Detailed knowledge of setting machines in printing and dyeing factories is worth having!

The styling workshop is an important part of the printing and dyeing factory. Its processing level directly affects the cleanliness, width and stability of the fabric surface. The finishing process is the main channel to increase the value of the fabric.

The purpose and principle of the setting machine

Purpose: To improve the feel, slip, color, width, strength, appearance, etc. of the fabric by padding various dyeing materials for softness, stiffness, anti-skid, tenter and resin finishing. For non-pure cotton Variety can also play a role in stabilizing size.

Principle: The cloth is dipped in chemical materials in the trough, and is evenly pressed by the roller before entering the oven. When the cloth passes through the oven, it will be dried and shaped under the action of high-temperature hot air. The shaped cloth will have a good feel and stable size.

1. Structural characteristics of the shaping machine and the functions of each unit

The setting machine mainly consists of five parts, including the feeding part, the weft straightener, the chain, the oven body and the drop and roll device. There are also chemical systems and oil furnace heating systems.

1. Feeding part.

The structure is relatively simple, consisting of a trough and a roller. The cloth enters the trough and carries chemical materials, and then the excess chemical materials are squeezed out by the rollers. Therefore, the chemical materials on the cloth are very uniform, which is a prerequisite for obtaining high-quality styling cloth.

What you need to pay attention to here is to always pay attention to whether the pressure on the left and right sides of the roller is consistent. Otherwise, the side with low pressure will load more material, and the side with high pressure will load less material, and the cloth will be inconsistent from left to right. Quality issues.

2. Weft trimmer.

The weft straightener currently configured on the setting machine is the Mahlo RFMC94H photoelectric weft straightener. There are four sets of sensors on the Mahlo photoelectric weft straightener. EachThe set of sensors includes two parts: luminous and photosensitive parts, which can detect the weft and inclination of the cloth through the photoelectric effect. The action part uses a hydraulic system. When the signal of the weft skew is transmitted back to the control main board, the control main board will issue an instruction to drive the hydraulic system to make the curved roller or straight roller adjust the corresponding angle, thereby correcting the weft skew. Specifically: when there is a difference between the center of the cloth and both sides, the curved roller will move; and when there is a difference between the left and right sides, the straight roller will move.

3. Chain part.

The tenting of the fabric on the setting machine is produced by a chain. The chain of the setting machine is driven by a high-power motor close to the cloth dropping place. The chain is equipped with a needle plate. When the cloth enters the chain, the brush wheel on the cloth pressing wheel presses the cloth on the small needle on the needle plate, and the cloth is ready. It enters the oven driven by two rows of chains. The chain of this setting machine is different from other setting machines. It can control the stretching of each section of the needle clip separately to achieve good results. However, some setting machines cannot adjust each section of the needle clip and can only adjust it to Rectangle or trapezoid.

4. Oven body.

The setting machine has eight sets of ovens. Under the blowing effect of the circulating fan (2), the air is continuously sprayed on the cloth surface through the pores on the star-shaped air jet frame. After the hot air contacts the wet cloth, the temperature drops and the humidity rises, and is discharged from the large hole on the star-shaped air jet frame, passes through the filter (6), is heated by the heat exchanger, and is continuously recycled. The heat exchanger (8) is located below the filter (6), and the hot coal used is hot oil. The heat exchanger has many thin radiating fins to produce efficient heat exchange.

5. Cloth dropping and rolling device.

The setting machine can adopt two cloth discharging methods: left-and-right type or rolling type according to production needs. Both methods use a motor to drive the chain drive. When the cloth is rolled out, the tension stability of the cloth is required to be high, and the cloth needs to pass through a tension-adjusting guide roller controlled by an air pump. With left-and-right drop cloth, the cloth does not need to pass through the tension adjustment roller but instead passes through a fixed guide roller.

Correct operation method of setting machine

1. Fabric feeding rules for setting machine – fabric feeding

1. Preparations before homework

1.1 Thread the guide cloth according to the prescribed route (or check the worn guide cloth).

1.2 Clean the machine (the cloth feed frame and the front of the machine), check whether there are any debris on the needle clamp, and tidy up the surrounding environment, such as floor cleaning, cloth car cleaning, cover cloth specifications, plastic box cover cloth, and cloth guide car Gaib et al.

1.3 Classify the cloths to be produced according to process conditions, and process cloths with the same process (formula) together.

1.4 Check the relevant information on the process card and cartoning card, and according to the requirements of different varieties, adjust the fabric feeding tension, weft detection width, tenter width and edge suction width, and set the air pressure of the edge suction device at the same time. At the same time, notify the material chemical personnel

1.5 Keep track of the production progress according to the plan, and prioritize the production of urgent products.

1.6 Check the guide cloth

1.6.1 Strictly distinguish fluorescent and non-fluorescent guide fabrics.

1.6.2 Each process should ensure that the guide cloth is complete, neat, strong, clean, and wide enough to avoid interruption, tearing, or needle detachment during the processing, or causing stains on the processed cloth. Dirty or torn guide cloths should be torn out. And re-sew the head. If you need to change it, please contact the squad leader in time to change it and make relevant registration.

1.6 Check the power cord and socket of the sewing machine. If there is any damage, notify the squad leader in time to replace it.

2. Operation process

2.1 Find cloth: According to the production plan, take the “Finishing Process Card” from the main console, find the cloth to be processed in the area to be processed according to the license plate number and other information, and prepare two to three cars at a time; if there is no plan, implement advanced FirstThe processing principle is based on the principles of color and fluorescence gradient.

2.2 Material preparation: After finding the cloth, notify the chemical industry to prepare the specified materials.

2.3 Chabutou.

2.3.1 Check whether the seam ends are pulled out as required in the previous process, and carefully check whether the corresponding “Finishing and Processing Packaging Card” matches the hot melt label of each section of fabric; if they match, push it to the machine head; If the quality of the seam ends does not meet the requirements (flat, straight, neat, and secure), the heavy seams must be torn off and registered and submitted to the squad leader for confirmation.

2.3.2 If the cloth head is not pulled out as required during the process, make a record in the error record book, and estimate the quantity on the card and the actual cloth quantity to avoid missing processing;

2.3.3 Check whether the cloth has been sampled and has no seams or cuts to prevent problems such as flying or tearing the cloth;

2.3.4 Check whether the front and back sides are correct and ensure that the machine is processing in the correct direction.

2.4 Check the quality of the cloth surface.

2.4.1 Check the records related to the pre-processing process, such as whether it has been processed or prompt the following precautions after processing.

2.4.2 Measure the width. Measure the width of the fabric to be processed and record it on the “Finishing and Processing Packaging Card”.

2.4.3 Check the fluorescence. Turn on the fluorescent light and turn off other lighting to check the fluorescence. If the ambient light is too strong, take about 10CM from the head and tail of the cloth truck and put it close to the fluorescent lamp to compare the fluorescence. If there is any discrepancy, it means that the cloth is defective. question.

2.4.4 Check the quality of other cloth surfaces. Carefully check the several yards of cloth on the upper layer of the incoming cloth before processing. Check the quality of other cloth surfaces frequently during processing.

2.4.5 For problems found in the above inspection, such as width or other aspects that do not meet the process requirements or previous process records, other quality problems, etc., notify the squad leader or superior, and suspend processing for problems that cannot be solved in this process.

2.4.6 Check the weft skew status of the incoming fabric, and turn the fabric to adjust if necessary.Adjust the direction in advance to facilitate processing by this machine.

2.5 Check the process requirements: Check the staining process requirements in the process column or remarks column of the “Finishing Process Card”. If roll packaging is required, inform the dropper immediately to prepare for roll preparation.

2.6 Ready to boot.

2.6.1 Tear off the uneven cloth ends (report them for processing if they cannot be torn normally), and use a sewing machine to connect the top fabric ends of the processing cloth with the guide fabric. When ready, ring the bell and verbally notify the main machine to start, and hand the process card to the main machine.

2.6.2 When feeding cloth into rolls, first manually rotate the rolled cloth to adapt to the accelerated movement of the initial processing and prevent short-term excessive tension.

2.7 Process inspections and matters.

2.7.1 During the processing, pay attention to the condition of the cloth surface, strictly ensure that the cloth surface does not deviate from the center of the cloth feeding roller, and use a sewing machine to sew the fabric segments from beginning to end. The seams must be straight and firm. Don’t mistake the front and back (if there’s butter pen writing on it, it’s the front or there’s a hot melt label on it, it’s the front), the two sides should be aligned and there should be no seams, especially the left and right seams should not be reversed. The fabric can be processed continuously (the seam thread used is the same as mentioned above). If any problems are found, report them promptly and keep records. In addition, you should also check that the joints must have butter notes or hot-melt labels. If not, notify the squad leader to rewrite and register.

2.7.2 Check whether the sampling interface and the packing card are marked by the sampling personnel as required. If not, the squad leader or on-site management personnel must be reported and registered.

2.7.2 Check whether the sampling interface and the packing card are marked by the sampling personnel as required. If not, the squad leader or on-site management personnel must be reported and registered.

2.8 Follow-up work.

2.8.1 When processing each car, prepare at least the cloth to be processed for the next car and place it parallelly in front of the cloth car being processed. When there is at least about 500Y left, be prepared for subsequent work. If there is cloth to continue processing, Prepare fabric, check, seam, etc. If there is no fabric that can be processed temporarily, the confirmed guide fabric should be connected.

2.9 End of workdo.

2.9.1 Immediately after each car’s fabric processing is completed, the empty fabric cart (broken fabric carts are sent to the designated location for repair, the old workshop is sent to the machine repair door, the new workshop is sent to the outside of the material room) and the cover cloth are sent to the cloth dropper’s office . After all work is completed, clean and tidy up, turn off water, lights, electricity, steam, air, and relieve pressure.

3. Things to note

3.1 Some special varieties are selective to the machine and must be processed according to process requirements or notifications.

3.2 When changing materials or varieties, the machine must be connected to the cloth guide, and normal cloth cannot be stopped in the machine.

3.3 For connection processing of different varieties, the cloth width differs by 5CM, and the wide-width transition fabric processing is required.

3.4 The cloth should be light-colored first and then dark-colored; first bleached and then extra white. It is not suitable to mix them together for processing.

3.5 After whitening, special white cloth should be produced, and bleached cloth cannot be made directly.

3.6 Insert the seam head of the fabric, make sure that the remaining thread at the seam head does not exceed 2CM, and clean the ground cloth and the head in time.

3.7 When processing rolled cloth or needing to unroll it for sampling, bamboo mats should be placed and the spindle guard should be used to prevent stains.

3.8 Broken or dirty bamboo mats must be replaced in time and records must be kept.

3.9 Turn off the power switch (OFF) of the sewing machine when not in use. Do not place cloth bags, rags and other debris on the sewing machine table.

3.10 During the production or transportation of fabrics, do not bring any part of the body close to the machine or other pressure points to ensure safety; when putting on fabrics or doing cleaning work, the machine must be stopped before proceeding.

3.22 For rolled cloth, only the same process can be rolled into the same roll. The “same process” means that the product names are only different in serial number, the finishing and processing procedures are the same, the formula is the same, and the width of the cloth clip is similar (the difference does not exceed 3cm). For different processes, up to two rolls are allowed in one roll, and they are connected with a guide cloth of more than 50Y in the middle.

3.12 Pay attention to the cleanliness and maintenance of the surrounding environment during processing (responsible for the front half of the machine and its surroundings

surrounding environment).

2. Operation rules – startup and shutdown

①. Boot

1.1 Click the cloth feeding mechanism button to enter the cloth feeding mechanism operation interface, and click the cloth feeding master control switch in the upper left corner to red.

1. 2 Click the cloth delivery mechanism button to enter the cloth delivery mechanism operation interface, and click the cloth delivery master control switch in the upper left corner to red.

1.3 Press the reset button “RESET” on the operation panel, the indicator light goes out, the power-on indicator light flashes, press the power-on indicator light chain to rotate, and the acceleration indicator light flashes.

1.4 Click the oven button to enter the heating system:

a. Click the circulation fan icon to enter the circulation fan power setting window. Click the circulation fan total button to pop up the circulation fan power setting window. Click the white bottom number box to pop up the numeric keypad. Enter the required output power value and press OK.

b. Click the exhaust fan icon in the upper left corner or upper right corner to enter the exhaust fan power setting window, click the manual control button and confirm, click the white background number box to pop up the small numeric keyboard to enter the required value and confirm. If you click the automatic control button and confirm, the exhaust fan will automatically adjust the exhaust fan power.

c. Click the digital box showing the temperature in the oven simulation icon to enter the heating window, click the heating total to set the heating temperature, or set the heating temperature of each oven section separately. When the heating temperature is below 90 degrees, click the small fire icon to heat. When the heating temperature is above 90 degrees, click the high fire icon to heat and confirm.

1. 5. Thread the guide belt of the cloth feeding part (9 from the cloth feeding frame to the operating table) according to the correct cloth threading route, and thread the guide belt of the cloth output part along the correct cloth threading route (from the cloth output overfeed roller to the cloth output frame).

1. 6. Press the red stop button on the operation panel. The chain will stop and the power-on indicator light will flash. Guide the guide fabric onto the tenter chain and press the push button of the overfeed wheel for about 10 seconds until the push button indicator light turns on. Turn on the motors of each part of the cloth feeding mechanism to “1”. Raise the slurry pouring trough, apply the padding pressure, turn on the motors on all parts of the console (except the upper needle protection entrance button), and click the cloth feeding master control button in the upper left corner of the cloth feeding mechanism until it turns green.

1.7 Start the front half of the machine. After the guide cloth passes the upper needle protection entrance, open the upper needle protection entrance button to “1”. Stop the machine when the guide cloth comes out of the oven and reaches the cloth discharge overfeed roller. Put the guide cloth and the upper needle protection entrance. The guide belt of the cloth outlet part is connected properly. Click the main control button of the cloth discharging mechanism to green, turn on each motor of the cloth discharging part to “1” (except the cooling barrel tension motor switch), restart the machine, introduce the guide cloth to the cloth discharging frame and stop it. Turn on the cooling barrel tension motor switch to “1”.

1.8 Click the tenter chain control button to enter the chain control interface, enter and confirm the width according to the process requirements on the process card.

1.9 According to the process card, find the cloth to be processed and push it to the cloth feeding place to connect the guide cloth, melt the raw material and put it into the pouring tank (drain the first 20L). According to the structural condition and process requirements of the cloth to be processed, the cloth is rolled or loaded. Set the parameters of each part, and preset the weft straightener with medium fast/medium slow, left fast/right fast according to the weft skew of the fabric to be processed. Ring the bell to notify the operator to prepare to start the machine. After the bell rings, press the start button and the acceleration indicator light will flash. Set the vehicle speed required by the process and confirm it. Click the acceleration button and the vehicle speed will automatically increase to the vehicle speed required by the process.

②. Shutdown

2.1 After processing the cloth, introduce the guide cloth to the console, tear the guide cloth, and click the cloth feeding master control button until it turns red., close the upper needle protection entrance button to “0”. Start the second half of the machine, stop when the cloth guide head reaches the cloth discharge overfeeding roller, connect the guide cloth to the guide belt, turn off the cooling barrel tension motor to “0”, start the second half of the machine until the cloth guide completely comes out of the cloth frame, and stop. Turn off the main cloth output control button to red, start the machine and let the chain idle.

2. 2. Click the oven button to enter the heating system interface, set the heating temperature to 150 degrees, the circulating fan power to 50%, and the exhaust fan to be manually controlled and exhausted at 100% power. This can effectively remove the remaining moisture in the oven and maintain the oven. role. After running for about 30 minutes, turn off the heating system and let the circulation fan and exhaust fan continue to run until the temperature in the oven drops below 100 degrees before turning off again.

2.3 Turn off the main power control switch of the power cabinet to “OFF”, the computer will automatically store the processing data and then shut down, and clean the entire machine.

③. Fabric dropping rules of setting machine – fabric dropping

1 Preparation before operation

1.1 Clean the machine (cloth drop frame and the rear half of the machine) and tidy up the surrounding environment, such as the floor, rear cloth carriage, etc.

1.2 Check whether there is any abnormality in the rear part of the equipment, stacker truck, etc., and whether the cloth guide and threading route is correct.

1.3 Get the <> and <> from the main machine to understand the process and quality requirements of the cloth to be processed.

1.4 Place the cloth guide car under the cloth drop frame, and prepare the empty car to receive and place the produced processed cloth

1.5 For fabrics that need to be rolled, such as windproof printing varieties for mercerization and subsequent processes, coated finishing varieties, VP finishing varieties, resin cloths, etc., it is necessary to find an appropriate empty roll rack (for external delivery cloth) 01~50 small roll rack), and adjust the position to ensure that the rolling roller and the cloth rolling roller are parallel.

1.6 Ring the bell to notify the main unit to start.

2. Operation process

2.1 After turning on the machine, smoothly introduce the guide cloth into the special cloth guide car of each machine. After the guide cloth is finished, push the empty cart to the bottom of the cloth drop frame, insert the normal cloth, and pull out the cloth head about 150CM. Fold it and place it on the frame of the cloth cart to facilitate sewing and checking information during the next production process.

2.2 Check the cloth head information and compare it with the information on the card. Pay attention to the correctness of the front and back sides.

2.3 Observe the condition of the dropped cloth surface, especially the first 100 to 300 yards of each load of cloth should be carefully inspected to see if there are any defects. If defects appear continuously for more than ten yards, the main block machine should be notified immediately. If the defects cannot be eliminated immediately, the fabric feeder should be notified to change the guide cloth and stop the machine for inspection. Production can only continue after the fault is eliminated.

2.4 During processing, pull out about 150CM every three hundred yards or so to carefully inspect the cloth surface, measure the width, and record the width change range on the <> and the “Finishing and Processing Flow Card” 》If the requirements are not met, report to the main machine or the squad leader in time to take measures (the allowable difference in fabric width is 0.5CM), and pull out at least 1.5Y of fabric from each car for review in the next process.

2.5 During the production process, the condition of the cloth surface must be continuously observed. The cloth surface must be inspected through light every 500 yards or so to detect defects such as weft shifts and holes in a timely manner.

2.6 Sampling on request.

2.6.1 On the cloth section marked with “sampling” on the <>, sampling is generally done more than 80 yards past the cloth head (within 80 yards, sampling is done at the cloth head. If the requirements are high, it is necessary to Tear off 0.5 yards of the fabric before taking a sample). When sampling, be careful not to cause short-coded fabrics below 30 yards or zero-code fabrics below 10 yards.

2.6.2 Measure the feel, color, hair volume, and hairiness. The effective length is 20CM. Leave a sample of the defective fabric, and generally take a cycle of defects.

2.7 Each time the machine changes process (such as changing materials, changing water, changing temperature, changing varieties, discharge(Troubleshooting) After restarting, you need to carefully observe the cloth surface for more than 300 yards, and report any problems in a timely manner.

2.8 During the production process, it is necessary to pull out more than half of the cloth ends of the produced cloth (except for rolls), and check the product name, code length, etc. If any discrepancy is found, notify the squad leader and record it.

2.9 When each car’s cloth is about to be processed (50 to 100Y is left), put all the cloth ends pulled out from the front of the car into the car.

2.10 After the production of each piece of cloth is completed, the name of the main machine/cloth dropper on duty shall be signed at the process of the machine on the <> and <> and production date, put the <> in the cloth car bag and register it in the computer. Change to the next load of cloth.

2.22 Cover the processed cloth with a cover cloth correctly and send it to a certain grade in the area to be processed in the next process, and write the grade on the <> and <> on, and then send the <> back to the main console.

2.12 When loading and unloading fabric, please note that the rolling machine must be hung with a protective hook after the rolling is completed to prevent the rolling machine from falling when the compressed air is stopped;

2.13 After all production tasks are completed, clean the machine and the surrounding environment, and turn off the water, pressure, lights, electricity, steam, and gas.

3. Things to note

3.1 During the production or transportation of fabrics, do not bring any part of the body close to the machine or other pressure points to ensure safety; when putting on fabrics or doing cleaning work, the machine must be stopped before doing so.

3.2 Pay attention to the cleanliness and maintenance of the surrounding environment during processing (responsible for the second half of the machine and its surrounding environment).

3.3 When rolling before grinding, if it is found that the edge is thicker than the cloth body, the needle clamp of the setting machine needs to be increased or decreased by about 1CM once (around the required value).

3.4 When there are repairable fabric defects (such as the wrong fabric width) exceeding 100Y, you need to fill in the unqualified product processing form and pull out a representative sample; for irreparable fabric defects (such as damage) 5Y When doing the above, a scrap form needs to be filled in and handed over to the main console or squad leader.

3.5 Drop weft skew/bow weft requirements:

3.5.1 Plain weave, herringbone twill and jacquard with symmetrical structure: setting 3%.

3.5.2 Unidirectional twill fabric and jacquard fabric whose main structure is unidirectional twill: each process before setting is based on the natural slope, and no control requirements are required; setting (no more setting afterward)/post-process: within the target value ;

3.5.3 One-way twill solid color/strip fabric and the main structure is one-way twill jacquard solid color/strip fabric, and the weft direction does not contain a dark grain effect. It is pre-stretched according to the percentage indicated in the process.

3.5.4 The main structure of unidirectional twill plaid fabric is unidirectional twill jacquard plaid fabric, which is pre-stretched at 1~3%.

3.5.5 For plain weave, herringbone twill and jacquard solid/striped fabrics with symmetrical structures, the drop weft bias bow control standard is 3.5%; for plain weave, herringbone twill and jacquard plaid fabrics with symmetrical structures, the drop weft bias bow control is The standard is 1.5%; the standard for plain weave, herringbone twill and jacquard plaid with symmetrical structure is 0.8cm/20cm; HUGOBOSS / TEXWOOD weft skew 2%, bow weft 1%.

3.6 When loading, the height of each truck should not be 50CM higher than the cloth truck and the width should not be 10CM wider than the truck; the cloth that needs to be loaded and transported should not be 20CM higher than the truck and 0CM wider than the truck; the diameter of each roll when rolled No more than 130CM.

Basic knowledge of shaping technology

1 Main process parameters and control

Formula: It refers to the proportion of various chemicals used in the material liquid when setting, which determines the feel, slippage, color, etc. of the cloth surface after setting.

Roller pressure. The roller pressure of feeding materials during shaping determines the amount of material liquid carried by the cloth, which has an important impact on the feel and color of the cloth surface.

Drying temperature, the drying temperature during shaping is one of the main factors affecting the shaping quality. Especially in the resin finishing process, the shaping and drying temperature has a great impact on the dimensional stability and surface smoothness of the fabric. For soft finishing, it is advisable to control the drying temperature until the cloth surface is dry. The drying temperature should not be too high, otherwise it will affect the feel of the fabric.

Overfeeding, the size of overfeeding directly affects the weft density of the fabric, thereby affecting the shrinkage performance of the fabric. At the same time, in order to take into account the tension during fabric production, wrinkles and weft skew must be appropriately prevented.

The stenter width and the stenter width determine the width of the fabric after shaping, so that the width of the fabric after shaping can meet the process requirements, and the width of the fabric after pre-shrinking can meet the customer’s requirements.

2 Analysis of heat setting process conditions

Fabric heat setting is usually a process in which the fabric is maintained at a certain size, heated for a certain period of time under certain temperature and humidity conditions, and then cooled. Therefore, the main process conditions for heat setting are nothing more than temperature, time, tension and swelling agent.

1. Temperature

Temperature is the main factor affecting the quality of heat setting. Because after the fabric is heat-set, the extent to which the original wrinkles are eliminated, the surface smoothness is improved, the dimensional thermal stability and other wearing properties of the fabric are closely related to the heat-set temperature.

2. Time

Setting time is another major process condition for heat setting. After the fabric enters the heating zone, the time required for heating and setting can be roughly divided into the following parts:

1. After the fabric enters the heating zone, the time required to heat the fabric surface to the setting temperature is also called the heating time.

2. After the fabric surface reaches the setting temperature, the heat penetration time required for the fibers inside and outside the fabric to have the same setting temperature is required.

3. After the fabric reaches the setting temperature, the time required for the molecules in the fiber to adjust according to the setting conditions is also called the molecular adjustment time.

4. The time required for the fabric to come out of the drying room and stabilize the size of the fabric for cooling, or called the cooling time. The finalization time usually refers to the time required for the first three items, but does not include the fourth item. If the first item is regarded as a preheating effect, then the setting time only refers to the time required for the second and third items, that is, the time required for heat penetration and molecular adjustment.

The time required for heating and heat penetration depends on the performance of the heat source, the weight of the fabric per unit area, the thermal conductivity of the fiber and the moisture content of the fabric.

3. Tension

The tension on the fabric during the heat setting process has a certain impact on the setting quality, including the dimensional thermal stability, strength and breaking elongation of the fabric.

The thermal stability of the warp dimension increases with the increase of warp overfeed during shaping, while the thermal stability of the weft dimension decreases with the increase of the width stretching degree.

The average single yarn strength of the fabric after shaping is slightly higher than that of the unshaped fabric, and the change in the weft direction is more obvious than that in the warp direction.

The breaking elongation of the fabric after setting, the weft direction decreases as the stretch degree increases, while the warp direction increases as the overfeed increases.

Therefore, in order to obtain good dimensional thermal stability of the fabric and improve the wearing performance of the fabric, the warp direction should be appropriately overfeeded during heat setting, and the weft stretch should not be too high. For this reason, it is required not to use a large warp tension in the pre-treatment to avoid excessive elongation in the weft direction and force a large contraction in the weft direction, which will require a larger stretching in the future.

(1. Reconstruction of molecular chainsThe number of folds increases with the increase of heat treatment temperature: 2. Tension hinders the refolding of molecular chains; 3. At very high temperatures, the role of tension in hindering chain folding is greatly reduced. ) Tension has a significant impact on fiber structure, and fiber structures are closely related. Therefore, it is important to pay attention to tension control during any shaping process.

4. Swelling agent

Moisture has a “loose” fiber structure, which enhances the fluid-like movement of macromolecular segments. The plasticizing effect of moisture during the heat setting process affects the supramolecular structure and physical properties of the fiber.

Control of shaping quality

1 Quality prevention and control

The quality of shaping is related to the quality of the entire finishing process, because most cloths have to be shaped after other finishing processes. Quality problems during shaping will inevitably lead to wasted efforts, so quality prevention during shaping Very important with control.

Machine cleaning, the cleaning of the setting machine is very important. At present, nearly half of the stains in post-finishing are caused by setting, which shows the importance of cleaning the setting machine. The focus of cleaning is mainly on the rolling roller. During the production process, flying particles are constantly stuck to the roller. The flying particles on the roller stick to the cloth surface, leaving colored stains (especially when producing white cloth). Therefore, constant inspection is required during the production process. Check whether there are foreign objects in the rollers. If any are found, clean them in time.

Rags and debris on the needle board will cause the processing cloth to come off the needles and cause ruffles. Too much hair on the hot air net affects heat dissipation. These must be cleaned in time. Others (such as guide rollers, etc.) are the same as others. The process is also indispensable for cleaning work. At present, the main machine is responsible for cleaning and sanitation, with the cooperation of the machine operators and the supervision of the squad leader.

2 Impact of operation and equipment maintenance on quality

First of all, improper tension control during operation will cause edge wrinkles and weft skew, and poor seams will cause obvious quality problems; secondly, equipment maintenance such as overfeeding wheels and brushes can avoid weft shifting and detachment. Needle etc.

Control of the production sequence, in order to avoid mutual contamination between processed cloths, prevent staining, fluorescent pollution, etc., in the production of garment dyed cloth and bleached cloth, in order to prevent the fluorescence of the guide cloth from contaminating the processed bleached cloth, When processing bleached cloth, you must use a bleaching guide cloth; after producing special white cloth and adding white cloth, if you want to process bleached cloth, you must wash the machine thoroughly. After processing some fabrics that are prone to stains or adding white cloth, the material cylinder, material tube, material trough, etc. must be thoroughly cleaned before processing other cloths.

3 Keep your machine free of accumulated dust and dirt

4 Clean carefully before starting up

Clean the fabric feed frame, trough, rollers, weft straightener J-box, fabric drop frame, etc. to ensure that the route the fabric passes through is clean. Check whether the needle clamp is intact and free of debris. Pull out the lint filter in the oven and sweep away the lint on it with a broom; use a soft cloth to wipe the guide rollers and drop cooling rollers where the fabric passes; wipe the trough and roller with a damp cloth and clean water to remove the lint on it. Wool, slurry, etc.

5 Clean the entire machine after shutting down

Including cloth feeding rack, trough, roller, weft straightener, J-shaped box, cloth dropping rack to ensure no dirt, lint, etc.

6 Save energy

In order to save energy, the power of the fan should be reduced as much as possible while ensuring the drying of the fabric (moisture content is 5%-6%).

7 Precautions for processing before sanding cloth

The main purpose of sanding cloth is to prevent the cloth surface from being degraded due to wrinkles, etc. when the hair is not polished during sanding. The following points should be paid attention to during processing:

1) Before sanding, use a special three-strand double-thread seam head for sanding, use a reverse seam head to distinguish the front and back sides, and feed the fabric with the sanded side upward

2) Check the condition of the incoming fabric. Generally, the crimping and shaping produced in the previous process has a great impact;

3) Check the wear of the needle plate and contact us to replace the damaged needle plate to prevent needle eye wrinkles;

8 Try not to use edge suction devices when processing easy weft shifting varieties

9 When processing the resin cloth before baking, the baking guide cloth must be connected to 200 yards

10 Processing MUJI anti-fluorescence varieties

When processing MUJI anti-fluorescence varieties, you must use a bleaching guide cloth washing machine to ensure that the cleaning is OK before adding a clean bleaching guide cloth. The squad leader will confirm that the entire guide cloth has no fluorescence before producing other types of bleached cloth 3000 normally. After coding, MUJI anti-fluorescence varieties can be processed.

22 Solve the problem of running edge

During the production and processing process in the finishing workshop, sometimes we encounter the problem of fabric running away. Although this situation does not happen often, once it occurs, it will produce edge stains and wrinkles on the cloth surface that are difficult to correct. , The edge stains are mainly caused by the oil stains and gray stains on the sides of the guide roller after the cloth has been run. Wrinkles are caused by the uneven cloth surface and the irrecoverable wrinkles formed after being rolled by the pressing roller. These are caused by running.The consequences caused by the edge are difficult to repair and will cause greater economic losses. Therefore, it is necessary to try to avoid the phenomenon of edge running during the final production process.

1. The main reasons for side running problems

As far as we know so far, the main reasons for side running problems are:

1. The cloth to be processed was not stacked neatly in the stacking car, and the workers did not make timely adjustments. As a result, the cloth surface swung too far left and right when feeding the cloth, causing edges to run. The pressure of the edge suction device is not strong enough, and the edge suction device cannot balance the left and right tensions when feeding the fabric to ensure smooth fabric feeding.

1. Causes side running.

2. The fabric itself had rotten edges, but the workers failed to detect and remedy them in time, resulting in the edges running out of the fabric.

3. When finalizing, the edge detector swings violently from left to right, or the width of the incoming cloth changes too much (width sometimes, sometimes narrow, uneven left and right), causing the needle plate of the cloth to run out of edge.

4. The incoming fabric has loose tissue and can withstand less tension. During the process of machine tension pulling, the tissue breaks, causing edge running.

5. If the setting overfeed is too large, it may also lead to partial stripping and edge running.

6. The incoming weft is seriously skewed, and the adjustment range during weft adjustment is too large, which may cause wrinkles and running edges.

7. Some parts of the machine are damaged, such as the needle plate of the setting machine, the cloth clips of the mercerizing machine, etc., which may cause the machine to run away.

8. Other environmental factors, such as strong winds interfering with cloth feeding, etc.

2. Main ways to solve the problem

After analyzing the main causes of edge running problems, measures can be formulated to control the occurrence of edge running problems, mainly including:

1. Operators are required to observe carefully and promptly adjust the stacking state of the cloth to be processed in the cloth cart to ensure stacking adjustment and ensure smooth and centered cloth feeding.

2. The operator is required to promptly adjust the distance between the edge suction devices and the pressure of the edge suction devices according to the width of the fabric to be processed.

3. When inspecting gray fabrics, deal with the rotten edges in a timely manner to prevent edge running caused by rotten edges.

4. Add a baffle or scale wheel on the crossbar at the cloth inlet end to control the range of lateral changes in the cloth surface, reduce the left and right swing of the cloth, and control the occurrence of edge running.

5. For the situation where the fabric width is uneven, the operator should carefully control the machine to minimize edge running caused by the violent swing of the edge detector.

6. The operator should appropriately control and adjust the tension of the machine according to the tightness of the incoming fabric’s tissue structure, and should not make the machine tension too high, resulting in bad edges and running edges.

7. For machines with an overfeeding device on the shaping machine roll, overfeeding should not be too much to avoid partial needle detachment due to excessive overfeeding, resulting in edge running.

8. Take appropriate measures to address the impact of environmental factors, such as adding a large screen to avoid interference from sudden winds. Regularly inspect the machine, troubleshoot in a timely manner, and replace damaged parts.

12 Yarn hooking prevention and weft shift control

All rollers, weft straighteners and other yarns in the cloth feeding frame of the setting machine, and the wind in the oven should not be too strong to prevent the cloth from being blown by the fan in the wind box. If there is label paper and yarn processing, hooking and weft movement will occur, so preventive measures must be taken when processing each machine. Experience in looking at cloth: Check the front, back and light transmission to see if there are abnormal light-transmitting holes and floating yarn hooks on the cloth surface.

13 CDF variety control plan

CDF variety shaping processing mainly requires cleaning, and there should be no contamination by softener. The specific processing methods are:

1) Use 0.1%Use glacial acetic acid to scrub the guide rollers, troughs, and weft straighteners where the fabric is processed on the machine once;

2) Use 66HK aqueous solution to scrub the guide rollers, troughs and distributors where the processing cloth passes on the machine once;

3) Use CDF special guide cloth (guide cloth after scouring and bleaching of more than 300 yards) with 0.1% glacial acetic acid solution to clean the softener on the needle plate through the small pressure washing machine of the trough rolling car for more than two times;

4) If you have processed fluorescent cloth before processing CDF varieties, you must use 0.1% sodium hypochlorite solution to wipe each guide roller of the machine and wash the machine more than twice with a special guide cloth liquid;

5) During the processing, pay attention to adjusting the weft skew, width, and fabric drop and roll packaging.

14 Latitude and skew control scheme

Weft and skew are among the top items for internal and external rework after finishing, so it is important to control the latitude and skew. First of all, let employees know the control standards for weft skew. The control standards for weft skew in finished products are:

1) Solid color cloth, striped cloth:

Full width: 3.5% (approximately 5.0CM for 58.5 fabric width, approximately 3.5CM for 44.5 fabric width)

Half width: 4.0% (approximately 3.0CM for 58.5 fabric width, approximately 2.2CM for 44.5 fabric width)

2) Plaid cloth:

Full width: 1.5% (approximately 2.2CM for 58.5 fabric width, approximately 1.7CM for 44.5 fabric width)

Half width: 2.0% (approximately 1.5CM for 58.5 fabric width, approximately 1.1CM for 44.5 fabric width)

Partial weft bias: no more than 4% within 20CM of the selvedge, that is, no more than 0.8CM

15 Fish scale wrinkle control plan

For general high-density fabrics such as OC type, if the moisture content of the cloth surface is not enough during the shaping process, fish scale wrinkles will easily occur during the pre-shrinking process, resulting in internal and external repairs. During the shaping process, the moisture content of the dropped fabric is set (generally set The moisture content is set at 12-14%) to control the moisture on the fabric surface to facilitate post-process processing.

16 About the control of shaping width

1. Check whether the mercerizing drop is normal

2. Refer to the processing situation of the same specifications or PPO varieties

3. Do a quick test on the fabric to be finalized

4. Check the post-process processing conditions to confirm whether the shape should be wide or narrow

17 The shape should be wide varieties

1. Fixed and trendy varieties

2. Varieties with calendering in the post-processing process

3. Special finishing varieties

4. Varieties that will stretch a lot during pre-shrinking

5. “D” and “CDF” varieties generally have a wider range of stereotypes

18 The shape should be wide and narrow varieties

1. Varieties of Oxford spinning and Fangping weaving

2. Pre-shrinkingVariety with large shrinkage rate

3. For varieties with large weft shrinkage, the preshrunk should be as narrow as possible. When appropriate, the needle eye can be moved to the side to take into account shrinkage and finished product width.

Main fabric defects and causes

1) Bad edge: The edge of the fabric breaks away from the needle chain, close the automatic stop of edge removal, slow down and press the fabric into the needle chain.

2) Weft skew: Adjust the preset twill weave for the entire weft. You can use the preset twill in the opposite direction to the grain.

3) Wrinkling: Generally, when edge wrinkles occur, the fabric feeding tension is increased, and when longitudinal straight wrinkles occur, the fabric feeding tension is reduced; for loose tissue and softness of the reworked cloth, the adjustable trough material surface should be as low as possible. The second step is to make the cloth smooth and enter the pressing roller

4) Stains, oil stains, rust stains: check the source and clean.

5) Weft shift: If it is caused by the overfeeding wheel, the rotation speed will be slowed down, and if it is caused by the edge suction device, it will push up the edge suction clamp.

6) Wind mark: Slight irregular indentations are formed on the cloth surface, and part of the oven is closed to allow the cloth to fall with moisture

7) Material stains: Materials react or dry out and condense, or are separated by excessive stirring or individual materials are not melted, etc.

8) The eye of the needle is inserted: take off the cloth and move it to the edge, so that the cloth clipper needle penetrates into the edge of the cloth. In serious cases, it may cause rotten edges. If you find out, take measures in time.