WO2016155164A1 - 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 - Google Patents
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 Download PDFInfo
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- WO2016155164A1 WO2016155164A1 PCT/CN2015/085266 CN2015085266W WO2016155164A1 WO 2016155164 A1 WO2016155164 A1 WO 2016155164A1 CN 2015085266 W CN2015085266 W CN 2015085266W WO 2016155164 A1 WO2016155164 A1 WO 2016155164A1
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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
- D01H5/44—Adjusting drafting elements, e.g. altering ratch
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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
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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
- D01H5/82—Arrangements for coupling roller sections
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- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
- D02G3/34—Yarns or threads having slubs, knops, spirals, loops, tufts, or other irregular or decorative effects, i.e. effect yarns
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- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
- D02G3/34—Yarns or threads having slubs, knops, spirals, loops, tufts, or other irregular or decorative effects, i.e. effect yarns
- D02G3/346—Yarns or threads having slubs, knops, spirals, loops, tufts, or other irregular or decorative effects, i.e. effect yarns with coloured effects, i.e. by differential dyeing process
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 two-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 spun the roving into a fine sand in a spinning process to obtain a linear density and A yarn that does not change in blending ratio.
- 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 one cannot achieve two or more fibers at any ratio in one step. Blend.
- the object of the present invention is to provide a two-component hetero-synchronous secondary draft fiber strand, and then combine and twist 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 two-component asynchronous drafting includes:
- the actuator mainly comprises a two-component split-type hetero-synchronous secondary drafting mechanism, a twisting mechanism and a winding forming mechanism, and the two-component split-type asynchronous secondary drafting mechanism comprises 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 comprises a first rear roller and a second rear roller arranged side by side on the same rear roller shaft; the first rear roller and the second rear roller respectively Rotating at line speeds V h1 and V h2 ; the middle roller is rotated at a linear velocity V z ; the secondary draft unit includes a front roller and the middle roller; the front roller is rotated at a linear velocity V q ; the first rear roller is The linear density of the first roving component and the second roving component drawn by the second rear roller are ⁇ 1 and ⁇ 2 , respectively, and the linear density of the yarn Y obtained by combining the front roller output and the twisting is ⁇ y , then:
- the blending ratio of the first roving component and the second roving component in the yarn Y is k 1 , k 2 , respectively, and the blending ratio of the yarn Y is K,
- the surface speed of the first back roller is V h1 :
- first roving component and the second roving component drawn by the first rear roller and the second rear roller are respectively any two of magenta, yellow, cyan, and black fibers.
- ⁇ V h1 is the speed change amount of the first rear roller
- ⁇ V h2 is the speed change amount of the second rear roller
- the linear velocity increments ⁇ V h1 and ⁇ V h2 of the first rear roller and the second rear roller are determined from the set linear density and the blending ratio, so that the linear density of the spun yarn and the blending ratio reach a predetermined index.
- V z is the middle roller speed
- ⁇ is the coarse yarn density
- ⁇ y is the linear density change of the yarn Y
- the adjusted linear density ⁇ ' y of the yarn Y and the blending ratio are:
- the adjustment process is such that the linear velocity of one of the first rear roller or the second rear roller is zero, and the two are not zero at the same time, the yarn is realized
- One component of Y is discontinuous while the other component varies continuously.
- the linear speeds of the first rear roller and the second rear roller are continuously adjusted at the same time, and the adjustment process causes the first rear roller or the second rear
- the linear velocity of one of the rollers is zero, and the two are not zero at the same time.
- the linear density and blending ratio of the adjusted yarn Y are:
- 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 and the second rear roller are V h1i and V h2i , respectively, where i ⁇ (1, 2, ..., n);
- the blending ratios k 1i and k 2i can be expressed as follows:
- the linear density of the yarn of the i-th segment is:
- the reference line segment Let the segment with the smallest line density of the n-segment yarn Y be defined as the reference line segment, the reference line density of the segment is ⁇ 0 , and the reference line speeds of the first rear roller and the second rear roller of the segment are V h10 and V, respectively. H20 ; the reference blending ratio of the first roving component and the second roving component of the segment is k 10 and k 20 respectively
- the reference linear velocities V h10 and V h20 of the first rear roller and the second rear roller are advanced according to the materials of the first roving component and the second roving component, the reference linear density ⁇ 0 and the reference blending ratios k 10 and k 20 set up;
- the rotational speeds of the first rear roller and/or the second rear roller are adjusted to achieve online dynamic adjustment of the linear density or/and the blending ratio of the i-th yarn Y.
- the linear density of the yarn Y is provided to increase the dynamic increment ⁇ ⁇ yi on the basis of the reference line density, i.e., thickness ⁇ ⁇ yi occurred; to
- the linear velocities of the first rear roller and the second rear roller respectively increase correspondingly on the basis of the reference linear velocity, that is, (V h10 + V h20 ) ⁇ (V h10 + ⁇ V h1i + V h20 + ⁇ V h2i )
- the yarn Y-line density is increased by:
- 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 and the second rear roller.
- ⁇ V h2i k 2i *(V z + ⁇ V i )-V h20 .
- V h1i or V h2i are zero and the other is not zero, a discontinuity of a roving component in the yarn i of the i-th segment is achieved, that is, only one roving component is contained.
- a two-component asynchronous drafting device for dynamically configuring a linear density and a blending ratio includes a control system and an actuator, and the actuator includes a two-component split-type asynchronous secondary drafting mechanism, a twisting mechanism, and a winding forming 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; and the combined rear roller comprises a first rear side of the same rear 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.
- first rear roller is fixedly disposed on the rear roller shaft
- second rear roller is rotatably disposed on the rear roller shaft
- the dot yarn, the slub yarn and the mixed color produced by the method and the device of the invention are more uniform and accurate, and the rotation speed of the two rows of the back roller is controlled to ensure that the blending effect is more stable, even if the yarn color difference of different batches is not There are obvious changes.
- the following table compares the technical effects of the present invention with the prior art.
- the method of the invention changes the conventional two-component front and rear zone synchronous drafting into two-component separated asynchronous drawing (hereinafter referred to as first-order asynchronous drawing) and two-component combined synchronous drawing (hereinafter referred to as two-stage synchronous drawing) ), the two-component mixing ratio and the dynamic change of the yarn linear density are controlled by the first-stage split asynchronous drafting, and the reference line density of the yarn is controlled by the two-stage combined drafting.
- the spinning device and the process of the two-component split-type hetero-synchronous second-stage drafting and the twisting and twisting into the yarn 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 .
- the draw ratio of the first stage draft is:
- the two strands that is, the linear density of the first component and the second component strand are ⁇ 1 ' and ⁇ 2 ', respectively.
- the first drafting zone equivalent draw ratio is
- the drafting ratio of the secondary drafting zone is:
- the linear density of the first component and the second component whisker after the secondary drawing is ⁇ " 1 and ⁇ " 2 .
- Total equivalent draw ratio It is a very important parameter in spinning, which is the product of the first-order equivalent draw ratio and the second draw ratio.
- the blending ratios k 1 and k 2 can be expressed as follows:
- the blending ratio of the two components in the yarn is related to the moving speeds V h1 and V h2 of the back roller and the two coarse yarn densities ⁇ 1 and ⁇ 2 .
- the values of ⁇ 1 and ⁇ 2 are constant regardless of time, and V h1 and V h2 are related to the spindle speed set by the spinning machine. Since the spindle speed is related to the output of the spinning machine, it is different in different enterprises and spinning. Different spindle speeds are used for raw material and product specifications.
- the blend ratio determined by the equations (16) and (17) changes V h1 and V h2 due to a change in the spindle speed even if the values of the rovings ⁇ 1 and ⁇ 2 are constant. This leads to uncertainty in the blending ratio.
- the linear density of the yarn is related to the moving speeds V h1 and V h2 of the back roller and the two coarse yarn densities ⁇ 1 and ⁇ 2 .
- the values of ⁇ 1 and ⁇ 2 are constant regardless of time, and V h1 and V h2 are related to the spindle speed set by the spinning machine. Since the spindle speed is related to the output of the spinning machine, it is different in different enterprises and spinning. Different spindle speeds are used for raw material and product specifications.
- the linear density determined by the equation (18) causes V h1 and V h2 to change due to a change in the spindle speed even if the values of the rovings ⁇ 1 and ⁇ 2 are constant. This leads to uncertainty in line density.
- V h1 +V h2 V z , that is, the sum of the speeds of the two rear rollers is equal to the linear velocity of the middle roller, so that the above two formulas can be simplified as:
- the blend ratio of the two components ⁇ 1 and ⁇ 2 in the yarn is equal to the reciprocal of their respective draw ratios in the primary draw zone.
- k 2 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, 0.1, 0
- the blending ratio (mixing ratio) of different fibers (different colors) in the yarn can be changed by changing V h1 and V h2 so that k 1 and k 2 are at 0 ⁇ . Changes are made within 100%.
- the color mixing ratio is incremented by 10% as the minimum increment, and the color matching can form the following color mixing:
- k 1 +k 2 100% can have countless combinations.
- the patent of the present invention selects gradient mixed color matching with 0.1 as a gradient. According to the above statistics, the two primary color rovings (two color rovings) are coupled and drawn. Transform color, gradient color matching, twisting and mixing, finally can form 11 kinds of color matching, and can also form segment color yarns with 11 color distributions on the yarn.
- the existing ring spinning process produces a blended yarn, mainly by mixing raw materials or sliver mixing to produce a blended yarn of a certain blending ratio.
- the invention adopts the roving of different raw materials or colors to be mixed in the spinning process, and can realize the spinning of the mixed yarn or the mixed color yarn of various ratios in one step.
- the blend ratio of the two components ⁇ 1 and ⁇ 2 in the yarn is equal to the reciprocal of their respective draw ratios in the primary draw zone.
- a one-step method for producing a linear density and a mixed color ratio of each mixed color ratio does not change the yarn: the following table:
- 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 two-component asynchronous drafting method for dynamically configuring a linear density and a blending ratio specifically comprising:
- the two-component asynchronous drafting device for dynamically configuring the linear density and blending ratio includes a control system and an actuator.
- the actuator mainly includes a two-component split-type hetero-synchronous secondary drafting mechanism.
- the ⁇ mechanism and the winding forming mechanism, the two-component split-type asynchronous secondary drafting mechanism 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; the combined rear roller comprises a first rear roller 1 and a second rear roller 2 arranged side by side on the same rear roller shaft; the first rear roller 1 and the second rear roller 2 respectively Rotate at line speeds V h1 and V h2 ; middle roller 5 rotates at a speed of line speed V z ; 9 is an aggregator.
- the secondary drafting unit includes a front roller 7 and a middle roller 5; the front roller rotates at a linear velocity V q ;
- the blending ratio of the first roving component and the second roving component in the yarn Y is k 1 , k 2 , respectively, and the blending ratio of the yarn Y is K,
- the surface speed of the first back roller is V h1 :
- the first roving component and the second roving component drawn by the first rear roller and the second rear roller are respectively any two of magenta, yellow, cyan, and black fibers.
- ⁇ V h1 is the speed change amount of the first rear roller
- ⁇ V h2 is the speed change amount of the second rear roller
- the linear density ⁇ y of the adjusted yarn Y and the blending ratios k 1 , k 2 are realized by the respective increments ⁇ V h1 , ⁇ V h2 of the linear velocities of the first rear roller and the second rear roller;
- the linear velocity increments ⁇ V h1 , ⁇ V h2 of the first rear roller and the second rear roller are determined from the set linear density change and the blending ratio, so that the linear density change and the blending ratio of the spun yarn are achieved. Specified indicators.
- V z is the middle roller linear velocity
- ⁇ coarse yarn density is the linear density variation of the yarn Y
- the speeds of the first rear roller and the second rear roller are continuously adjusted at the same time, and the adjustment process ensures that the speeds of the first rear roller and the second rear roller are both greater than zero, so that the two components in the yarn Y are continuously and continuously changed.
- the adjusted linear density ⁇ ' y of the yarn Y and the blending ratio are:
- the adjustment process is such that the linear velocity of one of the first rear roller or the second rear roller is zero, and the two are not zero at the same time, the yarn is realized
- One component of line Y is discontinuous while the other component varies continuously.
- the method for dynamically configuring the linear density and the blending ratio of the two-component asynchronous drafting in this embodiment is basically the same as that in the first embodiment, 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 and the second rear roller are V h1i and V h2i , respectively, where i ⁇ (1, 2, ..., n);
- the blending ratios k 1i and k 2i can be expressed as follows:
- the linear density of the yarn of the i-th segment is:
- the reference line segment Let the segment with the smallest line density of the n-segment yarn Y be defined as the reference line segment, the reference line density of the segment is ⁇ 0 , and the reference line speeds of the first rear roller and the second rear roller of the segment are V h10 and V, respectively. H20 ; the reference blending ratio of the first roving component and the second roving component of the segment is k 10 and k 20 respectively
- the reference linear velocities V h10 and V h20 of the first rear roller and the second rear roller are advanced according to the materials of the first roving component and the second roving component, the reference linear density ⁇ 0 and the reference blending ratios k 10 and k 20 set up;
- the rotational speeds of the first rear roller and/or the second rear roller are adjusted to achieve online dynamic adjustment of the linear density or/and the blending ratio of the i-th yarn Y.
- 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 and the second rear roller.
- ⁇ V h2i k 2i *(V z + ⁇ V i )-V h20 .
- V h1i or V h2i be zero, and the other one is not zero, then a discontinuity of a roving component in the yarn i of the i-th segment, that is, only one roving component is achieved.
- the method for dynamically configuring the linear density and the blending ratio of the two-component asynchronous drafting in this embodiment is basically the same as that in the first embodiment, 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 and the second rear roller are V h1i and V h2i
- the linear velocity of the middle roller is V zi
- the linear velocity of the front roller is V qi . I ⁇ (1,2,...,n);
- the blending ratios k 1i and k 2i can be expressed as follows:
- the linear density of the yarn of the i-th segment is:
- V zi V h1(i-1) +V h2(i-1) (35);
- 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 linear velocities V h1i and V h2i of the first rear roller and the second rear roller are calculated according to the formulas (32)-(35);
- the rotational speeds of the first rear roller and/or the second rear roller are adjusted to achieve on-line dynamic adjustment of the linear density or/and the blending ratio of the i-th yarn Y.
- the middle roller and the front roller are continuously adjusted with the speed of the rear combination roller, avoiding Due to the excessive adjustment of the rear combination roller, the speed of the middle roller and the front roller are not adjusted in time, resulting in a large change in the yarn pulling ratio and effective control of yarn breakage.
- 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 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 and the second rear roller.
- ⁇ V h2i k 2i *(V zi + ⁇ V i )-V h2(i-1) .
- V h1i or V h2i be zero, and the other one is not zero, then a discontinuity of a roving component in the yarn i of the i-th segment, that is, only one roving component is achieved.
- a two-component asynchronous drafting device for dynamically configuring a linear density and a blending ratio includes a control system and an actuator, and the actuator includes a two-component split-type asynchronous secondary drafting mechanism.
- the second drafting mechanism includes a first drafting unit and a second drafting unit;
- the first drafting unit includes a combined rear roller 10 and a middle roller 5; and
- the combined rear roller 10 includes the same root
- the first rear roller 2 and the second rear roller 1 are arranged side by side on the roller shaft;
- the secondary drafting unit comprises a front roller 7 and a middle roller 5.
- 3, 4 are upper rollers corresponding to the respective rear rollers, and 6 is a middle roller.
- the top roller, 8 is the top roller corresponding to the front roller.
- 9 is an aggregator, and 13 and 14 are a winding forming mechanism and a guide roller, respectively.
- the first rear roller 2 is fixedly disposed on the rear roller shaft, and the gear or pulley 23 rotates to drive the first rear roller 2 to move;
- the second rear roller 1 is rotatably disposed on the rear roller shaft and passes through the loop 21 drives its rotation.
- the two roving strands 11 and 12 are positioned by the yarn guide rod and the support roller during the drafting and twisting process, and the first rear roller 1 and the second rear roller 2 are at different speeds V h1 and V h2 .
- the yarn is fed into the first drafting zone, and the walking path of the yarn is as shown in FIG.
- the strand density is ⁇ 1 ' and ⁇ 2 ', respectively, and then enters the secondary drafting zone.
- the linear density of the two strands becomes ⁇ ′′ 1 And ⁇ " 2 , co-twisted to form a yarn.
- the function of the primary drawing unit is to form a blending ratio (or color mixing ratio) and a linear change in linear density; the function of the secondary drawing unit is to form a density density yarn reference line density.
- 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 steel ring plate, the spindle and the like through the servo driver.
Abstract
一种双组份异步牵伸动态配置线密度和混纺比的方法和装置，该装置包括控制系统和执行机构，执行机构包括牵伸、加捻和卷绕成型机构，牵伸机构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（10）、中罗拉（5）；二级牵伸单元包括前罗拉（7）和中罗拉（5）；该方法通过一级异步牵伸机构控制双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，特别涉及一种双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沙，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双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，本发明公开的一种双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)执行机构主要包括双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，所述双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；组合后罗拉包括同一根后罗拉轴上并排设置的第一后罗拉和第二后罗拉；第一后罗拉和第二后罗拉分别以线速度Vh1和Vh2转动；中罗拉以线速度Vz转动；所述二级牵伸单元包括前罗拉和所述中罗拉；前罗拉以线速度Vq转动；设第一后罗拉和第二后罗拉所牵伸的第一粗纱组份和第二粗纱组份的线密度分别为ρ1和ρ2，由前罗拉输出再并合加捻后得到的纱线Y的线密度为ρy，则：
纱线Y中第一粗纱组份和第二粗纱组份的混纺比分别为k1、k2，则纱线Y的混纺比为K,
4)保持前罗拉和中罗拉线速度之比Vq/Vz恒定，前罗拉和中罗拉的线速度大小取决于纱线的基准线密度；
5)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和第二后罗拉表面线速度变化规律；通过调整第一后罗拉和/或第二后罗拉的转速，实现纱线线密度或/和混纺比的在线动态调整,
其中，所述第一后罗拉的表面线速度Vh1：
所述第二后罗拉的表面线速度Vh2：
进一步，所述第一后罗拉和第二后罗拉所牵伸的第一粗纱组份和第二粗纱组份分别为品红色、黄色、青色、黑色纤维中的任意两种。
进一步，设定ρ1＝ρ2＝ρ；Vh1+Vh2＝Vz；所述纱线Y的线密度恒定，而纱线Y中第一粗纱组份和第二粗纱组份的混纺比k1、k2：
进一步，令ρ1＝ρ2＝ρ，调整第一后罗拉与第二后罗拉的线速度，使：
Vh1→Vh1+ΔVh1，Vh2→Vh2+ΔVh2
其中，ΔVh1为第一后罗拉的速度变化量，ΔVh2为第二后罗拉的速度变化量；
则纱线Y的线密度
且第一粗纱组份和第二粗纱组份的混纺比k1和k2分别为：
其中：k1+k2＝1；
由此，通过分别调整第一后罗拉与第二后罗拉的线速度的增量ΔVh1，ΔVh2，即实现调整纱线Y的线密度ρy及混纺比k1、k2的大小；
其中，由设定的线密度及混纺比求出第一后罗拉与第二后罗拉的线速度的增量ΔVh1，ΔVh2，使纺出纱线的线密度的和混纺比达到规定的指标。
进一步，具体调整方法如下：
1)保持第二后罗拉线速度Vh2不变，仅增减第一后罗拉的线速度Vh1，则实现纱线Y中线密度的变化和组份比例的变化，调整后的纱线Y的线密度及混纺比如下式：
其中，eq为二级牵伸比，Vz为中罗拉线速度，ρ为粗纱线密度，Δρy为纱线Y的线密度变化量；
2)保持第一后罗拉线速度Vh1不变，仅增减第二后罗拉的线速度Vh2，则实现纱线Y中线密度的变化和组份比例的变化，调整后纱线Y的线密度及混纺比如下式：
3)同时连续调整第一后罗拉和第二后罗拉的转速，调整过程保证第一后罗拉和第二后罗拉的速度均大于零，则实现纱线Y中两种组份连续且不断变化，调整后的纱线Y的线密度ρ′y以及混纺比为：
4)同时连续调整第一后罗拉和第二后罗拉的线速度，调整过程令第一后罗拉或第二后罗拉其中一个的线速度为零，且两者不同时为零，则实现纱线Y中一种组份的不连续，而另一种组份连续变化。
进一步，在连续的时间节点T1、T2、T3、T4、T5中，同时连续调整第一后罗拉和第二后罗拉的线速度，调整过程令第一后罗拉或第二后罗拉其中一个的线速度为零，且两者不同时为零，调整后的纱线Y的线密度和混纺比分别为：
①当(T1≤t≤T2)时：
②当(T2≤t≤T3)时
k1＝0
k2＝1
③当(T3≤t≤T4)时
④当(T4≤t≤T5)时
k1＝1
k2＝0
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，第一后罗拉和第二后罗拉的线速度分别为Vh1i和Vh2i，其中i∈(1,2，…，n)；
所述第一粗纱组份和第二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可表达如下：
第i段纱线Y的线密度为：
其中，
为二级牵伸比；
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和第二后罗拉的基准线速度分别为Vh10和Vh20；该段的第一粗纱组份和第二粗纱组份的基准混纺比分别为k10和k20
保持所述中罗拉的线速度恒定，
且Vz＝Vh10+Vh20 (5)；
同时，令二级牵伸比
恒定；
其中，第一后罗拉和第二后罗拉的基准线速度Vh10和Vh20根据第一粗纱组份和第二粗纱组份的材质、基准线密度ρ0以及基准混纺比k10和k20提前设定；
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和k2i前提下，根据公式(2)-(5)计算出所述第一后罗拉和第二后罗拉的线速度Vh1i和Vh2i；
在基准线段的基准线速度Vh10、Vh20基础上，调整第一后罗拉和/或第二后罗拉的转速，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＝ρ，则公式(4)简化为：
根据公式(2)、(3)、(5)和(6)计算出所述第一后罗拉和第二后罗拉的线速度Vh1i和Vh2i；在基准线速度Vh10、Vh20基础上，增减第一后罗拉和/或第二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△ρyi，即粗细发生△ρyi；为此所述第一后罗拉和第二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)→(Vh10+ΔVh1i+Vh20+ΔVh2i)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，则(7)变为：
通过控制所述第一后罗拉和第二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＝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)和(3)简化为：
通过控制所述第一后罗拉和第二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。
进一步，令Vh1i*ρ1+Vh2i*ρ2＝H，H为常数，则ΔVi恒为0，由此，通过控制增、减所述第一后罗拉线速度时，同时减、增所述第二后罗拉的线速度，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和ΔVh2i其中一个为零，另外一个不为零，则实现所述纱线Y中一种所述粗纱组份的变化，而另一种粗纱组份不变化，调整后的混纺比为：
或者，
进一步，令ΔVh1i和ΔVh2i都不为零，则实现所述纱线Y中两种所述粗纱组份的变化，调整后的混纺比为：
进一步，令Vh1i或Vh2i其中一个为零，而另外一个不为零，则实现在第i段纱线Y中一种粗纱组份的不连续，即只含有一种粗纱组份。
一种双组份异步牵伸动态配置线密度和混纺比的装置包括控制系统和执行机构，执行机构包括双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；组合后罗拉包括同一根后罗拉轴上并排设置的第一后罗拉和第二后罗拉；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，所述第一后罗拉固定设置在所述后罗拉轴上，所述第二后罗拉可转动设置在所述后罗拉轴上。
利用本发明的方法及装置生产出来的点点纱、竹节纱、混色更加均匀和准确，通过控制两列后罗拉的转速，保证了混纺效果更加稳定，即使不同批次的纱线色差也不会有明显的变化。下表为本发明技术效果与现有技术的对比。
表1.现有纺纱技术与本申请的对比
由此可见本发明的技术效果显著。
本发明方法将传统的双组份前后区同步牵伸改变为双组份分离式异步牵伸(下称一级异步牵伸)和双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双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。通过本发明的双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。
双组份分合式异同步二级牵伸并合加捻纺纱系统工艺参数的计算
根据牵伸理论可得：
一级牵伸的牵伸比为：
其中，经一级牵伸后两根须条，即第一组份和第二组份须条的线密度分别为ρ1′和ρ2′。
一级牵伸区当量牵伸比为
二级牵伸区的牵伸比为：
其中，二级牵伸后第一组分和第二组份须条的线密度为ρ″1和ρ″2。
总牵伸区当量牵伸比
则为：
总当量牵伸比
是纺纱中非常重要的参数，它是一级当量牵伸倍数与二级牵伸倍数的乘积。
根据本发明建立的纺纱模型可知，第一组分和第二组分粗纱ρ1和ρ2经两级牵伸和加捻形成纱线后，其混纺比k1、k2可表达如下：
由式(16)、(17)可知，纱线中两个组份的混纺比与后罗拉的运动速度Vh1、Vh2以及两根粗纱线密度ρ1、ρ2相关。一般ρ1、ρ2值为常量与时间无关，而Vh1、Vh2会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(16)、(17)确定的混纺比，即使粗纱ρ1、ρ2值不变，也会由于主轴速度的变化而导致Vh1、Vh2发生变化。由此导致混纺比的不确定性。
同理可得，两根粗纱须条经两级牵伸再汇合加捻后形成的纱线线密度为:
故得成纱后纱线的线密度：
由式(18)可知，纱线的线密度与后罗拉的运动速度Vh1、Vh2以及两根粗纱线密度ρ1、ρ2相关。一般ρ1、ρ2值是常量与时间无关，而Vh1、Vh2会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(18)确定的线密度，即使粗纱ρ1、ρ2值不变，也会由于主轴速度的变化而导致Vh1、Vh2发生变化。由此导致线密度的不确定性。
由式(11)得： 
由式(12)得： 
∴ 
将式(19)代入式(3)得后牵伸区的当量牵伸倍数
将式(20)代入式(15)得总当量牵伸倍数
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＝ρ (22)
将式(22)代入式(19)得：
将式(22)(23)代入式(20)得：
将式(22)(23)(24)代入式(16)(17)得：
特殊情况下，我们也可以设Vh1+Vh2＝Vz，即两个后罗拉的速度之和等于中罗拉的线速度，这样式上面两式：又可以简化为：
即双组份ρ1和ρ2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＝1，0.9，0.8，0.7，0.6，0.5，0.4，0.3，0.2，0.1，0
则可求得对应的eh1和eh2，如下表：
表2.混纺比与第一区牵伸比的关系
| 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 | 1 | 0.9 | 0.8 | 0.7 | 0.6 | 0.5 | 0.4 | 0.3 | 0.2 | 0.1 | 0 |
| eh2 | 1 | 10/9 | 10/8 | 10/7 | 10/6 | 10/5 | 10/4 | 10/3 | 5 | 10 |
通过混色比的梯度配置，实现不同配色的方案
在(Vh1+Vh2)保持恒定的条件下，通过改变Vh1、Vh2就可以改变纱线内不同纤维(不同色彩)的混纺比(混色比)，使k1、k2在0～100％范围内进行变化。在两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3.配色方案
注：k1+k2＝100％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，按两原色粗纱(两种色彩粗纱)经耦合牵伸、交变换色、梯度配色、加捻混合，最终可形成11种配色，也可在纱线上形成具有11种色彩分布的段彩纱。
而关于，线密度和混纺比均不变化的纱线，现有环锭纺纱工艺生产混纺纱，主要是通过原料混合或者条子混合，来生产一定混纺比的混纺纱。本发明采用不同原料或颜色的粗纱在细纱工序进行混合，可以实现一步纺制各种比例的混纺纱或混配色纱。
定义：基准混纺比k10、k20，在上述模型中，假定：ρ1＝ρ2＝ρ；Vh1+Vh2＝Vz；将其代入⑹⑺中，则基准混纺比k10、k20：
即双组份ρ1和ρ2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：一个一步法生产在任意混纺比条件下，线密度和混纺比均不变化的不同混纺比的纱线的方案：如下表:
表4.根据混纺比配置第一区牵伸比的方案
| 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 | 1 | 0.9 | 0.8 | 0.7 | 0.6 | 0.5 | 0.4 | 0.3 | 0.2 | 0.1 | 0 |
| eh2 | 1 | 10/9 | 10/8 | 10/7 | 10/6 | 10/5 | 10/4 | 10/3 | 5 | 10 |
例如：一个一步法生产各混配色比的线密度和混配色比均不变化纱线的方案：如下表：
表5.不同混纺比的配色方案
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
一种双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1-5所示，双组份异步牵伸动态配置线密度和混纺比的装置包括控制系统和执行机构，执行机构主要包括双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，所述双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；
一级牵伸单元包括组合后罗拉、中罗拉；组合后罗拉包括同一根后罗拉轴上并排设置的第一后罗拉1和第二后罗拉2；第一后罗拉1和第二后罗拉2分别以线速度Vh1和Vh2转动；中罗拉5以线速度Vz的速度转动；9为集合器。
二级牵伸单元包括前罗拉7和中罗拉5；前罗拉以线速度Vq转动；
2)设第一后罗拉和第二后罗拉所喂入的第一粗纱组份和第二粗纱组份的线密度分别为ρ1和ρ2，由前罗拉输出再并合加捻后得到的纱线Y的线密度为ρy，则：
纱线Y中第一粗纱组份和第二粗纱组份的混纺比分别为k1、k2，则纱线Y的混纺比为K,
4)保持前罗拉和中罗拉线速度之比Vq/Vz恒定，前罗拉和中罗拉的线速度大小取决于纱线的基准线密度；
5)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和第二后罗拉表面线速度变化规律；通过调整第一后罗拉和/或第二后罗拉的转速，实现纱线线密度或/和混纺比的在线动态调整,
其中，所述第一后罗拉的表面线速度Vh1：
所述第二后罗拉的表面线速度Vh2：
其中，第一后罗拉和第二后罗拉所牵伸的第一粗纱组份和第二粗纱组份分别为品红色、黄色、青色、黑色纤维中的任意两种。
6)设定ρ1＝ρ2＝ρ；Vh1+Vh2＝Vz；纱线Y的线密度恒定，而纱线Y中第一粗纱组份和第二粗纱组份的混纺比k1、k2：
7)令ρ1＝ρ2＝ρ，调整第一后罗拉与第二后罗拉的线速度，使：
Vh1→Vh1+ΔVh1，Vh2→Vh2+ΔVh2
其中，ΔVh1为第一后罗拉的速度变化量，ΔVh2为第二后罗拉的速度变化量；
则纱线Y的线密度
且第一粗纱组份和第二粗纱组份的混纺比k1和k2分别为：
其中：k1+k2＝1；
由此，通过第一后罗拉与第二后罗拉的线速度的分别增量ΔVh1，ΔVh2，即实现调整纱线Y的线密度ρy及混纺比k1、k2的大小；
其中，由设定的线密度的变化及混纺比求出第一后罗拉与第二后罗拉的线速度的增量ΔVh1，ΔVh2，使纺出纱线的线密度的变化和混纺比达到规定的指标。
8)具体调整方法如下：
(1)保持第二后罗拉线速度Vh2不变，仅增减第一后罗拉的线速度Vh1，则实现纱线Y中线密度的变化和组份比例的变化，调整后的纱线Y的线密度及混纺比如下式：
其中，eq为二级牵伸比，Vz为中罗拉线速度，ρ粗纱线密度，Δρy为纱线Y的线密度变化量；
(2)保持第一后罗拉线速度Vh1不变，仅增减第二后罗拉的线速度Vh2，则实现纱线Y中线密度的变化和组份比例的变化，调整后纱线Y的线密度及混纺比如下式：
(3)同时连续调整第一后罗拉和第二后罗拉的转速，调整过程保证第一后罗拉和第二后罗拉的速度均大于零，则实现纱线Y中两种组份连续且不断变化，调整后的纱线Y的线密度ρ′y以及混纺比为：
(4)同时连续调整第一后罗拉和第二后罗拉的线速度，调整过程令第一后罗拉或第二后罗拉其中一个的线速度为零，且两者不同时为零，则实现纱线Y中一种组份的不连续，而另一种组份连续变化。
(5)在连续的时间节点T1、T2、T3、T4、T5中，同时连续调整第一后罗拉和第二后罗拉的线速度，调整过程令第一后罗拉或第二后罗拉其中一个的线速度为零，且两者不同时为零，调整后的纱线Y的线密度和混纺比分别为：
①当(T1≤t≤T2)时：
②当(T2≤t≤T3)时
k1＝0
k2＝1
③当(T3≤t≤T4)时
④当(T4≤t≤T5)时
k1＝1
k2＝0
实施例2
本实施例双组份异步牵伸动态配置线密度和混纺比的方法与实施例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，第一后罗拉和第二后罗拉的线速度分别为Vh1i和Vh2i，其中i∈(1,2，…，n)；
第一粗纱组份和第二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可表达如下：
第i段纱线Y的线密度为：
其中，
为二级牵伸比；
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和第二后罗拉的基准线速度分别为Vh10和Vh20；该段的第一粗纱组份和第二粗纱组份的基准混纺比分别为k10和k20
保持所述中罗拉的线速度恒定，
且Vz＝Vh10+Vh20 (5)；
同时，令二级牵伸比
恒定；
其中，第一后罗拉和第二后罗拉的基准线速度Vh10和Vh20根据第一粗纱组份和第二粗纱组份的材质、基准线密度ρ0以及基准混纺比k10和k20提前设定；
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和k2i前提下，根据公式(2)-(5)计算出所述第一后罗拉和第二后罗拉的线速度Vh1i和Vh2i；
在基准线段的基准线速度Vh10、Vh20基础上，调整第一后罗拉和/或第二后罗拉的转速，实现第i段纱线Y的线密度或/和混纺比的在线动态调整。
(2)设ρ1＝ρ2＝ρ，则公式(4)简化为：
根据公式(2)、(3)、(5)和(6)计算出所述第一后罗拉和第二后罗拉的线速度Vh1i和Vh2i；在基准线速度Vh10、Vh20基础上，增减第一后罗拉和/或第二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。
(3)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，即粗细发生△ρyi；为此所述第一后罗拉和第二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)→(Vh10+ΔVh1i+Vh20+ΔVh2i)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，则(7)变为：
通过控制所述第一后罗拉和第二后罗拉的线速度增量之和ΔVi实现纱线Y的线密度变化。
(4)令ρ1＝ρ2＝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)和(3)简化为：
通过控制所述第一后罗拉和第二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。
(5)令Vh1i*ρ1+Vh2i*ρ2＝H，H为常数，则ΔVi恒为0，由此，通过控制增、减所述第一后罗拉线速度时，同时减、增所述第二后罗拉的线速度，实现所述纱线Y的混纺比调整的同时保证线密度不变。
(6)令ΔVh1i和ΔVh2i其中一个为零，另外一个不为零，则实现所述纱线Y中一种所述粗纱组份的变化，而另一种粗纱组份不变化，调整后的混纺比为：
或者，
进一步，令ΔVh1i和ΔVh2i都不为零，则实现所述纱线Y中两种所述粗纱组份的变化，调整后的混纺比为：
(7)令Vh1i或Vh2i其中一个为零，而另外一个不为零，则实现在第i段纱线Y中一种粗纱组份的不连续，即只含有一种粗纱组份。
实施例3
本实施例双组份异步牵伸动态配置线密度和混纺比的方法与实施例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，第一后罗拉和第二后罗拉的线速度分别为Vh1i和Vh2i，中罗拉的线速度为Vzi，前罗拉的线速度为Vqi，其中i∈(1,2，…，n)；
第一粗纱组份和第二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可表达如下：
第i段纱线Y的线密度为：
其中，
为二级牵伸比；
设定第一后罗拉和第二后罗拉的初始线速度分别为Vh10和Vh20；所述中罗拉的初始线速度Vz0＝Vh10+Vh20；
另外，设定
Vzi＝Vh1(i-1)+Vh2(i-1) (35)；
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和k2i前提下，根据公式(32)-(35)计算出第一后罗拉和第二后罗拉的线速度Vh1i和Vh2i；
在第i-1段的基础上，调整第一后罗拉和/或第二后罗拉的转速，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)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。
(2)设ρ1＝ρ2＝ρ，则公式(34)简化为：
根据公式(32)、(33)、(35)和(36)计算出所述第一后罗拉和第二后罗拉的线速度Vh1i和Vh2i；在基准线密度ρy(i-1)和基准混纺比k1(i-1)和k2(i-1)基础上，增减第一后罗拉和/或第二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。
(3)设在基准线密度的基础上增加的线密度动态增量为△ρyi，从而导致纱线Y的线密度(即粗细)发生变化；
当所述第一后罗拉和第二后罗拉的线速度发生增量，即(Vh1+Vh2)→(Vh1+ΔVh1+Vh2+ΔVh2)时，纱线Y线密度的增量为：
则在纱线Y从第i-1段转换到第i段的瞬间，纱线Y的线密度ρyi可表达如下：
令ΔVi＝ΔVh1i+ΔVh2i，则(37)变为：
通过控制所述第一后罗拉和第二后罗拉的线速度增量之和ΔVi实现纱线Y的线密度变化。
(4)令ρ1＝ρ2＝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(32)和(33)简化为：
通过控制所述第一后罗拉和第二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*(Vzi+ΔVi)-Vh1(i-1)
ΔVh2i＝k2i*(Vzi+ΔVi)-Vh2(i-1)。
(5)令Vh1i*ρ1+Vh2i*ρ2＝H，H为常数，则ΔVi恒为0，由此，通过控制增、减所述第一后罗拉线速度时，同时减、增所述第二后罗拉的线速度，实现所述纱线Y的混纺比调整的同时保证线密度不变。
(6)令ΔVh1i和ΔVh2i其中一个为零，另外一个不为零，则实现所述纱线Y中一种所述粗纱组份的变化，而另一种粗纱组份不变化，调整后的混纺比为：
或者，
令ΔVh1i和ΔVh2i都不为零，则实现所述纱线Y中两种所述粗纱组份的变化，调整后的混纺比为：
令Vh1i或Vh2i其中一个为零，而另外一个不为零，则实现在第i段纱线Y中一种粗纱组份的不连续，即只含有一种粗纱组份。
实施例4
如图1-5所示，一种双组份异步牵伸动态配置线密度和混纺比的装置，其包括控制系统和执行机构，执行机构包括双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；一级牵伸单元包括组合后罗拉10、中罗拉5；组合后罗拉10包括同一根后罗拉轴上并排设置的第一后罗拉2和第二后罗拉1；二级牵伸单元包括前罗拉7和中罗拉5。3、4为与各个后罗拉对应的上皮辊，6为中罗拉的上皮辊，8为前罗拉对应的上皮辊。9为集合器，13和14分别为卷绕成型机构和导辊。
如图2所示，第一后罗拉2固定设置在后罗拉轴上，齿轮或皮带轮23转动带动第一后罗拉2运动；第二后罗拉1可转动设置在后罗拉轴上，并通过环圈21带动其转动。
纺纱时，两根粗纱须条11和12在牵伸和加捻过程中，用导纱杆和支撑辊定位，第一后罗拉1和第二后罗拉2以不同的速度Vh1和Vh2将纱线喂入一级牵伸区，纱线的行走路径如图4所示。平行运动至中罗拉握持点并以速度Vz引出，两根须条分别受到eh1＝(Vz-Vh1)/Vh1、eh2＝(Vz-Vh1)/Vh1的异步牵伸后须条线密度分别为ρ1′和ρ2′，然后进入二级牵伸区，在前罗拉表面速度Vq的同步牵伸作用下两根须条的线密度变为ρ″1和ρ″2，共同加捻形成纱线。则所述一级牵伸单元的功能是形成混纺比(或混色比)和线密度动态变化；所述二级牵伸单元的功能则是形成变密度纱线基准线密度。
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、钢领板、锭子等工作。
表6.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 (14)
- 一种双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，其具体包括：1)执行机构主要包括双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，所述双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；组合后罗拉包括同一根后罗拉轴上并排设置的第一后罗拉和第二后罗拉；第一后罗拉和第二后罗拉分别以线速度Vh1和Vh2转动；中罗拉以线速度Vz转动；所述二级牵伸单元包括前罗拉和所述中罗拉；前罗拉以线速度Vq转动；设第一后罗拉和第二后罗拉所牵伸的第一粗纱组份和第二粗纱组份的线密度分别为ρ1和ρ2，由前罗拉输出再并合加捻后得到的纱线Y的线密度为ρy，则：
纱线Y中第一粗纱组份和第二粗纱组份的混纺比分别为k1、k2，则纱线Y的混纺比之比为K,
4)保持前罗拉和中罗拉线速度之比Vq/Vz恒定，前罗拉和中罗拉的线速度大小取决于纱线的基准线密度；5)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和第二后罗拉表面线速度变化规律；通过调整第一后罗拉和/或第二后罗拉的转速，实现纱线线密度或/和混纺比的在线动态调整,其中，所述第一后罗拉的表面线速度Vh1：
所述第二后罗拉的表面线速度Vh2：
- 如权利要求1所述方法，其特征在于，设定ρ1＝ρ2＝ρ；Vh1+Vh2＝Vz；所述纱线Y的线密度恒定，而纱线Y中第一粗纱组份和第二粗纱组份的混纺比k1、k2：
- 如权利要求1所述方法，其特征在于，令ρ1＝ρ2＝ρ，调整第一后罗拉与第二后罗拉的线速度，使：Vh1→Vh1+ΔVh1，Vh2→Vh2+ΔVh2其中，ΔVh1为第一后罗拉的速度变化量，ΔVh2为第二后罗拉的速度变化量；则纱线Y的线密度
且第一粗纱组份和第二粗纱组份的混纺比k1和k2分别为：
其中：k1+k2＝1；由此，通过第一后罗拉与第二后罗拉的线速度的分别增量ΔVh1，ΔVh2，即实现调整纱线Y的线密度ρy及混纺比k1、k2的大小；其中，由设定的线密度的变化及混纺比求出第一后罗拉与第二后罗拉的线速度的增量ΔVh1，ΔVh2，使纺出纱线的线密度的变化和混纺比达到规定的指标。 - 如权利要求3所述方法，其特征在于，具体调整方法如下：1)保持第二后罗拉线速度Vh2不变，仅增减第一后罗拉的线速度Vh1，则实现纱线Y中线密度的变化和组份比例的变化，调整后的纱线Y的线密度及混纺比如下式：
其中，eq为二级牵伸比，Vz为中罗拉线速度，ρ粗纱线密度，Δρy为纱线Y的线密度变化量；2)保持第一后罗拉线速度Vh1不变，仅增减第二后罗拉的线速度Vh2，则实现纱线Y中线密度的变化和组份比例的变化，调整后纱线Y的线密度及混纺比如下式：
3)同时连续调整第一后罗拉和第二后罗拉的转速，调整过程保证第一后罗拉和第二后罗拉的速度均大于零，则实现纱线Y中两种组份连续且不断变化，调整后的纱线Y的线密度ρ′y以及混纺比为：
4)同时连续调整第一后罗拉和第二后罗拉的线速度，调整过程令第一后罗拉或第二后罗拉其中一个的线速度为零，且两者不同时为零，则实现纱线Y中一种组份的不连续，而另一种组份连续变化。 - 如权利要求4所述方法，其特征在于，在连续的时间节点T1、T2、T3、T4、T5中，同时连续调整第一后 罗拉和第二后罗拉的线速度，调整过程令第一后罗拉或第二后罗拉其中一个的线速度为零，且两者不同时为零，调整后的纱线Y的线密度和混纺比分别为：①当(T1≤t≤T2)时：
②当(T2≤t≤T3)时
k1＝0k2＝1③当(T3≤t≤T4)时
④当(T4≤t≤T5)时
k1＝1k2＝0 - 如权利要求1所述方法，其特征在于，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，第一后罗拉和第二后罗拉的线速度分别为Vh1i和Vh2i，其中i∈(1,2，…，n)；所述第一粗纱组份和第二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可表达如下：
第i段纱线Y的线密度为：
其中，为二级牵伸比；
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 罗拉和第二后罗拉的基准线速度分别为Vh10和Vh20；该段的第一粗纱组份和第二粗纱组份的基准混纺比分别为k10和k20保持所述中罗拉的线速度恒定，且Vz＝Vh10+Vh20 (5)；同时，令二级牵伸比恒定；
其中，第一后罗拉和第二后罗拉的基准线速度Vh10和Vh20根据第一粗纱组份和第二粗纱组份的材质、基准线密度ρ0以及基准混纺比k10和k20提前设定；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和k2i前提下，根据公式(2)-(5)计算出所述第一后罗拉和第二后罗拉的线速度Vh1i和Vh2i；在基准线段的基准线速度Vh10、Vh20基础上，调整第一后罗拉和/或第二后罗拉的转速，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6所述方法，其特征在于，设ρ1＝ρ2＝ρ，则公式(4)简化为：
根据公式(2)、(3)、(5)和(6)计算出所述第一后罗拉和第二后罗拉的线速度Vh1i和Vh2i；在基准线速度Vh10、Vh20基础上，增减第一后罗拉和/或第二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7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，即粗细发生△ρyi；为此所述第一后罗拉和第二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)→(Vh10+ΔVh1i+Vh20+ΔVh2i)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，则(7)变为：
通过控制所述第一后罗拉和第二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8所述方法，其特征在于，令ρ1＝ρ2＝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)和(3)简化为：
通过控制所述第一后罗拉和第二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)-Vh20。 - 如权利要求8所述方法，其特征在于，令Vh1i*ρ1+Vh2i*ρ2＝H，H为常数，则ΔVi恒为0，由此，通过控制增、减所述第一后罗拉线速度时，同时减、增所述第二后罗拉的线速度，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8所述方法，其特征在于，令ΔVh1i和ΔVh2i其中一个为零，另外一个不为零，则实现所述纱线Y中一种所述粗纱组份的变化，而另一种粗纱组份不变化，调整后的混纺比为：
或者，
- 如权利要求8所述方法，其特征在于，令ΔVh1i和ΔVh2i都不为零，则实现所述纱线Y中两种所述粗纱组份的变化，调整后的混纺比为：
- 如权利要求8所述方法，其特征在于，令Vh1i或Vh2i其中一个为零，而另外一个不为零，则实现在第i段纱线Y中一种粗纱组份的不连续，即只含有一种粗纱组份。
- 一种实现权力要求1-13任一所述方法的双组份异步牵伸动态配置线密度和混纺比的装置，其特征在于，其包括控制系统和执行机构，执行机构包括双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；组合后罗拉包括同一根后罗拉轴上并排设置的第一后罗拉和第二后罗拉；所述二级牵伸单元包括前罗拉和所述中罗拉。
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| 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 |
| US10351975B2 (en) * | 2015-03-27 | 2019-07-16 | Jiangnan University | Method and device of dynamically configuring linear density and blending ratio of yarn by four-ingredient asynchronous/synchronous drafted |
| IT201800009292A1 (it) * | 2018-10-09 | 2020-04-09 | Savio Macch Tessili Spa | Apparato e metodo di stiro e filatura di filati misti per macchine di filatura ad aria con alimentazioni multiple |
| 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 |
| CN110079907B (zh) * | 2019-05-06 | 2023-06-27 | 滁州霞客环保色纺有限公司 | 一种双层包缠结构负泊松比的三组份复合纱线及其三通道环锭纺纱装置和控制方法 |
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