WO2022148274A1 - 染料拼色轧染过程中补液系统的数字化控制方法及其系统 - Google Patents

染料拼色轧染过程中补液系统的数字化控制方法及其系统 Download PDF

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WO2022148274A1
WO2022148274A1 PCT/CN2021/142029 CN2021142029W WO2022148274A1 WO 2022148274 A1 WO2022148274 A1 WO 2022148274A1 CN 2021142029 W CN2021142029 W CN 2021142029W WO 2022148274 A1 WO2022148274 A1 WO 2022148274A1
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dye
dyeing
color matching
dyeing process
pad
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PCT/CN2021/142029
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English (en)
French (fr)
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毛志平
代亚敏
徐红
钟毅
陆辉
张琳萍
隋晓锋
吴伟
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东华大学
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Priority to EP21917314.3A priority Critical patent/EP4276568A4/en
Priority to US18/271,242 priority patent/US20240052561A1/en
Publication of WO2022148274A1 publication Critical patent/WO2022148274A1/zh

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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
    • D06P1/00—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed
    • D06P1/0032—Determining dye recipes and dyeing parameters; Colour matching or monitoring
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05D—SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
    • G05D11/00—Control of flow ratio
    • G05D11/02—Controlling ratio of two or more flows of fluid or fluent material
    • G05D11/13—Controlling ratio of two or more flows of fluid or fluent material characterised by the use of electric means
    • G05D11/139—Controlling ratio of two or more flows of fluid or fluent material characterised by the use of electric means by measuring a value related to the quantity of the individual components and sensing at least one property of the mixture
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06B—TREATING TEXTILE MATERIALS USING LIQUIDS, GASES OR VAPOURS
    • D06B23/00—Component parts, details, or accessories of apparatus or machines, specially adapted for the treating of textile materials, not restricted to a particular kind of apparatus, provided for in groups D06B1/00 - D06B21/00
    • D06B23/24—Means for regulating the amount of treating material picked up by the textile material during its treatment
    • D06B23/28—Means for regulating the amount of treating material picked up by the textile material during its treatment in response to a test conducted on the treating material
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
    • D06P1/00—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed
    • D06P1/38—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using reactive dyes
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06B—TREATING TEXTILE MATERIALS USING LIQUIDS, GASES OR VAPOURS
    • D06B23/00—Component parts, details, or accessories of apparatus or machines, specially adapted for the treating of textile materials, not restricted to a particular kind of apparatus, provided for in groups D06B1/00 - D06B21/00
    • D06B23/20—Arrangements of apparatus for treating processing-liquids, -gases or -vapours, e.g. purification, filtration or distillation
    • D06B23/205—Arrangements of apparatus for treating processing-liquids, -gases or -vapours, e.g. purification, filtration or distillation for adding or mixing constituents of the treating material
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
    • D06P3/00—Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
    • D06P3/58—Material containing hydroxyl groups
    • D06P3/60—Natural or regenerated cellulose
    • D06P3/66—Natural or regenerated cellulose using reactive dyes
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Definitions

  • the invention belongs to the technical field of automatic control of printing and dyeing, and relates to a digital control method and a system for a liquid replenishing system in a pad dyeing process of dye color matching, in particular to a digital control method for a liquid replenishing system in the color matching dyeing process of two or more dyes and the same.
  • Control System a digital control method for a liquid replenishing system in the color matching dyeing process of two or more dyes and the same.
  • the dyeing factory mainly uses experienced masters to roughly judge the amount of each dye that needs to be added according to experiments such as seepage circle or ratio shift value, and to control the liquid replenishment system in the actual dyeing experiment by making small samples and continuously adjusting.
  • This method relies on the master's empirical formula, and through the transition stage, the concentration in the dye tank finally reaches a dynamic equilibrium. When the final equilibrium is reached, the concentration in the dye bath is inconsistent with the initial concentration, which consumes a lot of dyes and fabrics. And in the actual scale-up experiment, the approved color shall prevail.
  • the formula is the original formula for mass production. The original formula naturally becomes the balanced formula after the transition, and the color difference has changed. The color matching of the same group of dyes will also differ in the amount of dye liquor that needs to be added under different conditions such as dyed fabrics and dyeing processes. Precise control.
  • the invention provides a digital control method and a control system for a liquid replenishing system in a color-matching pad dyeing process, which is simple in method, accurate in analysis results, wide in application range of dyes and can improve the quality of dyed products.
  • the invention aims to solve the technical problem that the prior art is difficult to accurately control and obtain stable shades, and provides a digital control method and a system for a liquid replenishing system in the pad dyeing process of dye color matching, especially for two or more dye color matching pads A digital control method and a control system for the liquid replenishment system in the dyeing process.
  • a digital control method for a liquid replenishing system in a pad dyeing process of dye color matching the real-time addition amount of each dye in the liquid replenishing system in the entire dyeing process is accurately calculated according to the initial dyeing rate K 0,n of each dye, and the real-time addition amount is calculated according to the real-time addition amount of each dye. Replenish the dye solution.
  • the precision refers to the real-time addition of grams of each dye in the quantifiable color matching dye.
  • the digital control method of the liquid replenishing system in the pad dyeing process of a dye color matching as described above the calculation basis of the initial dyeing rate of each dye is consistent with the pad dyeing process conditions, that is, the type of dye, the concentration of the dye solution and the ratio , dyeing temperature, dyed fabric specifications, bath ratio and the same amount of additives.
  • the above-mentioned digital control method of a liquid replenishing system in the pad dyeing process of dye color matching includes the pad dyeing process of acid dyes, reactive dyes or direct dyes.
  • the pad dyeing process of dye color matching refers to the color matching continuous pad dyeing process of two or more dyes.
  • the pad dyeing process of the dye color matching is the process of continuously applying dye liquor to the fabric by a pad car, including but not limited to continuous pad dyeing process, batch padding process or cold padding process.
  • the initial concentration C n of the dye liquor (that is, the ratio of the quality of each dye to the dye liquor volume) is 0.01 ⁇ 200g/L;
  • the dyeing temperature is 10-100° C., and the amount of neutral salt in the dye liquor (the ratio of the mass of the neutral salt to the volume of water) is 0-300 g/L.
  • the digital control method of the liquid replenishment system in the pad dyeing process of a dye color matching as described above, the initial dyeing rate K 0 of each dye, the calculation method of n is: by Raman spectrometer, spectrophotometer or liquid chromatograph, Detect the change of the concentration of each dye in the dye liquor of a certain formula with the dyeing time under certain color-matching dyeing conditions, calculate the amount of each dye on the unit mass of fabric according to the concentration of each dye in the dye liquor under different dyeing times, and draw the dyeing process curve diagram, The zero-point slope obtained from the fitted dyeing process curve is the initial dyeing rate K 0,n .
  • a digital control system for a liquid replenishment system in a pad dyeing process of dye color matching comprising an automatic calculation K 0, n value unit, a central processing unit and a liquid replenishing pump; the automatic calculation K 0, n value unit transmits the K 0, n value to the The central processing unit calculates the amount of fluid replacement and controls the fluid replacement pump to perform fluid replacement through the central processing unit;
  • the unit for automatically calculating K 0, n value is composed of a dye concentration detection instrument, a sensor I and a BP neural network model;
  • the dye concentration detection instrument is a Raman spectrometer, a spectrophotometer or a liquid chromatograph;
  • the BP neural network The model is a BP neural network trained from the dye database.
  • the dye database contains multiple historical dye recipes and the K 0, n values of each dye in the dye recipe. During training, the concentration of each dye at different dyeing times in each historical dye recipe is calculated. The amount of each dye on the obtained unit mass fabric is used as an input item, and the K 0, n value corresponding to each dye amount is used as an output item;
  • the central processing unit is composed of sensor II and calculation processing unit.
  • the control system is specifically composed of Raman spectrometer, spectrophotometer or liquid chromatograph to detect the change of the concentration of each dye in a certain formula dye solution with the dyeing time under certain color matching dyeing conditions, according to the different dyeing time in the dye solution.
  • Each dye concentration calculates the amount of each dye on a unit mass of fabric and simultaneously inputs it into the same neural network model, which outputs the initial dyeing rate K 0,n of each dye. Change the dyeing conditions and dye formula respectively, and calculate the ratio of the amount of each dye on the fabric at different dyeing times to the total mass of the fabric, and its corresponding The initial dyeing rate K 0,n of each dye is used to train the neural network.
  • the ratio of the amount of each dye adsorbed to the fabric at different dyeing times and the total mass of the fabric under a certain dyeing condition and a certain dye formula is input into the trained neural network, and the neural network automatically outputs the initial dyeing rate K of each dye 0, n .
  • the K 0 , n value is transmitted from the sensor to the central processing unit, and the real-time addition amount of each dye is calculated by the calculation formula in the digital control method of the rehydration system in the processing unit, and the addition of each dye is accurately controlled by the rehydration pump. quantity.
  • a digital control method for a liquid replenishing system in the pad dyeing process of dye color matching is only 4-6 s. The difference is large, the dyeing rate K 0, n of each dye in this extremely short initial dyeing time remains unchanged. If the fabric is immersed in the dye liquor for t s, the dye will be adsorbed on the fabric per gram weight in t s. The amount of dye is m t, n (mg ⁇ g -1 ):
  • K 0,n is the initial dyeing rate of the nth (n ⁇ 1) dye during the dyeing process, mg ⁇ g -1 ⁇ min -1 ;
  • n (g) is:
  • TXP ⁇ 0 ⁇ Lroll +(m T, 1 +m T, 2 +...+m T, n ) (4)
  • ⁇ 0 is the density of the initial pad dyeing solution, g/mL
  • the amount of dyes mroll, n , g can be obtained by rolling onto the fabric:
  • n is the mass of the nth component dye that needs to be replenished after dyeing T min time, in g;
  • m pad n is the dye of the nth component dyed on the fabric by roller padding after dyeing T min time Mass, in g.
  • the dyeing process conditions for calculating the initial dyeing rate K 0,n of the dyeing rate curve of each dye must be consistent with the pad dyeing process conditions, that is, the type of dye, the concentration and proportion of dye liquor, the dyeing temperature, and the dyed fabric.
  • the dyeing conditions such as specifications are the same.
  • the real-time addition amount of each dye in the liquid replenishment system in the whole dyeing process can be accurately calculated, and the purpose of digital control of the liquid replenishment system can be achieved.
  • the invention quantifies the amount of dyes adsorbed on the fabric by the affinity of each dyestuff with fibers under a certain padding time by the initial dyeing rate of each dye in the color-blocking dyeing under certain dyeing conditions;
  • the amount of dyes on the fabric through the padding of the following dyes according to the conservation of dye quality, the amount of each dye that needs to be supplemented after padding for a certain period of time is the amount of dyes adsorbed on the fabric through the affinity with the fiber and the amount of dyes that pass through the padding.
  • the sum of the amount of dye to the fabric According to the total amount of dye liquor pad dyed on the fabric, the volume of dye liquor pad dyed on the fabric is calculated as the volume of dye liquor that needs to be supplemented, so that the concentration of each dye that needs to be supplemented can be obtained.
  • the digital control method of the liquid replenishment system in the pad dyeing process of a dye color matching of the present invention can accurately calculate the liquid replenishment amount of the dye, and realize the digital control of the liquid replenishment system;
  • the digital control system of the liquid replenishing system in the pad dyeing process of a dye color matching of the present invention converts variables such as initial dye concentration, initial dye ratio, dyeing temperature, and dosage of auxiliaries into the initial dyeing process through a neural network.
  • the rate K 0,n is a controllable variable with a specific value.
  • the central processing unit calculates the real-time addition amount of each dye, and controls the rehydration pump for precise rehydration, realizing the conversion of the rehydration system from human experience control to digital control.
  • Fig. 1 is the contrast diagram of each dye concentration change in the dye liquor after the original dye liquor in the embodiment 1 and the calculation of the supplementary liquor concentration infusion;
  • Fig. 2 is the color difference contrast diagram of the batch sample fabric after the original dye liquor in embodiment 1 and calculating the concentration of the supplementary liquid to be replenished;
  • the original solution refers to the experimental results after the concentration of the original dye solution is replenished
  • the replenishment refers to the experimental results after the concentration of the replenished solution is replenished.
  • a digital control method for a liquid replenishing system in a pad dyeing process of dye color matching is to calculate the real-time addition amount of each dye in the liquid replenishing system in the entire dyeing process according to the initial dyeing rate K 0,n of each dye, that is, each dyestuff.
  • the data points taken are half of the data points in the entire dyeing process. Due to the close sampling interval of the first 2 minutes, rapid sampling was not possible, and considering that the change of dye solution after sampling was negligible, 6 groups of parallel staining experiments were set up, and 6 points were taken from each group, and 800 ⁇ L was taken with a pipette each time. The above experiments were repeated three times. The dyeing process curves of the three experiments were tested by Raman spectroscopy, and the average value was calculated at each time point, and the average dyeing rate curve was finally obtained as shown in Figure 1.
  • C n is the initial concentration of the dye solution
  • K 0,1 is the The initial dyeing rate of reactive red 3BE, in mg ⁇ g -1 ⁇ min -1 , is 28.10 mg ⁇ g -1 ⁇ min -1
  • K 0,2 is the initial dyeing rate of reactive blue M-2GE,
  • the unit is mg ⁇ g -1 ⁇ min -1 , and the value is 36.63 mg ⁇ g -1 ⁇ min -1
  • ⁇ 0 is the density of the initial pad dyeing solution, the unit is g/mL, and the value is 1.048g/mL
  • P is the liquid rate (%) of the fabric, the value is 74%
  • t is the time that the fabric is immersed in the pad dyeing solution, the unit is s, the value is 6s
  • T is the pad dyeing time, the unit is min, the value is 0.1
  • the volume of pad dyeing solution to be supplemented is 2.15 mL, and the masses of reactive red 3BE and reactive blue M-2GE to be supplemented are 13.80 mg and 16.36 mg respectively. mg, the concentration of each dye to be supplemented is 6.42g/L and 7.61g/L, respectively.
  • the concentration of each group of dye liquor was tested after pad dyeing 5, 10, 15, 20, and 25 fabrics of each group of pad dyeing solution respectively.
  • the concentration of the original dye solution was used as the concentration of the supplementary solution, and the above experiments were repeated.
  • the changes in the concentration of dyes supplemented by the supplemented solution and the changes in the concentration of each dye supplemented by the original dye solution and the corresponding changes in fabric color difference were shown in Figure 1 and Figure 1, respectively. 2 shown.
  • a digital control system for a liquid replenishment system in the pad dyeing process of dye color matching comprising an automatic calculation K 0 , n value unit, a central processing unit and a liquid replenishing pump; III is transmitted to the central processing unit, and the central processing unit calculates the amount of fluid replacement and controls the fluid replacement pump for fluid replacement.
  • the unit for automatically calculating K 0, n value is composed of a dye concentration detection instrument, a sensor I and a BP neural network model; the dye concentration detection instrument is a Raman spectrometer, a spectrophotometer or a liquid chromatograph; the central processing unit is composed of a sensor II and the calculation processing unit.
  • the digital control system of the liquid replenishment system in the pad dyeing process of dye color matching is used in the color matching pad dyeing process in Example 1, and the concrete steps are as follows:
  • the value of each dye in multiple historical dye formulations is detected by Raman spectrometer.
  • the historical dye formulation includes two dyes (reactive red 3BE and reactive blue).
  • M-2GE take one of the historical dye formulas as an example: First, according to the historical dye formula, prepare 5g/L of reactive red 3BE and reactive blue M-2GE mixed dye solution (mass ratio is 1:1), sodium sulfate 60g/L L, put the cotton fabric in the mixed dye solution for color-matching dyeing, control the liquor ratio to be 1:25, and the dyeing temperature to be 40 °C; calculate the amount of each dye on the fabric per unit mass according to the concentration of each dye in the dye solution under different dyeing times ; Draw each dye concentration under different dyeing time and calculate the fitting curve of each dye quantity-time on the fabric of unit mass, the correlation coefficient of the fitting curve of dyeing quantity-time is not less than 0.90, and finally by fitting the quantity-time of dyeing quantity-time The first
  • the amount of each dye on the fabric per unit mass calculated by the concentration of each dye under different dyeing times in a plurality of historical dye formulations and its corresponding K 0, n value constitute a dye database, and the historical dye formulations in the dye database are Calculate the amount of each dye on a unit mass of fabric and its corresponding K 0, n value under different dyeing time of each dye concentration as the input item and output item to train the neural network model, and obtain the trained BP neural network model; training;
  • the termination condition is: the number of wrongly identified training samples accounts for no more than 5% of the total training samples, and the wrongly identified training samples refer to the K 0, n value output by the BP neural network model and the actual K 0, n Training samples with inconsistent values;

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Abstract

本发明涉及一种染料拼色轧染过程中补液系统的数字化控制方法及其系统，该方法是依据各染料的初始上染速率精确计算出整个染色过程中补液系统中各染料的实时添加量，按实时添加量补充染液；该系统包括自动计算K 0，n值单元、中央处理单元和补液泵；自动计算K 0，n值单元由染液浓度检测仪器、传感器Ⅰ和BP神经网络模型组成；所述BP神经网络模型是由染料数据库训练后的BP神经网络；自动计算K 0，n值单元将K 0，n值传输到中央处理单元，通过中央处理单元计算出补液量并控制补液泵进行补液。本发明的一种染料拼色的轧染过程中补液系统的数字化控制方法，能够精确计算染料的补液量，实现对补液系统的数字化控制；实现补液系统由人为经验控制到数字化控制的转换。

Description

染料拼色轧染过程中补液系统的数字化控制方法及其系统 技术领域
本发明属印染自动控制技术领域，涉及一种染料拼色的轧染过程中补液系统的数字化控制方法及其系统，特别涉及两种及以上染料拼色染色过程中补液系统的数字化控制方法及其控制系统。
背景技术
在两种及以上染料拼色的连续轧染过程中，需要不断的调整补液系统中各染料的给液量来确保染液槽内的染料浓度配比保持不变以获得稳定的色光。
目前染厂主要是有经验师傅根据渗圈或者比移值等实验大致判断各染料需要补加量，并通过打小样不断调整来实现控制实际染色实验中的补液系统。此方法依赖师傅的经验公式，通过过渡阶段使染槽内浓度最终达到动态平衡，最终平衡时染液槽内的浓度与初始浓度已不一致，这消耗大量染料和织物。且在实际放大实验中，以核准的颜色为准，其配方是作为大生产的原始配方，原始配方自然地变成过渡以后的平衡配方，发生了色差变化。同一组染料的拼色在不同的被染织物和染色工艺等条件下需要补加的染液量也会有差异，这种根据经验修正补液系统的方法会导致补液系统中各染料的添加量难以精确控制。
因此，研究一种方法简单，结果精准，染料适用范围广且能提高染色产品质量的一种染料拼色的过程中补液系统的数字化控制方法及其控制系统具有十分重要的意义。
发明内容
本发明针对现有技术的不足，提供一种方法简单、分析结果精准、染料适用范围广且能提高染色产品质量的一种拼色轧染过程中补液系统的数字化控制方法及其控制系统。本发明旨在解决现有技术难以精确控制获得稳定的色光的技术问题，提供一种染料拼色的轧染过程中补液系统的数字化控制方法及其系统，特别针对两种及以上染料拼色轧染过程中补液系统的数字化控制方法及其控制系统。
为达到上述目的，本发明采用的方案如下：
一种染料拼色的轧染过程中补液系统的数字化控制方法，依据各染料的初始上染速率K 0，n精确计算出整个染色过程中补液系统中各染料的实时添加量，按实时添加量补充染液。
作为优选的技术方案：
如上所述的一种染料拼色的轧染过程中补液系统的数字化控制方法，各染料的实时添加 量m 补，n(g)：
Figure PCTCN2021142029-appb-000001
其中，C n为染液中各染料的初始浓度，单位g/mL，n≥2，为染料种类数；K 0，n为各染料的初始上染速率，单位mg·g -1·min -1；k 0，1为第一支染料的初始上染速率，单位mg·g -1·min -1；K 0，2为第二支染料的初始上染速率，单位mg·g -1·min -1；ρ 0为初始轧染染色液的密度，单位g/mL；P为织物带液率(％)；t为织物在轧染液中浸渍的时间，单位s；T为轧染的时间，单位min；X为单位时间轧染织物重，单位g/min。
如上所述的一种染料拼色的轧染过程中补液系统的数字化控制方法，所述精确是指可量化拼色染料中每支染料的实时添加克数。
如上所述的一种染料拼色的轧染过程中补液系统的数字化控制方法，各染料的初始上染速率的计算基础是与轧染染色工艺条件一致，即染料种类、染液浓度及配比、染色温度、被染织物规格、浴比及助剂添加量相同。
如上所述的一种染料拼色的轧染过程中补液系统的数字化控制方法，所述染料拼色的轧染过程包括酸性染料、活性染料或直接染料的轧染过程。
如上所述的一种染料拼色的轧染过程中补液系统的数字化控制方法，所述染料拼色的轧染过程是指两种以上染料的拼色连续轧染过程。
如上所述的一种染料拼色的轧染过程中补液系统的数字化控制方法，所述染料拼色的轧染过程为通过轧车对织物连续施加染液的过程，包括但不限于连续轧染过程、间歇式轧染过程或冷轧堆轧染过程。
如上所述的一种染料拼色的轧染过程中补液系统的数字化控制方法，所述染液的初始浓度C n(即各染料的质量与染液体积的比值)为0.01～200g/L；所述染色的温度为10～100℃，染液中中性盐用量(中性盐的质量与水的体积之比)为0～300g/L。
如上所述的一种染料拼色的轧染过程中补液系统的数字化控制方法，各染料的初始上染速率K 0，n计算方法为：通过拉曼光谱仪、分光光度计或液相色谱仪，检测一定拼色染色条件下，一定配方染液中各染料浓度随染色时间的变化，根据染液中不同染色时间下各染料浓度计算单位质量织物上的各染料量，绘制上染过程曲线图，由拟合的上染过程曲线图得到零点斜率即为初始上染速率K 0，n。
一种染料拼色的轧染过程中补液系统的数字化控制系统，包括自动计算K 0，n值单元、中央处理单元和补液泵；自动计算K 0，n值单元将K 0，n值传输到中央处理单元，通过中央处理单元计算出补液量并控制补液泵进行补液；
自动计算K 0，n值单元由染液浓度检测仪器、传感器Ⅰ和BP神经网络模型组成；所述染液浓度检测仪器为拉曼光谱仪、分光光度计或液相色谱仪；所述BP神经网络模型是由染料数据库训练后的BP神经网络，染料数据库包含多个历史染料配方及染料配方中各染料的K 0，n值，训练时分别以各历史染料配方中不同染色时间下各染料浓度计算得到的单位质量织物上的各染料量作为输入项，以各染料量对应的K 0，n值作为输出项；
中央处理单元由传感器Ⅱ和计算处理单元组成。
控制系统是由具体包括通过拉曼光谱仪、分光光度计或液相色谱仪，检测一定拼色染色条件下，一定配方染液中各染料浓度随染色时间的变化，根据染液中不同染色时间下各染料浓度计算单位质量织物上的各染料量并将其同时输入到同一神经网络模型中，由其输出各染料的初始上染速率K 0，n。分别改变染色条件和染料配方，并根据不同染色条件和染料配方染液中各染料对应的各染料浓度随时间的变化，计算不同染色时间织物上各染料量与织物总质量的比值，及其对应的各染料的初始上染速率K 0，n对神经网络进行训练。将一定染色条件，一定染料配方下各染料在不同染色时间下吸附到织物上的量与织物总质量的比值，输入训练好的神经网络中，由神经网络自动输出各染料的初始上染速率K 0，n。将K 0，n值由传感器传输到中央处理单元中并通过计算处理单元中补液系统数字化控制方法中的计算公式计算各染料实时添加量m 补，n，最后通过补液泵精确控制各染料的添加量。
各染料的实时添加量m 补，n(g)的计算方法的推理过程如下：
一种染料拼色的轧染过程中补液系统的数字化控制方法，拼色轧染过程中，织物浸渍染液的时间仅为4～6s，在这极短的初染时间内，纤维内外的浓度差大，这极短的初染时间内各染料的上染速率K 0，n不变，若织物在轧槽浸渍染液的时间为t s时，则染料在t s吸附到单位克重织物上的染料量为m t，n(mg·g -1)：
Figure PCTCN2021142029-appb-000002
式中：K 0，n为第n(n≥1)种染料在染色过程中的初始上染速率，mg·g -1·min -1；
轧染过程中，若单位时间染色的织物重X(g/min)，则染色T(min)时间后，染料通过与纤维的亲和力作用吸附到织物上的量m T，n(g)为：
m T，n＝m t，n×T×X   (2)
结合(1)和(2)式可得：
Figure PCTCN2021142029-appb-000003
由上可知，染色时间T min后，染液槽内除去需补充轧染到织物上的染料外，额外需补充的各染料通过与纤维的亲和力作用吸附到纤维上的染料量。
轧染过程中，若织物带液率为P(％)，染液槽内各染料初始浓度分别为(C 1，C 2，…，C n，n≥2，g/mL)则染色T min后根据轧染前后质量守恒：
TXP＝ρ 0×L 轧+(m T，1+m T，2+…+m T，n)    (4)
则：
Figure PCTCN2021142029-appb-000004
式中：ρ 0为初始轧染染色液的密度，g/mL；L 轧为轧染到织物上染液的体积，即为补充液体积(体积守恒：L 补＝Ｌ 轧)，mL。
由公式(5)可得通过轧辊轧到织物上的染料量m 轧，n，g：
m 轧，n＝ L轧×C n    (6)
即为：
Figure PCTCN2021142029-appb-000005
由上可知，染色时间T min后，轧染到织物上的各染料量m 轧，n。
根据各染料质量守恒：m 补，n＝m 轧，n+m T，n，结合公式(3)和(7)可得：
Figure PCTCN2021142029-appb-000006
式中：m 补，n为染色T min时间后需要补充的第n组分染料的质量，单位g；m 轧，n为染色T min时间后第n组分通过轧辊轧染到织物上的染料质量，单位g。式中，计算各染料的初始上染速率K 0，n的上染速率曲线的染色工艺条件需与轧染染色工艺条件一致，即染料种类、染液浓度及配比，染色温度，被染织物规格等染色条件相同。即可精确计算出整个染色过程中补液系统中各染料的实时添加量，达到数字化控制补液系统的目的。
本发明的原理如下：
本发明通过在一定染色条件下拼色染色中各染料的初始上染速率，量化一定轧染时间下各染料通过与纤维亲和力吸附到织物上的染料量；再通过轧液率可知一定轧染时间下各染料通过轧辊轧染到织物上的染料量，根据染料质量守恒，轧染一定时间后需要补充的各染料量即为其通过与纤维亲和力作用吸附到织物上的染料量与通过轧辊轧染到织物上的染料量之和。根据轧染到织物上的染液总量计算出轧染到织物上的染液体积即为需要补充的染液的体积，从而可求得各染料需要补充的浓度。
有益效果
(1)本发明的一种染料拼色的轧染过程中补液系统的数字化控制方法，能够精确计算染料的补液量，实现对补液系统的数字化控制；
(2)本发明的一种染料拼色的轧染过程中补液系统的数字化控制方法，方法简单，结果准确，方便实现染色过程中补液系统的精确控制，为提高染色产品质量提高理论技术支持，极具应用前景；
(3)本发明的一种染料拼色的轧染过程中补液系统的数字化控制系统，将染料初始浓度、染料初始配比、染色温度、助剂用量等变量通过神经网络转化为以初始上染速率K 0，n为具体数值的可控变量，由中央处理单元计算各染料的实时添加量，并控制补液泵进行精准补液，实现补液系统由人为经验控制到数字化控制的转换。
附图说明
图1为实施例1中的原染液与计算补充液浓度补液后染液中各染料浓度变化对比图；
图2为实施例1中的原染液与计算补充液浓度补液后批次样织物的色差对比图；
其中，原液是指原染液浓度补液后的实验结果，补液是指补充液浓度补液后的实验结果。
具体实施方式
下面结合具体实施方式，进一步阐述本发明。应理解，这些实施例仅用于说明本发明而不用于限制本发明的范围。此外应理解，在阅读了本发明讲授的内容之后，本领域技术人员可以对本发明作各种改动或修改，这些等价形式同样落于本申请所附权利要求书所限定的范围。
实施例1
一种染料拼色的轧染过程中补液系统的数字化控制方法，是依据各染料的初始上染速率K 0，n计算出整个染色过程中补液系统中各染料的实时添加量，即每支染料的实时添加克数，按实时添加克数补充染液；具体过程如下：
(1)将棉织物剪成3g长宽相等的布块若干，配置5g/L的活性红3BE和活性蓝M-2GE混合染料溶液(质量比为1:1)，硫酸钠60g/L，将棉织物置于混合染料溶液中进行拼色染色，控制浴比为1:25，染色温度为40℃；
(2)计算各染料的初始上染速率K 0，n：通过拉曼光谱仪、分光光度计或液相色谱仪，检测一定拼色染色条件下，一定配方染液中各染料浓度随染色时间的变化，根据染液中不同染色时间下各染料浓度计算单位质量织物上的各染料量，绘制上染过程曲线图，由拟合的上染过程曲线图得到零点斜率即为初始上染速率K 0，n，具体如下：
为了得到较准确的初染速率，在染色前期，即染色前2min，取的数据点为整个上染过程数据点的一半。因前2min取样间隔较近无法快速取样，且考虑取样后染液变化可以忽略不计，设置6组平行染色实验，每组取6个点，每次用移液枪取800μL，上述实验重复三次。通过拉曼光谱测试三次实验的上染过程曲线，每个时间点求平均值，最终得到平均后的上染速率曲线如图1所示，对此上染过程曲线过定点(0,0)进行非线性拟合，进而求得0点斜率即为K 0，n。通过计算可知：活性红3BE和活性蓝M-2GE的初始上染速率分别为28.10mg·g -1·min -1，36.63mg·g -1·min -1。
(3)配置相同的活性红3BE和活性蓝M-2GE混合染料溶液，计算活性红3BE和活性蓝M-2GE的实时添加量m 补，n(g)，计算公式为：
Figure PCTCN2021142029-appb-000007
其中，C n为染液的初始浓度，K 0，n为各染料的初始上染速率，单位mg·g -1·min -1，n＝2，为 染料的种类数；K 0，1为活性红3BE的初始上染速率，单位mg·g -1·min -1，取值为28.10mg·g -1·min -1；K 0，2为活性蓝M-2GE的初始上染速率，单位mg·g -1·min -1，取值为36.63mg·g -1·min -1；ρ 0为初始轧染染色液的密度，单位g/mL，取值为1.048g/mL；P为织物带液率(％)，取值为74％；t为织物在轧染染色液中浸渍的时间，单位s，取值为6s；T为轧染的时间，单位min，取值为0.1min；X为单位时间轧染织物重，单位g/min，取值为30g/min。
拼色轧染布块，每轧染一块后，收回轧出的染液，需补充轧染液体积为2.15mL，需补充的活性红3BE和活性蓝M-2GE的质量分别为13.80mg和16.36mg，需补充各染料的浓度分别为6.42g/L和7.61g/L。
每组轧染液分别轧染5块，10块，15块，20块，25块织物后测试各组染液的浓度。并用原染液浓度作为补充液浓度，重复上述实验，做5组对比后，经补充液补充的染料浓度变化与原染液补充的各染料浓度变化与对应的织物色差变化分别如图1和图2所示。
实施例2
一种染料拼色的轧染过程中补液系统的数字化控制系统，包括自动计算K 0，n值单元、中央处理单元和补液泵；自动计算K 0，n值单元将K 0，n值由传感器Ⅲ传输到中央处理单元，通过中央处理单元计算出补液量并控制补液泵进行补液。自动计算K 0，n值单元由染液浓度检测仪器、传感器Ⅰ和BP神经网络模型组成；所述染液浓度检测仪器为拉曼光谱仪、分光光度计或液相色谱仪；中央处理单元由传感器Ⅱ和计算处理单元组成。
将染料拼色的轧染过程中补液系统的数字化控制系统用于实施例1中的拼色轧染过程中，具体步骤如下：
(1)通过拉曼光谱仪，检测多个历史染料配方中各染料的值(染色过程中单位质量织物上各染料的初始上染速率)，历史染料配方包括两种染料(活性红3BE和活性蓝M-2GE)，以其中一种历史染料配方为例：首先按照历史染料配方配制5g/L的活性红3BE和活性蓝M-2GE混合染料溶液(质量比为1:1)，硫酸钠60g/L，将棉织物置于混合染料溶液中进行拼色染色，控制浴比为1:25，染色温度为40℃；根据染液中不同染色时间下各染料浓度计算单位质量织物上的各染料量；绘制不同染色时间下各染料浓度计算单位质量织物上的各染料量-时间拟合曲线，上染量-时间拟合曲线的相关系数不低于0.90，最后通过对上染量-时间拟合曲线进行一阶求导处理得到0时刻时上染量-时间拟合曲线的斜率，进而得到该染料配方中各染料的K 0，n值。依次针对多个历史染料配方进行以上操作获取多个历史染料配方中各染料的K 0，n值；
(2)多个历史染料配方中不同染色时间下各染料浓度计算得到的单位质量织物上的各染料量及其对应的K 0，n值构成染料数据库，该染料数据库中的多个历史染料配方中不同染色时间下各染料浓度计算单位质量织物上的各染料量及其对应的K 0，n值分别作为输入项和输出项对神经网络模型进行训练，得到训练好的BP神经网络模型；训练的终止条件为：被错误识别的训练样本的数量占训练样本总数的比例不高于5％，被错误识别的训练样本是指BP神经网络模型输出的K 0，n值与实际K 0，n值不一致的训练样本；
(3)将活性红3BE和活性蓝M-2GE染料配方中不同染色时间下各染料浓度计算得到的单位质量织物上的各染料量输入训练好的BP神经网络模型中，由其输出各染料的K 0，n值，将各染料的K 0，n值由传感器Ⅲ传输到中央处理单元中并通过计算处理单元中补液系统数字化控制方法中的计算公式计算各染料实时添加量m 补，n，最后通过补液泵精确控制各染料的添加量。

Claims (10)

  1. 一种染料拼色的轧染过程中补液系统的数字化控制方法，其特征是：依据各染料的初始上染速率精确计算出整个染色过程中补液系统中各染料的实时添加量，按实时添加量补充染液。
  2. 根据权利要求1所述的一种染料拼色的轧染过程中补液系统的数字化控制方法，其特征在于，各染料的实时添加量m 补，n：
    Figure PCTCN2021142029-appb-100001
    其中，C n为染液中各染料的初始浓度，单位g/mL，n≥2，为染料的种类数；K 0，n为各染料的初始上染速率，单位mg·g -1·min -1；K 0，1为第一支染料的初始上染速率，单位mg·g -1·min -1；K 0，2为第二支染料的初始上染速率，单位mg·g -1·min -1；ρ 0为初始轧染染色液的密度，单位g/mL；P为织物带液率，单位％；t为织物在轧染液中浸渍的时间，单位s；T为轧染的时间，单位min；X为单位时间轧染织物重，单位g/min。
  3. 根据权利要求1所述的一种染料拼色的轧染过程中补液系统的数字化控制方法，其特征在于，所述精确是指可量化拼色染料中每支染料的实时添加克数。
  4. 根据权利要求1所述的一种染料拼色的轧染过程中补液系统的数字化控制方法，其特征在于，各染料的初始上染速率的计算基础是与轧染染色工艺条件一致，即染料种类、染液浓度及配比、染色温度、被染织物规格、浴比及助剂添加量相同。
  5. 根据权利要求1所述的一种染料拼色的轧染过程中补液系统的数字化控制方法，其特征在于，所述染料拼色的轧染过程包括酸性染料、活性染料或直接染料的轧染过程。
  6. 根据权利要求1所述的一种染料拼色的轧染过程中补液系统的数字化控制方法，其特征在于，所述染料拼色的轧染过程是指两种以上染料的拼色轧染过程。
  7. 根据权利要求6所述的一种染料拼色的轧染过程中补液系统的数字化控制方法，其特征在于，所述染料拼色的轧染过程为通过轧车对织物连续施加染液的过程，包括连续轧染过程、间歇式轧染过程或冷轧堆轧染过程。
  8. 根据权利要求1所述的一种染料拼色的轧染过程中补液系统的数字化控制方法，其特征在于，所述染液的初始浓度C n为0.01～200g/L；所述染色的温度为10～100℃，染液中中性盐用量为0～300g/L。
  9. 根据权利要求1所述的一种染料拼色的轧染过程中补液系统的数字化控制方法，其特征在于，各染料的初始上染速率K 0，n计算方法为：通过拉曼光谱仪、分光光度计或液相色谱仪， 检测一定拼色染色条件下，一定配方染液中各染料浓度随染色时间的变化，根据染液中不同染色时间下各染料浓度计算单位质量织物上的各染料量，绘制上染过程曲线图，由拟合的上染过程曲线图得到零点斜率即为初始上染速率K 0，n。
  10. 一种染料拼色的轧染过程中补液系统的数字化控制系统，其特征是：包括自动计算K 0，n值单元、中央处理单元和补液泵；
    自动计算K 0，n值单元由染液浓度检测仪器、传感器Ⅰ和BP神经网络模型组成；所述染液浓度检测仪器为拉曼光谱仪、分光光度计或液相色谱仪；所述BP神经网络模型是由染料数据库训练后的BP神经网络，染料数据库包含多个历史染料配方及染料配方中各染料的K 0，n值，训练时分别以各历史染料配方中不同染色时间下各染料浓度计算得到的单位质量织物上的各染料量作为输入项，以各染料量对应的K 0，n值作为输出项；
    中央处理单元由传感器Ⅱ和计算处理单元组成；
    自动计算K 0，n值单元将K 0，n值传输到中央处理单元，通过中央处理单元计算出补液量并控制补液泵进行补液。
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