Software |¶
Architecture, Ideation & sketches¶
The process¶
The numerically controlled automatic loom Loom One involves a process of signal transmission to the loom that begins with the selection of an image and a type of weave to be used, with options including, for example, taffeta, twill, and satin. Subsequently, the selected image is converted into a bitmap considering the resolution and the number of colors to be used, where the resolution is determined by the number of threads per linear centimeter that the loom has in the direction of the weft. In this bitmap conversion, a first filter is applied to ensure that each pixel corresponds to a pick of each individual thread.
Subsequently, a conditioning procedure of a file is carried out to be worked on the loom conditioned by the design and the selected weave, where this conditioning can be done automatically, partially automatically, or manually, depending on the complexity or effects intended for the fabric finish. Finally, the color matrix in pixels is converted into bits of zeros and ones, where this conversion is done line by line of the design, respecting the order of these lines since each bit represents the pick in each of the weft threads. The resulting matrix of zeros and ones will be interpreted by the loom's processor line by line to carry out the weaving.
In other words, the process of sending transmission signals to the loom begins at a textile design stage where a user creates, defines, or selects a pattern that serves as a base for weaving. This textile design can be crafted using specialized graphic tools, allowing the designer to precisely define the visual elements that characterize the fabric, such as colors, shapes, geometric patterns, and the chosen weave type. This textile design is the visual representation that will later be transformed into detailed instructions for the loom.
Once the textile design has been completed, the next step is to convert it into a bitmap, where the initial textile design, which could be in a vector or raster format, is transformed into a bitmap (bitmap) format. This format is particularly relevant as it represents the image as a grid of pixels, where each pixel is interpreted as an individual point in the design. In this bitmap conversion stage, the design is broken down into a series of discrete points, each corresponding to a specific action of the loom. The conversion to bitmap not only adapts the textile design for digital processing but also optimizes the file for use in the subsequent stages of the process.
After the conversion to a bitmap, the signal is transferred to an automatic conditioning stage (90) where a series of automatic adjustments are made to the file to ensure it is in the best condition to be processed by the loom. This conditioning may include correcting any distortion that occurred during the bitmap conversion, optimizing the color palette to match the loom's capabilities, and adapting the design to the specific dimensions of the fabric to be produced. Even in alternative implementations, there are automatic adjustments to the image resolution, ensuring that every detail of the design remains intact during the weaving process. Automatic conditioning (90) is important to minimize errors and prepare the design for precise interpretation by the machine.
In some cases, automatic conditioning may not be sufficient to ensure that the design is reproduced with the desired fidelity in the final fabric. Therefore, an auxiliary phase of manual conditioning is included, which allows for operator intervention to review the automatically prepared file and make additional manual adjustments. These adjustments may include correcting minor undetectable errors, adapting certain design elements to better fit the characteristics of the material to be used, or modifying details to ensure that the final design meets the client's or project's expectations. Manual conditioning is a crucial stage to ensure that the final design perfectly meets the specific needs of textile production.
Subsequent to the design being fully conditioned, the process is taken to a matrix generation stage, which is an essential stage in the process, as it involves the creation of a data structure in the form of a matrix that maps each part of the design to specific instructions that the
The Matrix generation¶
The matrix generation includes a start, where the dimensions of the matrix are defined using the variables "m" and "n," these variables being fundamental since "m" indicates the total number of rows the matrix will have representing the number of threads the weft in the fabric will have, while "n" determines the number of columns obtained by multipling the number of threads per centimeter and the with of the fabric. At this point, after the start, only the necessary foundations for what will come next are established, without yet performing any concrete operation.
Next, the sequence of matrix generation enters a loop that controls the iterations over the rows of the matrix, and this loop starts with a primary assignment where i = 1, indicating the beginning of work with the first row. This assignment will ensure that each row of the matrix is processed, iterating from i = 1 to i = m, and each time an iteration over a row is completed, the index "i" is incremented by one, thus moving to the next row.
Moreover, within the row cycle, the sequence enters a secondary assignment that controls the columns of the matrix where this assignment starts with j = 1, it is responsible for iterating over all the columns of the current row, just as the row cycle ensures that each row is processed, the column cycle guarantees that all cells within a row are assigned correctly where this sequence continues as long as "j" is less than or equal to "n", and with each iteration, the index j is incremented, moving to the next column.
A crucial stage within this cycle is the tertiary assignment for the value of a cell a(i, j) in the matrix, as it is here where the matrix generation sequence truly "builds" the matrix, filling each cell with a specific value and where this value could be constant, generated, or derived from a mathematical function, depending on the particular application of the sequence and where the reference to (i, j) identifies the specific cell in the matrix where "i" corresponds to the row and "j" to the column.
Once the value has been assigned to a(i, j), the column loop continues, processing the next cell in the same row, and when all the columns of a row have been processed, the column loop completes, and control returns to the row loop. At this point, the index "i" is incremented, and the process of traversing the columns starts again, but now for the next row.
This iterative process continues until all the rows and columns of the matrix have been processed, ensuring that each cell has been filled and subsequently, the sequence has an end. Preferred implementations of matrix generation include one or more validation stages to ensure that the matrix has been generated correctly and, depending on the environment, it may also be necessary to release resources such as memory or processes that were used during the execution of the sequence. The result of this process is a fully formed matrix of size m x n, where each cell a(i, j) contains a value assigned according to the rules defined in the assignment step.
The final step¶
Finally, once the fully formed matrix has been generated, it becomes a dataset for the loom, as this data is essential for the loom's operation, providing all the necessary instructions to accurately reproduce the textile design. The loom uses this data to control the movement of the threads and the creation of the pattern on the fabric. During this process, the loom follows only the instructions provided by the fully formed matrix, ensuring that each thread is placed in the correct position, with the appropriate tension, and in the specified order, resulting in a fabric that faithfully reflects the original design, from the shapes and colors to the smallest details.
Subsequently, the fully formed matrix is introduced to a master loom circuit for interpretation, where the first line of instructions is separated to divide the information among the slave circuits distributed in a matrix, depending on the number of threads assigned, the corresponding instruction will be given.
Subsequently, there is a transfer of information corresponding to each slave microprocessor; this assigns to the controller, corresponding to the electromagnets of the actuators, the state of the central arc to be positive, negative, or floating, as the case may be, where it will act to one side, the other, or nothing will happen. This configuration is in view of the matrix arrangement of the actuators, which allows reducing the number of circuit components.
Once the actuators have changed state, the frame is raised to take the free meshes and lift the corresponding threads from the foot using the magnetic or spring mechanism, and then the weft is manually woven.
At the lower limit switch of the frame, there is a switch, preferably a micro switch, that sends a signal to the master microcontroller to read the next line and continue the weaving process until the entire information matrix is complete.