Method and apparatus for weaving pattern formation in woven fabrics with additional weft effects

• US 8,733,406 B2
• Filed: 05/04/2011
• Issued: 05/27/2014
• Est. Priority Date: 07/09/2010
• Status: Expired due to Fees

• Current Assignee: Lindauer Dornier Gesellschaft Mit Beschrã¤Nkter Haftung (Mercedes-Benz Group AG)
• Original Assignee: Lindauer Dornier Gesellschaft Mit Beschrã¤Nkter Haftung (Mercedes-Benz Group AG)
• Inventors: Hannes, Christian, Mueller, Herbert
• Primary Examiner(s): Muromoto, Jr., Bobby
• Application Number:
  US13/809,271
• Publication Number:
  US 20130105029A1
• Time in Patent Office: 1,119 Days
• Field of Search: 139/1.R, 139/232, 139/453, 139/317
• US Class Current: 139/1.R
• CPC Class Codes: D03C 19/00 Methods or devices concerned with designing or making patterns, not provided for in other groups of this subclass
• CPC Class Codes: D03C 19/005 Electronic
• CPC Class Codes: D03C 7/06 Mechanisms having eyed needles for moving warp threads from side to side of other warp threads
• CPC Class Codes: D03D 13/002 With diagonal warps or wefts
• CPC Class Codes: D03D 13/004 with weave pattern being non-standard or providing special effects
• CPC Class Codes: D03D 21/00 Lappet- or swivel-woven fabrics
• CPC Class Codes: D03D 31/00 Lappet, swivel or other looms for forming embroidery-like decoration on fabrics
• CPC Class Codes: D03D 47/38 Weft pattern mechanisms

Abstract

For weaving pattern formation of a woven fabric with weft threads (3), warp threads (1) and effect threads (2), data sets (20) are produced according to a method in which data values are derived from weft sequence numbers (30) and from positions of interlacing points (P) of an effect thread (2) with the weft threads (3) in the pattern repeat (29). These data sets (20) are supplemented by further data values (31, 32, 33, 34) derived from the weaving pattern, in such a manner so that they form a pattern draft (28) for a weaving pattern with additional weft effects. In a weaving machine with devices for slidingly displacing effect threads (2) in the weft direction (12), the weaving pattern formation is derived from the data sets (20) of this pattern draft (28).

Claims

1. A method of controlling a weaving machine for producing a woven fabric of warp threads, weft threads and at least one effect thread, wherein each said effect thread forms interlacing points at which said effect thread crosses behind respective ones of said weft threads on a back side of said woven fabric and crossing points at which said effect thread crosses over in front of respective ones of said weft threads on a front side of said woven fabric, wherein respective ones of said interlacing points are spaced apart from one another with a respective plurality of said warp threads therebetween in a weft direction of said woven fabric, and wherein said method comprises steps:

a) specifying a pattern repeat area for said woven fabric, wherein said pattern repeat area extends in said weft direction and in a warp direction of said woven fabric and represents a pattern repeat of a weave pattern of said woven fabric, wherein said weave pattern comprises successive weave pattern rows successively after one another in said warp direction, and wherein said weave pattern rows include interlacing weave pattern rows that respectively include at least a respective one of said interlacing points in said pattern repeat;

b) producing plural data sets including a respective interlacing data set for each respective one of said interlacing weave pattern rows, wherein each said interlacing data set includes plural data values comprising a first data value derived from a weft sequence number of a respective one of said weft threads behind which said effect thread crosses at said respective interlacing point, a second data value derived from a position of said respective interlacing point in said weft direction in said pattern repeat, and at least one further data value derived from said weave pattern;

c) forming, with said plural data sets, a pattern draft for said weave pattern;

d) storing said pattern draft in a data storage medium; and

e) using a control device of said weaving machine, reading out said data values of said data sets of said pattern draft from said data storage medium, and in accordance with said data values controlling a weaving operation of said weaving machine to produce said woven fabric.

2. The method according to claim 1, wherein said weave pattern rows further include non-interlacing weave pattern rows that do not include one of said interlacing points, wherein said plural data sets further include a respective non-interlacing data set respectively for each said non-interlacing weave pattern row, and wherein said respective non-interlacing data set includes a first non-interlacing row data value derived from a weft sequence number of said respective non-interlacing weave pattern row and a second non-interlacing row data value derived from said second data value of said respective interlacing data set of said interlacing weave pattern row that follows successively in said warp direction after said respective non-interlacing weave pattern row.

3. The method according to claim 1, wherein each one of said weave pattern rows corresponds to one weaving motion cycle of said weaving machine, which may include a weft insertion and a reed beat-up of one of said weft threads or may be a weftless motion cycle in which no weft thread is inserted.

4. The method according to claim 1, wherein said weave pattern rows further include non-interlacing weave pattern rows that do not include one of said interlacing points, wherein said plural data sets further include a respective non-interlacing data set respectively for each said non-interlacing weave pattern row, wherein each said non-interlacing data set includes plural data values comprising a first data value derived from a weft sequence number of said respective non-interlacing weave pattern row and at least one further data value derived from said weave pattern, further comprising determining locations of said crossing points at which said effect thread is on said front side of said woven fabric and of said interlacing points at which said effect thread is on said back side of said fabric, and wherein said at least one further data value in each said data set comprises an effect thread position data value which indicates whether said effect thread is on said front side or said back side of said fabric in said respective weave pattern row to which said respective data set pertains.

5. The method according to claim 1, further comprising defining a reference line extending in said warp direction along said fabric, and wherein said second data value in each respective said interlacing data set is equal to a respective geometric spacing distance from said reference line, in said weft direction, of said respective interlacing point in said respective interlacing weave pattern row.

6. The method according to claim 1, further comprising defining a reference line extending in said warp direction along said fabric, and wherein said second data value in each respective said interlacing data set is calculated from a difference between two geometric spacing distances from said reference line, in said weft direction, respectively of two successive ones of said interlacing points in two successive ones of said interlacing weave pattern rows.

7. The method according to claim 1, further comprising drawing said warp threads into reed gaps of a reed of a weaving reed device of said weaving machine, wherein said reed gaps are spaced from one another according to a defined reed division, a respective reference indicium is assigned respectively to each one of said reed gaps, said first data value in each respective said interlacing data set is respectively equal to said weft sequence number, and said second data value in each respective said interlacing data set is respectively derived from said respective reference indicium of a respective one of said reed gaps associated with said respective interlacing point.

8. The method according to claim 7, wherein said reference indicia of said reed gaps comprise respective numbers in an increasing or decreasing number sequence.

9. The method according to claim 8, wherein said second data value in each respective said interlacing data set is calculated from a difference between two of said respective numbers assigned respectively to two of said reed gaps.

10. The method according to claim 1, wherein said at least one effect thread of said woven fabric comprises plural effect threads within said pattern repeat area, said plural effect threads respectively form a plurality of said interlacing points with a respective one of said weft threads in a respective one of said interlacing weave pattern rows, and said data values of each said respective interlacing data set include a plurality of said second data values respectively derived from respective different positions of said plural interlacing points in said respective interlacing weave pattern row.

11. The method according to claim 1, further comprising defining additional data values that relate to parameters of said woven fabric and associated adjustments of said weaving machine, and combining said additional data values with one or more said pattern draft to form an article data set.

12. The method according to claim 1, wherein said data storage medium comprises an exchangeable memory device in which said pattern draft is stored in a specified data format.

13. The method according to claim 1, further comprising graphically or tabularly displaying said data sets on a computer display screen of said weaving machine using a computer program being executed in said control device of said weaving machine.

14. The method according to claim 13, further comprising producing said data sets using said computer program, by interactive input of graphic symbols or alphanumeric characters in graphically represented raster fields of an effect raster area and in graphically represented data fields or raster fields of said pattern draft on said computer display screen.

15. A non-transitory tangible machine-readable data storage medium encoded with and storing a functional data structure comprising a pattern draft, which when read by a control device of a weaving machine controls a weaving operation of said weaving machine to produce a woven fabric, in accordance with said pattern draft, of warp threads, weft threads and at least one effect thread, wherein each said effect thread forms interlacing points at which said effect thread crosses behind respective ones of said weft threads on a back side of said woven fabric and crossing points at which said effect thread crosses over in front of respective ones of said weft threads on a front side of said woven fabric, wherein respective ones of said interlacing points are spaced apart from one another with a respective plurality of said warp threads therebetween in a weft direction of said woven fabric,

wherein:

said pattern draft comprises plural data sets respectively allocated to successive weave pattern rows of a weave pattern in a pattern repeat area for said woven fabric,

said pattern repeat area extends in said weft direction and in a warp direction of said woven fabric and represents a pattern repeat of said weave pattern,

said successive weave pattern rows follow successively after one another in said warp direction,

said weave pattern rows include interlacing weave pattern rows that respectively include at least a respective one of said interlacing points in said pattern repeat, and

said plural data sets include a respective interlacing data set for each respective one of said interlacing weave pattern rows, wherein each said interlacing data set includes plural data values comprising a first data value derived from a weft sequence number of a respective one of said weft threads behind which said effect thread crosses at said respective interlacing point, a second data value derived from a position of said respective interlacing point in said weft direction in said pattern repeat, and at least one further data value derived from said weave pattern.

16. A weaving system comprising said data storage medium according to claim 15 in combination and connected with a weaving machine, wherein said weaving machine comprises:

an effect thread guide device that is configured and arranged to guide said effect thread,

a sliding displacement device that is configured and arranged and connected to said guide device so that said guide device and therewith said effect thread are slidably displaceable in said weft direction,

a sliding displacement drive connected with said sliding displacement device so as to drive a sliding displacement thereof,

a vertical motion mechanism connected to said guide means and configured to vertically move said guide means by a vertical motion,

a weaving reed device configured and arranged to beat-up said weft thread against a woven fabric edge of said woven fabric by carrying out a back-and-forth beat-up motion, wherein said weaving reed device comprises a row of reed blades with reed gaps respectively therebetween, wherein said reed gaps are upwardly open, and wherein said weaving reed device and said guide device are configured and arranged so that said effect thread can be submerged downwardly into and emerged upwardly out of said reed gaps,

a user input device;

a control device that is configured to execute a computer program and that is connected for signal transmission with said user input device, said data storage medium, said sliding displacement drive and said vertical motion mechanism, so that said control device executing said computer program reads out said pattern draft from said data storage medium and accordingly controls successive motion cycles of said weaving machine respectively according to successive ones of said data sets of said pattern draft, wherein at least said sliding displacement of said sliding displacement device and said guide device and said effect thread is controlled according to said second data values of said interlacing data sets of said pattern draft by said control device executing said computer program.

17. The weaving system according to claim 16, wherein:

said vertical motion mechanism of said weaving machine comprises a shedding device configured and arranged to form sheds of said warp threads, and a shedding machine that is connected to said shedding device so as to drive a shedding motion of said shedding device,

said control device is connected for signal transmission with said vertical motion mechanism in that said control device is connected for signal transmission with said shedding machine, and

said vertical motion mechanism is connected to said guide device in that said shedding device is connected with said sliding displacement drive and with said sliding displacement device which is connected to said guide device, such that said guide device can be moved by said shedding device under control by said control device according to said at least one further data value in a respective said data set of said pattern draft, to move said effect thread above or below a weft thread that is to be inserted.

18. A non-transitory tangible machine-readable data storage medium storing a data structure comprising a pattern draft, which when read by a control device of a weaving machine controls a weaving operation of said weaving machine to produce, in accordance with said pattern draft, a woven fabric of warp threads running in a warp direction, weft threads running in a weft direction, and at least one effect thread that crosses over a respective one of said weft threads at a crossing point and crosses under a respective one of said weft threads at an interlacing point according to a weave pattern,

wherein:

said weave pattern comprises successive pattern rows that extend in said weft direction and successively follow one another in said warp direction,

said pattern draft comprises successive data sets that are respectively individually allocated to said pattern rows, and

a respective one of said data sets allocated to a respective one of said pattern rows having at least one of said interlacing points includes a first data value identifying said respective pattern row, and a second data value identifying a position, in said weft direction, of said interlacing point in said respective pattern row.