, the roving component stretched by the two rear rollers in the yarn Y is successively interrupted, while the other roving components are continuous, and the adjusted linear density ⁇ ' y of the yarn Y is:
- T 1 , T 2 and T 3 are three time points, and t is a time variable
- the adjustment process is such that the speeds of the three rear rollers are adjusted to zero, and the speeds of the other rear rollers are not Zero, the roving component stretched by the three rear rollers in the yarn Y is successively interrupted, while the other roving components are continuous, and the adjusted linear density ⁇ ' y of the yarn Y is:
- T 1 , T 2 , T 3 and T 4 are four time points, and t is a time variable
- V h1 * ⁇ 1 +V h2 * ⁇ 2 +V h3 * ⁇ 3 +V h4 * ⁇ 4 constant
- the blending ratio of the four components ⁇ 1 , ⁇ 2 , ⁇ 3 and ⁇ 4 in the yarn is equal to the reciprocal of their respective draw ratios in the primary draw zone:
- the collector is disposed between the combined roller and the middle roller, and the middle roller maintains the same speed
- the first drafting unit forms a blending or color mixing unit
- the secondary drafting unit constitutes a simple Linear density adjustment unit.
- the yarn blending is more uniform and thorough, and the influence of the linear density adjustment process on the blending process is avoided.
- the speed of the rear middle roller below V h1 +V h2 +V h3 +V h4 , the blending is more uniform.
- the method of this embodiment is basically the same as that of Embodiment 1, except that:
- the first rear roller, the second rear roller, the third rear roller, and the fourth rear roller are respectively drawn with yellow, magenta, cyan, and black yarns; the front roller speed V q is kept constant, and the first rear roller is adjusted.
- the speed of the second rear roller, the third rear roller and the fourth rear roller realizes the color matching of the yarn; when the color is mixed, the black yarn is used to adjust the color depth of the color spinning.
- the linear densities of the yellow, magenta, cyan, and black yarns are ⁇ 1 , ⁇ 2 , ⁇ 3 , and ⁇ 4 , respectively ; the speed processes of the first rear roller, the second rear roller, the third rear roller, and the fourth rear roller are adjusted.
- V h1 ⁇ ⁇ 1 + V h2 ⁇ ⁇ 2 + V h3 ⁇ ⁇ 3 + V h4 ⁇ ⁇ 4 constant
- the invention realizes the adjustment of the blending ratio or the color mixing ratio of the yellow, magenta, cyan, and black yarns by changing the speeds of the first rear roller, the second rear roller, the third rear roller, and the fourth rear roller,
- the blending ratios of the primary yarns are as follows:
- the method of this embodiment is basically the same as that of Embodiment 1, except that:
- the yarn Y is divided into n segments, the linear density and the blending ratio of each yarn Y are the same, and the linear density or blending ratio of the adjacent two segments is different;
- the linear velocities of the first rear roller, the second rear roller, the third rear roller and the fourth rear roller are V h1i , V h2i , V h3i and V h4i , respectively , where i ⁇ ( 1,2,...,n); after the i-th yarn Y of the first roving component, the second roving component, the third roving component and the fourth roving component formed by two-stage drafting and twisting
- the blending ratios k 1i , k 2i , k 3i and k 4i can be expressed as follows:
- the linear density of the yarn of the i-th segment is:
- the section with the smallest line density of the n-segment Y be defined as the reference line segment, the reference line density of the segment is ⁇ 0 , and the first rear roller, the second rear roller, the third rear roller and the fourth of the segment
- the reference linear velocity of the rear roller is V h10 , V h20 , V h30 and V h40 ; the reference blend ratio of the first roving component, the second roving component, the third roving component and the fourth roving component of the segment K 10 , k 20 , k 30 and k 40 , respectively
- V z V h10 +V h20 +V h30 +V h40 (7);
- the reference speeds V h10 , V h20 , V h30 and V h40 of the first rear roller, the second rear roller, the third rear roller and the fourth rear roller are based on the first roving component, the second roving component, and the first
- the material of the three roving components and the fourth roving component, the reference line density ⁇ 0 and the reference blending ratios k 10 , k 20 , k 30 and k 40 are set in advance;
- the linear density of the yarn Y is increased by the dynamic line increment ⁇ yi based on the reference line density, that is, the thickness change ⁇ yi ;
- the linear velocities of the first rear roller, the second rear roller, the third rear roller, and the fourth rear roller respectively increase in accordance with the reference linear velocity, that is, (V h10 +V h20 +V h30 +V h40 ) ⁇ (V h10 + ⁇ V h1i +V h20 + ⁇ V h2i +V h30 + ⁇ V h3i +V h40 + ⁇ V h4i ), the increment of yarn Y-line density is:
- the linear density variation of the yarn Y is achieved by controlling the sum of the linear velocity increments ⁇ V i of the first rear roller, the second rear roller, the third rear roller, and the fourth rear roller.
- Adjusting the blending ratio of the yarn Y by controlling the linear velocity increments of the first rear roller, the second rear roller, the third rear roller, and the fourth rear roller;
- V h1i , V h2i , V h3i and V h4i be zero, while others are not zero, then the 1-3 roving components in the yarn i of the i-th segment are realized. continuous.
- the method for dynamically configuring the linear density and the blending ratio of the four-component asynchronous drafting of the present embodiment is basically the same as that of the third embodiment, except that:
- the initial linear velocities of the first rear roller, the second rear roller, the third rear roller, and the fourth rear roller are set to V h10 , V h20 , V h30 , and V h40 , respectively ;
- the initial linear velocity of the middle roller V z0 V h10 +V h20 +V h30 +V h40 ;
- V zi V h1(i-1) +V h2(i-1) +V h3(i-1) +V h4(i-1) ;
- the linear density and the blending ratio of the yarn Y of the i-1th stage are respectively taken as the reference line density of the i-th stage and the reference blending ratio, and the setting of the i-th stage is known.
- the rotational speeds of the first rear roller, the second rear roller, the third rear roller and the fourth rear roller are adjusted to realize the linear density or/and the blending ratio of the yarn of the i-th segment Y. Dynamic Adjustment.
- the speed of each roller can be recorded at any time by using a computer or other intelligent control unit.
- the speeds of the next middle roller and the front roller can be automatically calculated, and the formula and model are used to quickly calculate
- the speed increase and decrease of the roller the set blending ratio and the linear density adjustment are realized, thereby making it simpler and more accurate.
- the device for four-component hetero-synchronized drafting and spinning colorful slub yarn comprises a control system and an actuator, and the actuator comprises a four-component split-type hetero-synchronous secondary drafting mechanism, a twisting mechanism and a winding forming mechanism;
- the stage drafting mechanism comprises a first stage drafting unit and a second stage drawing unit;
- the primary drafting unit includes a combined rear roller 15 and a middle roller 3; the combined rear roller 15 has four rotational degrees of freedom, including a first rear roller 6 disposed side by side on the same rear roller shaft 21. a second rear roller 8, a third rear roller 10, and a fourth rear roller 12; the secondary drafting unit includes a front roller 1 and a middle roller 3.
- 4 is a top roller corresponding to the middle roller 3, 5, 7, 9, 11 It is the four top rollers corresponding to the four rear rollers.
- 2 is a top roller corresponding to the front roller 1.
- 23, 26 and 27 are bearings.
- the four-degree-of-freedom combination rear roller with four nestings, six, eight, ten and twelve active roller loops are on the same mandrel 21, and are respectively driven by pulleys 30, 32, 20, 24 drives.
- the four rear rollers are disposed adjacent to each other, and the drive mechanism pulleys 30, 32, 20, 24 are disposed on both sides of the four rear rollers.
- the control system mainly includes a PLC programmable controller, a servo driver, a servo motor, and the like.
- the programmable controller controls the motor to drive the roller, the program board, the spindle and the like through the servo driver.
- the mechanical structure is more compact and the four coarse yarns drawn by the four rear rollers are closer together when blended.
- the interference and contamination of the yarn during operation can be effectively prevented, and when the four primary color yarns pass through the bell mouth, the clamping angle is smaller, which is more favorable for the mixing of the yarns.
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Abstract
一种四组份异步牵伸动态配置线密度和混纺比的方法和装置，该装置包括牵伸和加捻系统，牵伸系统包括前后设置的一级牵伸单元、二级牵伸单元和并合加捻单元，一级牵伸单元包括组合后罗拉（15）、中罗拉（3），二级牵伸单元包括前罗拉（1）和所述中罗拉（3）；该方法通过一级异步牵伸机构控制四组份混合比例及线密度动态变化，通过二级同步牵伸控制基准线密度的大小。本方法和装置不仅能对纱线线密度变化，例如附着在基准纱上竹节的形状实现精确控制，而且能对纱线颜色的变化，例如竹节及其基准纱的色彩进行精准控制。同时，通过控制中罗拉以恒定的设定速度转动，保证了变线密度纱线的花型及色彩的可再现性，纺纱效果更加稳定。
Description
本发明涉及到属纺织行业的环锭纺纱领域，特别涉及一种四组份异步牵伸动态配置线密度和混纺比的方法及装置。
纱线是由纤维平行取向经加捻形成的细长的纤维集合体。纱线的特征参数一般包括细度(线密度)、捻度、混纺比(混色比)等。纱线的特征参数是其成形加工过程中需要控制的重要特征。
纱线依据特征参数具体可分为四类：
⑴线密度恒定而混纺比变化的纱线，如具有渐变色彩或分段色彩的等线密度段彩纱；
⑵混纺比恒定而线密度变化的纱线，竹节纱、大肚纱、点点纱等；
⑶线密度和混纺比均变化的纱线，如段彩竹节纱、段彩大肚纱、段彩点点纱等；
⑷线密度和混纺比不变化，但以任意比例混配的混纺纱或混配色纱。
纱线加工技术的发展主要是围绕特种纱线提出的问题来开展的。依据已有的纺纱技术和已申请的专利技术，无法指导上述四类纱线的纺纱生产。这对现有的纺纱理论提出了挑战。具体分析如下：
(1)线密度恒定而混纺比(或混色比)变化的纱线：
线密度恒定而混纺比(或混色比)变化的纱线，我们可以设想为具有渐变色彩或分段色彩的等线密度段彩纱。在已有的专利中，尚无涉及类似纱线。
(2)混纺比恒定而线密度变化的纱线：
混纺比恒定而线密度变化的纱线，如竹节纱、大肚纱、点点纱等。已有的环锭纺生产变线密度纱线的方法，均采用中、后罗拉分别喂入一根粗纱，通过后罗拉不均匀的喂入进行断续式纺纱来生产变线密度纱线。如专利“一种断续纺工艺及其纱线”(授权号ZL01126398.9)，它的原理是把由后罗拉喂入的一根辅纱须条B，经中、后罗拉不均匀牵伸，再与另一根由中罗拉后点喂入的主纱须条A交汇再进入前牵伸区，经前、中罗拉牵伸后由前罗拉钳口输出，进入加捻区共同加捻形成纱线。由于辅纱是由后罗拉间隙式喂入与主纱汇合，在前区主牵伸倍数的作用下，主纱须条被均匀地拉细至一定的线密度，辅纱须条则依附在主纱须条上形成断续式不均匀的线密度分布。控制后罗拉不均匀喂入辅纱波动量的大小，就可以最终在纱线上形成点点纱、竹节纱、大肚纱等不同效果。这种方法的缺点是，主辅纱不能交换，竹节粗细的变化调整范围有限，
(3)线密度和混纺比均变化的纱线：
在已有的专利中，尚无涉及。
(4)线密度不变，以任意混纺比均不变化的纱线：
线密度和混纺比不变化，但以任意比例混配的混纺纱或混配色纱。目前的方法是通过前纺工序，将两种或两种以上不同品种的原料进行混合，得到一定混纺比的粗纱，再将这种粗纱在细纱工序上纺制成细纱，以得到线密度和混纺比均不变化的纱线。传统工艺只能实现几种比较常规的比例，如50:50,65:35,60:40。存在的主要问题是，一是不能以任意比例进行混纺，第二不能一步法实现两种或两种以上纤维以任意比例进行混纺。
发明内容
为解决上述问题，本发明的目的在于提供一种四组份异同步二级牵伸纤维须条，再汇合加捻形成纱线的工艺，可任意调控环锭纺纱成纱的线密度及混纺比。本发明能同时改变纺纱线密度和混纺比，突破已有纺纱方法无法在线调控纱线特征参数的局限，生产上述四类纱线。
为实现上述目的，本发明公开的一种四组份异步牵伸动态配置线密度和混纺比的方法，具体包括：
1)执行机构主要包括四组份分合式异同步二级牵伸机构、加捻机构和卷绕成型机构，所述四组份分合式异同步二级牵伸机构包括前后设置的一级牵伸单元、二级牵伸单元；
2)所述一级牵伸单元包括组合后罗拉、中罗拉；组合后罗拉具有四个转动自由度，其包括同一根后罗拉轴上并排设置的第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉；第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉分别以速度Vh1、Vh2、Vh3和Vh4运动；中罗拉以速度Vz的速度转动；所述二级同步牵伸单元包括前罗拉和所述中罗拉；前罗拉以表面线速
度Vq转动；
设第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉所牵伸的第一粗纱组份、第二粗纱组份、第三粗纱组份和第四粗纱组份的线密度分别为ρ1、ρ2、ρ3和ρ4，前罗拉牵伸加捻后得到的纱线Y的线密度为ρy，
第一粗纱组份、第二粗纱组份、第三粗纱组份和第四粗纱组份的混纺比k1、k2、k3和k4表达如下：
3)保持前罗拉和中罗拉线速度之比Vq/Vz恒定，前罗拉和中罗拉线的速度大小取决于纱线的基准线密度；
4)通过调整第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的转速，实现纱线Y线密度或/和混纺比的在线动态调整。
进一步，通过已知设定所述纱线Y混纺比K随时间t的变化规律，以及已知纱线Y线密度ρy随时间t的变化规律,推导出所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉表面线速度变化规律；设定第一粗纱组份、第二粗纱组份、第三粗纱组份和第四粗纱组份的混纺比k1、k2、k3和k4，则纱线Y的混纺比之比K1、K2和K3如下：
纱线Y线密度 
则得到后罗拉1表面线速度： 
后罗拉2表面线速度： 
后罗拉3表面线速度： 
后罗拉4表面线速度： 
其中，ρ1、ρ2、ρ3、ρ4、Vq为常数，Ki和ρy都是随时间t变化的函数。
进一步，令ρ1＝ρ2＝ρ3＝ρ4＝ρ，则：
1)改变第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉中的任一后罗拉的速度，其它三个后罗拉速度不变，则实现纱线Y中所述任一后罗拉的所牵伸的粗纱组份及其线密度的变化，调整后的纱线Y的线密度ρ′y为：
或 
或 
或 
其中，Δρy为纱线Y的线密度变化量，ΔVh1、ΔVh2、ΔVh3和ΔVh4为第一、二、三和四后罗拉的速度变化量；
2)改变第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉中的任意两个后罗拉的速度，其它两个后罗拉速度不变，则实现纱线Y中所述任意两个后罗拉的所牵伸的粗纱组份及其线密度的变化，调整后的纱线Y的线密度ρ′y为：
或 
或 
或 
或 
或 
3)同时改变第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉中的任意三个后罗拉的速度，剩余的后罗拉速度不变，则实现纱线Y中三个后罗拉的所牵伸的粗纱组份及其线密度的变化，调整后的纱线Y的线密度ρ′y为：
或 
或 
或 
4)同时改变第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的速度，且四个后罗拉的速度之和不为零，则实现纱线Y中四个后罗拉的所牵伸的粗纱组份及其线密度的变化，调整后的纱线Y的线密度ρ′y为：
进一步，调整所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的速度，调整过程令任一后罗拉的速度为零，而其它三个后罗拉的速度不为零，则实现纱线Y中所述任一后罗拉所牵伸的粗纱组份的不连续，而其它三种粗纱组份连续，调整后的纱线Y的线密度ρ′y为：
(0≤t≤T1)
或者，
或者，
或者，
其中，T1和T2为持续的两个时间点，t为时间变量。
进一步，调整所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的速度，调整过程令任两个后罗拉的速度为零，而其它两个后罗拉的速度不为零，则实现纱线Y中所述任两个后罗拉所牵伸的粗纱组份的不连续，而其它两种粗纱组份
连续，调整后的纱线Y的线密度ρ′y为：
(0≤t≤T1)
其中，T1和T2为持续的两个时间点，t为时间变量；i≠j，且i，j∈(1,2,3,4)。
进一步，调整所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的速度，调整过程令任意三个后罗拉的速度为零，而其它后罗拉的速度不为零，则实现纱线Y中所述任意三个后罗拉所牵伸的粗纱组份的不连续，而其它粗纱组份连续，调整后的纱线Y的线密度ρ′y为：
(0≤t≤T1)
其中，T1和T2为持续的两个时间点，t为时间变量；j∈(1,2,3,4)。
进一步，调整所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的速度，调整过程令其中两个后罗拉的速度先后调整为零，而其它后罗拉的速度不为零，则实现纱线Y中所述两个后罗拉所牵伸的粗纱组份的先后间断，而其它粗纱组份连续，调整后的纱线Y的线密度ρ′y为：
(0≤t≤T1)
其中，T1、T2和T3为三个时间点，t为时间变量；
i≠j≠k，且i，j，k∈(1,2,3,4)。
进一步，调整所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的速度，调整过程令其中三个后罗拉的速度先后调整为零，而其它后罗拉的速度不为零，则实现纱线Y中所述三个后罗拉所牵伸的粗纱组份的先后间断，而其它粗纱组份连续，调整后的纱线Y的线密度ρ′y为：
(0≤t≤T1)
其中，T1、T2、T3和T4为四个时间点，t为时间变量；
i≠j≠k，且i，j，k∈(1,2,3,4)。
进一步，调整所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的速度，同时保持
Vh1*ρ1+Vh2*ρ2+Vh3*ρ3+Vh4*ρ4＝常数，
并令ρ1＝ρ2＝ρ3＝ρ4＝ρ，则实现纱线Y的线密度不变化而其组份的混纺比变化；所述第一粗纱组份和、第二粗纱组份、第三粗纱组份和第四粗纱组份的混纺比k1、k2、k3和k4为：
其中，j∈(1,2,3,4)。
进一步，根据设定混纺比和/或线密度，将所述纱线Y分为n段，每段纱线Y的线密度和混纺比相同，而相邻两段的线密度或混纺比不同；牵伸第i段纱线Y时，第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的线速度分别为Vh1i、Vh2i、Vh3i和Vh4i，其中i∈(1,2，…，n)；所述第一粗纱组份、第二粗纱组份、第三粗纱组份和第四粗纱组份经两级牵伸和加捻形成的第i段纱线Y后，其混纺比k1i、k2i、k3i和k4i可表达如下：
第i段纱线Y的线密度为：
其中，
为二级牵伸比；
(1)设将n段纱线Y中线密度最小的一段定义为基准线段，该段的基准线密度为ρ0，以及该段的第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的基准线速度分别为Vh10、Vh20、Vh30和Vh40；该段的第一粗纱组份、第二粗纱组份、第三粗纱组份和第四粗纱组份的基准混纺比分别为k10、k20、k30和k40，
保持所述中罗拉的线速度恒定，
且Vz＝Vh10+Vh20+Vh30+Vh40 (7)；
同时，令二级牵伸比
恒定；
其中，第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的基准线速度Vh10、Vh20、Vh30和Vh40根据第一粗纱组份、第二粗纱组份、第三粗纱组份和第四粗纱组份的材质、基准线密度ρ0以及基准混纺比k10、k20、k30和k40提前设定；
(2)牵伸混纺第i段纱线Y时，在已知第i段的设定线密度ρyi和设定混纺比k1i、k2i、k3i和k4i前提下，根据公式(2)-(7)计算出所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的线速度Vh1i、Vh2i、Vh3i和Vh4i；
(3)在基准线段的基准线速度Vh10、Vh20、Vh30和Vh40基础上，增减第一后罗拉、第二后罗拉、第三后罗拉和/或第四后罗拉的转速，实现第i段纱线Y的线密度或/和混纺比的在线动态调整。
进一步，设ρ1＝ρ2＝ρ3＝ρ4＝ρ，则公式(6)简化为：
根据公式(2)-(5)和(7)-(8)计算出所述第一后罗拉、第二后罗拉和第三后罗拉的线速度Vh1i、Vh2i、Vh3i和Vh4i；在基准线速度Vh10、Vh20、Vh30和Vh40的基础上，增减第一后罗拉、第二后罗拉、第三后罗拉和/或第四后罗拉的转速实现设定的第i段纱线Y线密度或/和混纺比。
进一步，在纱线Y从第i-1段转换到第i段的瞬间，设纱线Y的线密度在基准线密度的基础上增加动态增量Δρyi，即粗细变化Δρyi；为此所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的线速度分别在基准线速度的基础上发生相应增量，即(Vh10+Vh20+Vh30+Vh40)→(Vh10+ΔVh1i+Vh20+ΔVh2i+Vh30+ΔVh3i+Vh40+ΔVh4i)时，纱线Y线密度的增量为：
则纱线Y的线密度ρyi可表达如下：
令ΔVi＝ΔVh1i+ΔVh2i+ΔVh3i+ΔVh4i，则(9)变为：
通过控制所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的线速度增量之和ΔVi实现纱线Y的线密度变化。
进一步，令ρ1＝ρ2＝ρ3＝ρ4＝ρ，则在纱线Y从第i-1段转换到第i段的瞬间，纱线Y的混纺比，即公式(2)-(5)简化为：
通过控制所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的线速度增量实现纱线Y的混纺比的调整；
其中,
ΔVh1i＝k1i*(Vz+ΔVi)-Vh10
ΔVh2i＝k2i*(Vz+ΔVi)-Vh20
ΔVh3i＝k3i*(Vz+ΔVi)-Vh30
ΔVh4i＝k4i*(Vz+ΔVi)-Vh40。
进一步，令Vh1i*ρ1+Vh2i*ρ2+Vh3i*ρ3+Vh4i*ρ4＝H，H为常数，则ΔVi恒为0，由此，实现所述纱线Y的混纺比调整的同时保证线密度不变。
进一步，令ΔVh1i、ΔVh2i、ΔVh3i和ΔVh4i其中任意一个、两个或三个为零，其他不为零，则实现所述纱线Y中一种、两种或三种粗纱组份的变化，而其他粗纱组份不变化，调整后的混纺比为：
其中，k，j∈(1,2,3,4)，且k≠j。
进一步，令ΔVh1i、ΔVh2i、ΔVh3i和ΔVh4i都不为零，则实现所述纱线Y中四种粗纱组份的变化。
进一步，令Vh1i、Vh2i、Vh3i和Vh4i其中一个、两个或三个为零，而其它不为零，则实现在第i段纱线Y中1-3种粗纱组份的不连续。
进一步，所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉分别所牵伸着黄色、品红色、青色、黑色纱线；保持前罗拉速度Vq恒定，调整第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的速度，则实现纱线的色彩调配；混色时，利用黑色纱线调整色纺纱的色深或饱和度。
在四原色的各种混色模式下，混色比的递增以10％为最小增量，进行配色可形成如下混色：
表1配色方案
在满足K1+K2+K3+K4＝100％条件下，可以有无数种组合，本发明专利选择以0.1为一个梯度进行梯度混色配色，经以上统计，按四原色粗纱(四种色彩粗纱)经耦合牵伸、交变换色、加捻混合，最终可形成248种配色，即可形成具有248种色彩分布的段彩纱。大大丰富了混色种类。黄、品红、青三种基色纱线由于存在材料本身及制作工艺工程中的种种缺陷，由此带来了在用三种基色混色时，无法带来理论上的色彩效果，在色深上与理论色彩存在差异，本发明通过引进黑色，并利用黑色的纱线调节最终纱线的色深，弥补了上述缺陷，进而获得了理想的色彩效果。
一种四组份异同步牵伸调控纱线线密度及混纺比的装置，其包括控制系统和执行机构，执行机构包括四组份分合式异同步二级牵伸机构、加捻机构和卷绕成型机构；所述二级牵伸机构包括一级牵伸单元和二级牵伸单元；所述一级牵伸单元包括组合后罗拉、中罗拉；组合后罗拉具有四个转动自由度，包括同一根后罗拉轴上并排设置的第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉；所述二级牵伸单元包括前罗拉和所述中罗拉。
进一步，所述控制系统主要包括PLC可编程控制器、伺服驱动器、伺服电机等。
进一步，第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉中任一个固定设置在所述后罗拉轴上，其他三个后罗拉彼此独立转动地设置在所述后罗拉轴上。
进一步，所述第三后罗拉固定设置在所述后罗拉轴上，其他三个后罗拉彼此独立转动地设置在所述后罗拉轴上；所述第二后罗拉设置有与所述驱动机构连接的轴套，该轴套套装在所述后罗拉轴上，所述第一后罗拉可转动地套装在该轴套外侧。
进一步，牵伸过程中，所述中罗拉的速度固定且不大于所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的速度之和。
本发明方法将传统的四组份前后区同步牵伸改变为四组份分离式异步牵伸(下称一级异步牵伸)和四组份并合式同步牵伸(下称二级同步牵伸)，通过一级分离式异步牵伸控制四组份混合比例及纱线线密度的动态变化，通过二级并合式同步牵伸控制纱线的基准线密度的大小。通过本发明的四组份分合式异同步二级牵伸再并合加捻成纱的纺纱装置及工艺，可实现随机在线动态调控纺纱线线密度及混纺比的变化，突破原有竹节纱纺制过程中的三大技术瓶颈：①只能调节线密度的变化，不能调节其混纺比变化(或色彩变化)；②竹节纱线花型单一；③竹节花型的再现性差。
四组份分合式异同步二级牵伸同轴加捻纺纱系统工艺参数的计算
根据牵伸理论可得：
一级牵伸的牵伸比：
一级牵伸的当量牵伸比：
二级牵伸的牵伸比：
总当量牵伸比
：
总当量牵伸比
是纺纱中非常重要的参数，它是前区牵伸倍数与后区牵伸倍数的乘积。
根据本发明建立的纺纱模型可知，粗纱ρ1、ρ2、ρ3和ρ4经后区的异步牵伸和前区的同步牵伸后，再汇合加捻形成纱线，其混纺比k1、k2、k3、k4可表达如下：
由式⑻、⑼、⑽、⑾可知，纱线中四个组份的混纺比与后罗拉表面转动速度Vh1、Vh2、Vh3、Vh4以及四根粗纱线密度ρ1、ρ2、ρ3、ρ4相关。一般ρ1、ρ2、ρ3、ρ4值是常量与时间无关，而Vh1、Vh2、Vh3、Vh4与纺纱机设定的主轴速度有关，由于主轴速度关系到纺纱机产量，在不同的企业、纺制不同的原料及产品规格时会使用不同的主轴转速。这样，由式⑻、⑼、⑽、⑾确定的混纺比，即使粗纱ρ1、ρ2、ρ3、ρ4值不变，也会由于主轴速度的变化而导致Vh1、Vh2、Vh3、Vh4发生变化。由此导致混纺比的不确定性。
同理可得，四根粗纱须条经两级牵伸再汇合加捻后形成的纱线Y线密度为:
故纱线线密度为：
由式⑿可知，纱线的线密度与后罗拉的运动速度Vh1、Vh2、Vh3、Vh4以及四根粗纱线密度ρ1、ρ2、ρ3、ρ4相关。一般ρ1、ρ2、ρ3、ρ4值是常量与时间无关，而Vh1、Vh2、Vh3、Vh4则随纺纱机设定的主轴速度有关，由于主轴速度关系到纺纱机产量，在不同的企业、纺制不同的原料及产品规格时会使用不同的主轴转速。这样，由式⑻确定的线密度，即使粗纱ρ1、ρ2、ρ3、ρ4值不变，也会由于主轴速度的变化而导致Vh1、Vh2、Vh3、Vh4发生变化。由此导致线密度的不确定性。
由式⑴得： 
由式⑵得： 
由式⑶得： 
由式⑷得： 
∴ 
将式⑾代入式⑸得后区的当量牵伸倍数
将式⒁代入式⑺得总的当量牵伸倍数
为了去除主轴速度不同导致的参数变化，设以下限定条件：
ρ1＝ρ2＝ρ3＝ρ4＝ρ ⒃
将式⑿代入式⑼得：
将式⑿⒀代入式⑽得：
将式(14)代入式⑸得：
将式⒄⒅⒆代入式⑻⑼⑽⑾得：
由式⒄⒅可以看出，混纺比的变化完全取决于(Vh1+ΔVh1)、(Vh2+ΔVh2)、(Vh3+ΔVh3)、(Vh4+ΔVh4)的变化，也是由四个后罗拉速度变化决定的。
设ΔVh1+ΔVh2+ΔVh3+ΔVh4＝0，则上式又可以简化为：
特殊情况下，我们也可以设Vh1+Vh2+Vh3+Vh4＝Vz，即四个后罗拉的速度之和等于中罗拉的线速度，这样上面四个式子：又可以简化为：
即四组份ρ1、ρ2、ρ3和ρ4在纱线中的混纺比，等于它们在一级牵伸区中各自牵伸倍数的倒数。
例如：假定k1＝0，0.1，0.2，0.3，0.4，0.5，0.6，0.7，0.8，0.9，1
k2＝0.7，0.6，0.5，0.4，0,3，0,2，0.1，0，0.1，0.1，0
k3＝0.2，0.2，0.2，0.2，0.2，0.2，0.2，0,2，0.1，0，0
k3＝0.1，0.1，0.1，0.1，0.1，0.1，0.1，0,1，0，0，0
则可求得对应的eh1、eh2、eh3和eh4，如下表：
表2.混纺比与第一级牵伸比的关系
| k1 | 0 | 0.1 | 0.2 | 0.3 | 0.4 | 0.5 | 0.6 | 0.7 | 0.8 | 0.9 | 1 |
| eh1 | ╳ | 10 | 5 | 10/3 | 10/4 | 10/5 | 10/6 | 10/7 | 10/8 | 10/9 | 1 |
| k2 | 0.7 | 0.6 | 0.5 | 0.4 | 0.3 | 0.2 | 0.1 | 0 | 0.1 | 0.1 | 0 |
| eh2 | 10/7 | 10/6 | 10/5 | 10/4 | 10/3 | 5 | 10 | ╳ | 10 | 10 | ╳ |
| k3 | 0.2 | 0.2 | 0.2 | 0.2 | 0.2 | 0.2 | 0.2 | 0.2 | 0.1 | 0 | 0 |
| eh3 | 10/2 | 10/2 | 10/2 | 10/2 | 10/2 | 10/2 | 10/2 | 10/2 | 10 | ╳ | ╳ |
| k4 | 0.1 | 0.1 | 0.1 | 0.1 | 0.1 | 0.1 | 0.1 | 0.1 | 0 | 0 | 0 |
| eh4 | 10 | 10 | 10 | 10 | 10 | 10 | 10 | 10 | ╳ | ╳ | ╳ |
图1为二级牵伸纺纱装置的原理示意图；
图2为组合后罗拉结构示意图；
图3为二级牵伸纺纱装置的结构侧视图；
图4为实施例中二级牵伸中纱线的行进路径图；
图5为控制系统结构示意图。
下面结合附图对本发明的具体实施方式进行说明。
实施例1
如图1-5所示，一种四组份异步牵伸动态配置线密度和混纺比的方法具体包括：
1)如图1-4所示，牵伸和加捻系统包括前后设置的一级牵伸单元和二级牵伸单元；
2)一级牵伸单元包括组合后罗拉、中罗拉3；组合后罗拉具有四个转动自由度，包括同一根后罗拉轴上并排设置的第一后罗拉6、第二后罗拉8、第三后罗拉10和第四后罗拉12；二级牵伸单元包括前罗拉1和中罗拉3。4为中罗拉3对应的上皮辊，5、7、9、11为与四个后罗拉对应的四个上皮辊。2为与前罗拉1相对应的上皮辊。O1O′1、O2O′2、O3O′3分别代表后罗拉、中罗拉、前罗拉的轴心线。中罗拉与后罗拉构成一级牵伸，前罗拉与中罗拉构成二级牵伸。15为卷绕成型机构，14为导辊，16为纱线Y。
如图2所示，具有四重嵌套的4自由度组合后罗拉，6、8、10和12四个活动后罗拉活套在同一心轴上，并分别由皮带轮20、24、30、32驱动。第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉分别以速度Vh1、Vh2、Vh3和Vh4运动；中罗拉以速度Vz的速度转动；二级同步牵伸单元包括前罗拉和中罗拉；前罗拉以表面线速度Vq转动；设第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉所牵伸的第一粗纱组份、第二粗纱组份、第三粗纱组份和第四粗纱组份的线密度分别为ρ1、ρ2、ρ3和ρ4，前罗拉牵伸加捻后得到的纱线Y的线密度为ρy。
四个同轴同外径的后罗拉分别与四个同轴同外径的后上皮辊对应，后区四对平行排列、上下对应的上下皮圈分别握持四根粗纱。纺纱时，四根粗纱须条在牵伸和加捻过程中，用导纱杆和喇叭口定位，使其按照图4所示路径行走。四根粗纱ρ1、ρ2、ρ3、ρ4由后罗拉钳口a1、a2、a3、a4以不同的速度喂入一级牵伸区，平行运动至中罗拉握持点b1、b2、b3、b4并以速度Vz引出，三根须条分别受到异步牵伸后须条线密度分别为ρ1'、ρ2'、ρ3'和ρ4'，然后进入二级牵伸区并交汇于前罗拉握持点c，在前罗拉表面速度Vq的同步牵伸作用下三根须条的线密度变为ρ1″、ρ1″、ρ3″和ρ4″，四根须条汇合于前罗拉钳口c处后再同轴加捻形成纱线Y。
3)二级牵伸单元包括前罗拉和所述中罗拉；前罗拉以速度Vq运动；
4)保持前罗拉速度Vq和中罗拉速度Vz恒定，仅仅调整第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的速度，同时实现纱线线密度或/和混纺比的调整。
具体调整线密度的方法为：
设第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉所牵伸的第一粗纱组份、第二粗纱组份、第三粗纱组份和第四粗纱组份的线密度分别为ρ1、ρ2、ρ3和ρ4，前罗拉牵伸加捻后得到的纱线Y的线密度为ρy，
1)改变第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉中的任一后罗拉的速度，其它三个后罗拉速度不变，则实现纱线Y中所述任一后罗拉的所牵伸的粗纱组份及其线密度的变化，调整后的纱线Y的线密度ρ′y为：
或 
或 
或 
其中，Δρy为纱线Y的线密度变化量，ΔVh1、ΔVh2、ΔVh3和ΔVh4为第一、二、三和四后罗拉的速度变化量；
2)改变第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉中的任意两个后罗拉的速度，其它两个后罗拉速度不变，则实现纱线Y中所述任意两个后罗拉的所牵伸的粗纱组份及其线密度的变化，调整后的纱线Y的线密度ρ′y为：
或 
或 
或 
或 
或 
3)同时改变第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉中的任意三个后罗拉的速度，剩余的后罗拉速度不变，则实现纱线Y中三个后罗拉的所牵伸的粗纱组份及其线密度的变化，调整后的纱线Y的线密度ρ′y为：
或 
或 
或 
4)同时改变第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的速度，且四个后罗拉的速度之和不为零，则实现纱线Y中四个后罗拉的所牵伸的粗纱组份及其线密度的变化，调整后的纱线Y的线密度ρ′y为：
5)调整所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的速度，调整过程令任一后罗拉的速度为零，而其它三个后罗拉的速度不为零，则实现纱线Y中所述任一后罗拉所牵伸的粗纱组份的不连续，而其它三种粗纱组份连续，调整后的纱线Y的线密度ρ′y为：
或者，
或者，
或者，
其中，T1和T2为持续的两个时间点，t为时间变量。
6)调整所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的速度，调整过程令任两个后罗拉的速度为零，而其它两个后罗拉的速度不为零，则实现纱线Y中两个后罗拉所牵伸的粗纱组份的不连续，而其它两种粗纱组份连续，调整后的纱线Y的线密度ρ′y为：
其中，T1和T2为持续的两个时间点，t为时间变量；i≠j，且i，j∈(1,2,3,4)。
7)调整所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的速度，调整过程令任意三个后罗拉的速度为零，而其它后罗拉的速度不为零，则实现纱线Y中任意三个后罗拉所牵伸的粗纱组份的不连续，而其它粗纱组份连续，调整后的纱线Y的线密度ρ′y为：
(0≤t≤T1)
其中，T1和T2为持续的两个时间点，t为时间变量；j∈(1,2,3,4)。
8)调整所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的速度，调整过程令其中两个后罗拉的速度先后调整为零，而其它后罗拉的速度不为零，则实现纱线Y中两后罗拉所牵伸的粗纱组份的先后间断，而其它粗纱组份连续，调整后的纱线Y的线密度ρ′y为：
(0≤t≤T1)
其中，T1、T2和T3为三个时间点，t为时间变量；
i≠j≠k，且i，j，k∈(1,2,3,4)。
9)调整所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的速度，调整过程令其中三个后罗拉的速度先后调整为零，而其它后罗拉的速度不为零，则实现纱线Y中三个后罗拉所牵伸的粗纱组份的先后间断，而其它粗纱组份连续，调整后的纱线Y的线密度ρ′y为：
(0≤t≤T1)
其中，T1、T2、T3和T4为四个时间点，t为时间变量；
i≠j≠k，且i，j，k∈(1,2,3,4)。
具体调整混纺比的方法为：
调整所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的速度，同时保持
Vh1*ρ1+Vh2*ρ2+Vh3*ρ3+Vh4*ρ4＝常数，
并令ρ1＝ρ2＝ρ3＝ρ4＝ρ，则实现纱线Y的线密度不变化而其组份的混纺比变化；所述第一粗纱组份和、第二粗纱组份、第三粗纱组份和第四粗纱组份的混纺比k1、k2、k3和k4为：
其中，j∈(1,2,3,4)。
令ρ1＝ρ2＝ρ3＝ρ4＝ρ，同时调整所述第一后罗拉、第二后罗拉、第三后罗拉及第四后罗拉的速度使得Vh1+Vh2+Vh3+Vh4＝Vz，即四个后罗拉的速度之和等于中罗拉的线速度，由此可得：
即四组份ρ1、ρ2、ρ3和ρ4在纱线中的混纺比，等于它们在一级牵伸区中各自牵伸倍数的倒数：
其中，集合器设置在组合后罗拉和所述中罗拉之间，所述中罗拉保持速度不变，则所述一级牵伸单位形成混纺或混色单元，所述二级牵伸单元构成单纯的线密度调整单元。所述中罗拉的速度Vz＝Vh1+Vh2+Vh3+Vh4。
通过控制后中罗拉的运行速度，而不考虑后面线密度调整工艺，从而切实保障了纱线混纺更加均匀和彻底，避免了线密度调整工艺对混纺工艺的影响。另外，通过将后中罗拉的速度控制在Vh1+Vh2+Vh3+Vh4以下，有效保证了混纺更加均匀。
实施例2
本实施例方法与实施例1基本相同，不同之处在于：
第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉分别所牵伸着黄色、品红色、青色、黑色纱线；保持前罗拉速度Vq恒定，调整第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的速度，则实现纱线的色彩调配；混色时，利用黑色纱线调整色纺纱的色深。
黄色、品红色、青色、黑色纱线的线密度分别为ρ1、ρ2、ρ3和ρ4；调整第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的速度过程中，始终保证Vh1×ρ1+Vh2×ρ2+Vh3×ρ3+Vh4×ρ4＝常量，
或者
则可以保证混色后的纱线线密度始终保持不变。
其中，Ei＝Vq/Vhi为前罗拉相对于第i后罗拉环圈的牵伸倍数，i＝1、2、3。
本发明通过改变所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的速度，实现所述黄色、品红色、青色、黑色纱线混纺比或混色比的调整，四种基色纱线的混纺比分别如下：
令ρ1＝ρ2＝ρ3＝ρ4，第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的速度和恒定，即Vh1+Vh2+Vh3+Vh4保持恒定的条件下，通过改变Vh1、Vh2、Vh3、Vh4改变纱线内不同基色纱线的混纺比或混色比，四种基色纱线的混纺比分别如下：
由此可以大大简化混色时计算量，提高了效率，并且混色更加精准。
实施例3
本实施例方法与实施例1基本相同，不同之处在于：
1)根据设定混纺比和/或线密度，将所述纱线Y分为n段，每段纱线Y的线密度和混纺比相同，而相邻两段的线密度或混纺比不同；牵伸第i段纱线Y时，第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的线速度分别为Vh1i、Vh2i、Vh3i和Vh4i，其中i∈(1，2，…，n)；所述第一粗纱组份、第二粗纱组份、第三粗纱组份和第四粗纱组份经两级牵伸和加捻形成的第i段纱线Y后，其混纺比k1i、k2i、k3i和k4i可表达如下：
第i段纱线Y的线密度为：
其中，
为二级牵伸比；
2)设将n段纱线Y中线密度最小的一段定义为基准线段，该段的基准线密度为ρ0，以及该段的第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的基准线速度分别为Vh10、Vh20、Vh30和Vh40；该段的第一粗纱组份、第二粗纱组份、第三粗纱组份和第四粗纱组份的基准混纺比分别为k10、k20、k30和k40，
保持所述中罗拉的线速度恒定，
且Vz＝Vh10+Vh20+Vh30+Vh40 (7)；
同时，令二级牵伸比
恒定；
其中，第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的基准线速度Vh10、Vh20、Vh30和Vh40根据第一粗纱组份、第二粗纱组份、第三粗纱组份和第四粗纱组份的材质、基准线密度ρ0以及基准混纺比k10、k20、k30和k40提前设定；
3)牵伸混纺第i段纱线Y时，在已知第i段的设定线密度ρyi和设定混纺比k1i、k2i、k3i和k4i前提下，根据公式(2)-(7)计算出所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的线速度Vh1i、Vh2i、Vh3i和Vh4i；
4)在基准线段的基准线速度Vh10、Vh20、Vh30和Vh40基础上，增减第一后罗拉、第二后罗拉、第三后罗拉和/或第四后罗拉的转速，实现第i段纱线Y的线密度或/和混纺比的在线动态调整。
5)设ρ1＝ρ2＝ρ3＝ρ4＝ρ，则公式(6)简化为：
根据公式(2)-(5)和(7)-(8)计算出所述第一后罗拉、第二后罗拉和第三后罗拉的线速度Vh1i、Vh2i、Vh3i和Vh4i；在基准线速度Vh10、Vh20、Vh30和Vh40的基础上，增减第一后罗拉、第二后罗拉、第三后罗拉和/或第四后罗拉的转速实现设定的第i段纱线Y线密度或/和混纺比。
6)在纱线Y从第i-1段转换到第i段的瞬间，设纱线Y的线密度在基准线密度的基础上增加动态增量Δρyi，即粗细变化Δρyi；为此所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的线速度分别在基准线速度的基础上发生相应增量，即(Vh10+Vh20+Vh30+Vh40)→(Vh10+ΔVh1i+Vh20+ΔVh2i+Vh30+ΔVh3i+Vh40+ΔVh4i)时，纱线Y线密度的增量为：
则纱线Y的线密度ρyi可表达如下：
令ΔVi＝ΔVh1i+ΔVh2i+ΔVh3i+ΔVh4i，则(9)变为：
通过控制所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的线速度增量之和ΔVi实现纱线Y的线密度变化。
7)令ρ1＝ρ2＝ρ3＝ρ4＝ρ，则在纱线Y从第i-1段转换到第i段的瞬间，纱线Y的混纺比，即公式(2)-(5)简化为：
通过控制所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的线速度增量实现纱线Y的混纺比的调整；
其中，
ΔVh1i＝k1i*(Vz+ΔVi)-Vh10
ΔVh2i＝k2i*(Vz+ΔVi)-Vh20
ΔVh3i＝k3i*(Vz+ΔVi)-Vh30
ΔVh4i＝k4i*(Vz+ΔVi)-Vh40
8)令Vh1i*ρ1+Vh2i*ρ2+Vh3i*ρ3+Vh4i*ρ4＝H，H为常数，则ΔVi恒为0，由此，实现所述纱线Y的混纺比调整的同时保证线密度不变。
9)令ΔVh1i、ΔVh2i、ΔVh3i和ΔVh4i其中任意一个、两个或三个为零，其他不为零，则实现所述纱线Y中一种、两种或三种粗纱组份的变化，而其他粗纱组份不变化，调整后的混纺比为：
其中，k，j∈(1，2，3，4)，且k≠j。
10)令ΔVh1i、ΔVh2i、ΔVh3i和ΔVh4i都不为零，则实现所述纱线Y中四种粗纱组份的变化。
11)令Vh1i、Vh2i、Vh3i和Vh4i其中一个、两个或三个为零，而其它不为零，则实现在第i段纱线Y中1-3种粗纱组份的不连续。
实施例4
本实施例四组份异步牵伸动态配置线密度和混纺比的方法与实施例3基本相同，不同之处在于：
设定第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的初始线速度分别为Vh10、Vh20、Vh30和Vh40；所述中罗拉的初始线速度Vz0＝Vh10+Vh20+Vh30+Vh40；
另外，设定
Vzi＝Vh1(i-1)+Vh2(i-1)+Vh3(i-1)+Vh4(i-1)；
同时，令二级牵伸比
恒定为设定值eq；
牵伸混纺第i段纱线Y时，将第i-1段的纱线Y的线密度和混纺比分别作为第i段的基准线密度和基准混纺比，在已知第i段的设定线密度ρyi和设定混纺比k1i、k2i、k3i和k4i前提下，计算出第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的线速度Vh1i、Vh2i、Vh3i和Vh4i；
在第i-1段的基础上，调整第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的转速，实现第i段纱线Y的线密度或/和混纺比的在线动态调整。
本方法通过将Vzi＝Vh1(i-1)+Vh2(i-1)+Vh3(i-1)+Vh4(i-1)以及二级牵伸比恒定，从而使得中罗拉和前罗拉不断随着后组合罗拉的速度进行调整，避免了由于后组合罗拉调整过大，而中罗拉及前罗拉速度未及时调整导致纱线牵引比大幅度变化，以及有效控制断纱的发生。
另外，利用计算机或其他智能控制单元随时记录各个罗拉的运行速度，在已知现有后罗拉速度时，能够自动推算出下一步的中罗拉和前罗拉的速度，利用上述公式及模型快速计算出组合后罗拉的速度增减量，进而实现设定的混纺比和线密度调整，由此更加简单、准确。
实施例5
一种四组份异同步牵伸纺制多彩竹节纱的装置包括控制系统和执行机构，执行机构包括四组份分合式异同步二级牵伸机构、加捻机构和卷绕成型机构；二级牵伸机构包括一级牵伸单元和二级牵伸单元；
如图1和2所示，一级牵伸单元包括组合后罗拉15、中罗拉3；组合后罗拉15具有四个转动自由度，包括同一根后罗拉轴21上并排设置的第一后罗拉6、第二后罗拉8、第三后罗拉10和第四后罗拉12；二级牵伸单元包括前罗拉1和中罗拉3。4为中罗拉3对应的上皮辊，5、7、9、11为与四个后罗拉对应的四个上皮辊。2为与前罗拉1相对应的上皮辊。23、26和27为轴承。
如图2所示，具有四重嵌套的4自由度组合后罗拉，6、8、10和12四个活动后罗拉活套在同一心轴21上，并分别由皮带轮30、32、20、24驱动。四个后罗拉依次相邻设置，其驱动机构皮带轮30、32、20、24设置在四个后罗拉的两侧。
如图5所示，控制系统主要包括PLC可编程控制器、伺服驱动器、伺服电机等。可编程控制器通过伺服驱动器控制电机带动罗拉、纲领板、锭子等工作。
通过将四个后罗拉并排设置在一根轴上，并且其驱动装置设置在两侧，其机械结构更加紧凑，并且使得四个后罗拉所牵伸的四种粗纱线在混纺时更加贴近，可以有效防止驱动设置在工作时对纱线的干扰和污染，并且四种基色纱线通过喇叭口时，夹持角度更小，有利于纱线的混合更加均匀。
表2.异步牵伸与同步牵伸纺纱参数对比(以纺18.45tex棉纱为例)
以上结合附图仅描述了本申请的几个优选实施例，但本申请不限于此，凡是本领域普通技术人员在不脱离本申请的精神下，做出的任何改进和/或变形，均属于本申请的保护范围。
Claims (21)
- 一种四组份异步牵伸动态配置线密度和混纺比的方法，其特征在于，具体包括：1)执行机构主要包括四组份分合式异同步二级牵伸机构、加捻机构和卷绕成型机构，所述四组份分合式异同步二级牵伸机构包括前后设置的一级牵伸单元、二级牵伸单元；2)所述一级牵伸单元包括组合后罗拉、中罗拉；组合后罗拉具有四个转动自由度，其包括同一根后罗拉轴上并排设置的第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉；第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉分别以速度Vh1、Vh2、Vh3和Vh4运动；中罗拉以速度Vz的速度转动；所述二级同步牵伸单元包括前罗拉和所述中罗拉；前罗拉以表面线速度Vq转动；设第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉所牵伸的第一粗纱组份、第二粗纱组份、第三粗纱组份和第四粗纱组份的线密度分别为ρ1、ρ2、ρ3和ρ4，前罗拉牵伸加捻后得到的纱线Y的线密度为ρy，
第一粗纱组份、第二粗纱组份、第三粗纱组份和第四粗纱组份的混纺比k1、k2、k3和k4表达如下：
3)保持前罗拉和中罗拉线速度之比Vq/Vz恒定，前罗拉和中罗拉线的速度大小取决于纱线的基准线密度；4)通过调整第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的转速，实现纱线Y线密度或/和混纺比的在线动态调整。 - 如权利要求1所述方法，其特征在于，通过已知设定所述纱线Y混纺比K随时间t的变化规律，以及已知纱线Y线密度ρy随时间t的变化规律,推导出所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉表面线速度变化规律；设定第一粗纱组份、第二粗纱组份、第三粗纱组份和第四粗纱组份的混纺比k1、k2、k3和k4，则纱线Y的混纺比之比K1、K2和K3如下：
纱线Y线密度
则得到后罗拉1表面线速度：
后罗拉2表面线速度：
后罗拉3表面线速度：
后罗拉4表面线速度：
其中，ρ1、ρ2、ρ3、ρ4、Vq为常数，Ki和ρy都是随时间t变化的函数。 - 如权利要求1所述方法，其特征在于，令ρ1＝ρ2＝ρ3＝ρ4＝ρ，则：1)改变第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉中的任一后罗拉的速度，其它三个后罗拉速度不变，则实现纱线Y中所述任一后罗拉的所牵伸的粗纱组份及其线密度的变化，调整后的纱线Y的线密度ρ′y为：
或
或
或
其中，Δρy为纱线Y的线密度变化量，ΔVh1、ΔVh2、ΔVh3和ΔVh4为第一、二、三和四后罗拉的速度变化量；2)改变第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉中的任意两个后罗拉的速度，其它两个后罗拉速度不变，则实现纱线Y中所述任意两个后罗拉的所牵伸的粗纱组份及其线密度的变化，调整后的纱线Y的线密度ρ′y为：
或
或
或
或
或
3)同时改变第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉中的任意三个后罗拉的速度，剩余的后罗拉速度不变，则实现纱线Y中三个后罗拉的所牵伸的粗纱组份及其线密度的变化，调整后的纱线Y的线密度ρ′y为：
或
或
或
4)同时改变第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的速度，且四个后罗拉的速度之和不为零，则实现纱线Y中四个后罗拉的所牵伸的粗纱组份及其线密度的变化，调整后的纱线Y的线密度ρ′y为：
- 如权利要求3所述方法，其特征在于，调整所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的速度，调整过程令任一后罗拉的速度为零，而其它三个后罗拉的速度不为零，则实现纱线Y中所述任一后罗拉所牵伸的粗纱组份的不连续，而其它三种粗纱组份连续，调整后的纱线Y的线密度ρ′y为：
或者，
或者，
或者，
其中，T1和T2为持续的两个时间点，t为时间变量。 - 如权利要求3所述方法，其特征在于，调整所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的速度，调整过程令任两个后罗拉的速度为零，而其它两个后罗拉的速度不为零，则实现纱线Y中所述任两个后罗拉所牵伸的粗纱组份的不连续，而其它两种粗纱组份连续，调整后的纱线Y的线密度ρ′y为：
其中，T1和T2为持续的两个时间点，t为时间变量；i≠j，且i，j∈(1,2,3,4)。 - 如权利要求3所述方法，其特征在于，调整所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的速度，调整过程令任意三个后罗拉的速度为零，而其它后罗拉的速度不为零，则实现纱线Y中所述任意三个后罗拉所牵伸的粗纱组份的不连续，而其它粗纱组份连续，调整后的纱线Y的线密度ρ′y为：
其中，T1和T2为持续的两个时间点，t为时间变量；j∈(1,2,3,4)。 - 如权利要求3所述方法，其特征在于，调整所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的速度，调整过程令其中两个后罗拉的速度先后调整为零，而其它后罗拉的速度不为零，则实现纱线Y中所述两个后罗拉所牵伸的粗纱组份的先后间断，而其它粗纱组份连续，调整后的纱线Y的线密度ρ′y为：
其中，T1、T2和T3为三个时间点，t为时间变量；i≠j≠k，且i，j，k∈(1,2,3,4)。 - 如权利要求3所述方法，其特征在于，调整所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的速度，调整过程令其中三个后罗拉的速度先后调整为零，而其它后罗拉的速度不为零，则实现纱线Y中所述三个后罗拉所牵伸的粗纱组份的先后间断，而其它粗纱组份连续，调整后的纱线Y的线密度ρ′y为：
其中，T1、T2、T3和T4为四个时间点，t为时间变量；i≠j≠k，且i，j，k∈(1,2,3,4)。 - 如权利要求3所述方法，其特征在于，调整所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的速度，同时保持Vh1*ρ1+Vh2*ρ2+Vh3*ρ3+Vh4*ρ4＝常数，并令ρ1＝ρ2＝ρ3＝ρ4＝ρ，则实现纱线Y的线密度不变化而其组份的混纺比变化；所述第一粗纱组份和、第二粗纱组份、第三粗纱组份和第四粗纱组份的混纺比k1、k2、k3和k4为：
其中，j∈(1,2,3,4)。 - 如权利要求1所述方法，其特征在于，根据设定纱线Y的混纺比和/或线密度，将所述纱线Y分为n段，每段纱线Y的线密度和混纺比相同，而相邻两段的线密度或混纺比不同；牵伸第i段纱线Y时，第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的线速度分别为Vh1i、Vh2i、Vh3i和Vh4i，其中i∈(1,2，…，n)；所述第一粗纱组份、第二粗纱组份、第三粗纱组份和第四粗纱组份经两级牵伸和加捻形成的第i段纱线Y后，其混纺比k1i、k2i、k3i和k4i可表达如下：
第i段纱线Y的线密度为：
其中，为二级牵伸比；
(1)设将n段纱线Y中线密度最小的一段定义为基准线段，该段的基准线密度为ρ0，以及该段的第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的基准线速度分别为Vh10、Vh20、Vh30和Vh40；该段的第一粗纱组份、第二粗纱组份、第三粗纱组份和第四粗纱组份的基准混纺比分别为k10、k20、k30和k40，保持所述中罗拉的线速度恒定，且Vz＝Vh10+Vh20+Vh30+Vh40 (7)；同时，令二级牵伸比恒定；
其中，第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的基准线速度Vh10、Vh20、Vh30和Vh40根据第一粗纱组份、第二粗纱组份、第三粗纱组份和第四粗纱组份的材质、基准线密度ρ0以及基准混纺比k10、k20、k30和k40提前设定；(2)牵伸混纺第i段纱线Y时，在已知第i段的设定线密度ρyi和设定混纺比k1i、k2i、k3i和k4i前提下，根据公式(2)-(7)计算出所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的线速度Vh1i、Vh2i、Vh3i和Vh4i；(3)在基准线段的基准线速度Vh10、Vh20、Vh30和Vh40基础上，增减第一后罗拉、第二后罗拉、第三后罗拉和/或第四 后罗拉的转速，实现第i段纱线Y的线密度或/和混纺比的在线动态调整。 - 如权利要求10所述方法，其特征在于，设ρ1＝ρ2＝ρ3＝ρ4＝ρ，则公式(6)简化为：
根据公式(2)-(5)和(7)-(8)计算出所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的线速度Vh1i、Vh2i、Vh3i和Vh4i；在基准线速度Vh10、Vh20、Vh30和Vh40的基础上，增减第一后罗拉、第二后罗拉、第三后罗拉和/或第四后罗拉的转速实现设定的第i段纱线Y线密度或/和混纺比。 - 如权利要求10所述方法，其特征在于，在纱线Y从第i-1段转换到第i段的瞬间，设纱线Y的线密度在基准线密度的基础上增加动态增量△ρyi，即粗细变化△ρyi；为此所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的线速度分别在基准线速度的基础上发生相应增量，即(Vh10+Vh20+Vh30+Vh40)→(Vh10+ΔVh1i+Vh20+ΔVh2i+Vh30+ΔVh3i+Vh40+ΔVh4i)时，纱线Y线密度的增量为：
则纱线Y的线密度ρyi可表达如下：
令ΔVi＝ΔVh1i+ΔVh2i+ΔVh3i+ΔVh4i，则(9)变为：
通过控制所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的线速度增量之和ΔVi实现纱线Y的线密度变化。 - 如权利要求12所述方法，其特征在于，令ρ1＝ρ2＝ρ3＝ρ4＝ρ，则在纱线Y从第i-1段转换到第i段的瞬间，纱线Y的混纺比，即公式(2)-(5)简化为：
通过控制所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的线速度增量实现纱线Y的混纺比的调整；其中,ΔVh1i＝k1i*(Vz+ΔVi)-Vh10ΔVh2i＝k2i*(Vz+ΔVi)-Vh20ΔVh3i＝k3i*(Vz+ΔVi)-Vh30ΔVh4i＝k4i*(Vz+ΔVi)-Vh40 - 如权利要求12所述方法，其特征在于，令Vh1i*ρ1+Vh2i*ρ2+Vh3i*ρ3+Vh4i*ρ4＝H，H为常数，则ΔVi恒为0，由此，实现所述纱线Y的混纺比调整的同时保证线密度不变。
- 如权利要求12所述方法，其特征在于，令ΔVh1i、ΔVh2i、ΔVh3i和ΔVh4i其中任意一个、两个或三个为零，其他不为零，则实现所述纱线Y中一种、两种或三种粗纱组份的变化，而其他粗纱组份不变化，调整后的混纺比为：
其中，k，j∈(1,2,3,4)，且k≠j。 - 如权利要求12所述方法，其特征在于，令ΔVh1i、ΔVh2i、ΔVh3i和ΔVh4i都不为零，则实现所述纱线Y中四种粗纱组份的变化。
- 如权利要求12所述方法，其特征在于，令Vh1i、Vh2i、Vh3i和Vh4i其中一个、两个或三个为零，而其它不为零，则实现在第i段纱线Y中1-3种粗纱组份的不连续。
- 如权利要求1所述方法，其特征在于，所述第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉分别所牵伸着黄色、品红色、青色、黑色纱线；保持前罗拉速度Vq恒定，调整第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉的速度，则实现纱线的色彩调配；混色时，利用黑色纱线调整色纺纱的色深或饱和度。
- 实施权利要求1-18任一所述方法的一种四组份异同步牵伸调控纱线线密度及混纺比的装置，其特征在于，其包括控制系统和执行机构，执行机构包括四组份分合式异同步二级牵伸机构、加捻机构和卷绕成型机构；所述二级牵伸机构包括一级牵伸单元和二级牵伸单元；所述一级牵伸单元包括组合后罗拉、中罗拉；组合后罗拉具有四个转动自由度，包括同一根后罗拉轴上并排设置的第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉；所述二级牵伸单元包括前罗拉和所述中罗拉。
- 如权利要求19所述装置，其特征在于，第一后罗拉、第二后罗拉、第三后罗拉和第四后罗拉中任一个固定设置在所述后罗拉轴上，其他三个后罗拉彼此独立转动地设置在所述后罗拉轴上。
- 如权利要求20所述装置，其特征在于，所述第三后罗拉固定设置在所述后罗拉轴上，其他三个后罗拉彼此独立转动地设置在所述后罗拉轴上；所述第二后罗拉设置有与所述驱动机构连接的轴套，该轴套套装在所述后罗拉轴上，所述第一后罗拉可转动地套装在该轴套外侧。
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| US10316434B2 (en) * | 2015-03-27 | 2019-06-11 | Jiangnan University | Method and device of dynamically configuring linear density and blending ratio of yarn by five-ingredient asynchronous/synchronous drafting |
| US10316436B2 (en) * | 2015-03-27 | 2019-06-11 | Jiangnan University | Method and device of dynamically configuring linear density and blending ratio of yarn by three-ingredient asynchronous/synchronous drafted |
| WO2016155164A1 (zh) * | 2015-03-27 | 2016-10-06 | 江南大学 | 双组份异步牵伸动态配置纱线线密度和混纺比的方法及装置 |
| IT201800010209A1 (it) * | 2018-11-09 | 2020-05-09 | Savio Macch Tessili Spa | Apparato e metodo di stiro per macchine di filatura ad aria con alimentazioni multiple |
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