WARPING
BENNINGER WARPING MACHINE
INTRODUCTION
To produce the a fabric we require a large number of threads i.e approximately 1000 to 10000 or more threads on a Weaver beam. To install a creel of many threads at the back of Sizing or Loom it is impossible to accommodate. So, we need to make sections on warping machines and then combining them on Sizing machine and finally on Loom.
DEFINITION:
Warping is a process by which we transfer the yarn from multi number of packages loaded on creel forming a parallel sheet of threads wound on a cylindrical package with large flanges at both sides called the warper beam.
OBJECT OF WARPING:
Yarn from individual package is combined in a parallel sheet form on the beam to get the required no of ends, prepared beam is called warper beam.
IMPORTANCE:
· Reduction of working area at Sizing
· Reduction in complications to tackle the yarn sheet at Sizing and subsequent process.
DIRECT WARPING
In this type of Warping threads are withdrawn from the single-end yarn packages on the creel and directly wound on the beam. It is used in two ways;
· DIRECT BEAMING:
Direct Warping can be used to directly produce the weaver beam in a single operation. This is especially useful for strong yarns, which do not require Sizing or when number of threads are smaller, therefore this type is also called direct beaming.
· BEAMING:
Due to excess number of ends instead of one single beam, intermediate beams (warper beams) are made, which are transformed finally into a Weaver beam.
WARPING MACHINES SPECIFICATIONS:
Total No of Machines. = 03
SPECIFICATIONS M/C # 01 M/C # 02 M/C # 03
COMPANY NAME BENNINGER BENNINGER BENNINGER
MADE IN SWITZERLAND SWITZERLAND SWITZERLAND
YEAR OF MANUFACTURING 2000 2002 2004
CREEL CAPACITY 1080 Spindles 1080 Spindles 960 Spindles
VOLTAGE/FREQUENCY 400V 50/60Hz 400V 50/60Hz 400V 50/60Hz
AMBIENT TEMP. 35°C 35°C 35°C
BEAM LENGTH 2400mm 2400mm 2400mm
BEAM DIA. 307mm 307mm 307mm
MACNINE DETAILS:
The major parts of machine are shown in the figure
MAIN PARTS OF MACHINE
1. Creel portion
2. Head stock
CREEL PORTION
A. Creel
B. Cone stand
C. Tension rods
D. Thread brake stop motion sensor
E. Guide rod
HEAD STOCK
F. Yarn sheet
G. v-shape expandable comb
H. Blow pipe
I. Wind sheet
J. Guide roller
K. Flange of warper beam
L. Warper beam
M. Pressure drum (hydraulic pressure)
CREEL SECTION:
CREEL
The part of machine where a package can place in a suitable manner that permits unwinding of yarn smoothly and without any hindrance (peg).Maximum no of packages that can be used on creel is called creel capacity .creel capacity was 1224 ends ,V _shape creel and by working truck creel. there are 68 vertical column having 9 cones on each side of creel.
CREEL ANGLE …………………………20-25 (degree)
PARTS
· Rod
· Cone holder (spindle)
· Guide
· Tensioner
· Sensor (stop motion)
· Cutter
WARPING MACHINE LAYOUT:
ADVANTAGES OF V TYPE CREEL:
· Uniform tension across full width of beam
· Less chance of entanglements of yarn due to its appropriate angle
· No need of separate yarn guides except for last 5-6 rear rods
TENSION RODS:
Tension rods on warping machine control tension in warp yarn.
Fine yarn requires low tension as compared coarse yarn i.e; Tension (g.p.m) varies directly rod movement (mm)
Rod movement ranges from 4 to 50mm.
Figure showing optostop and Tension rods
YARN COUNT (NE) ROD MOVEMENT (MM)
10, s 12mm
20, s 10mm
30, s 8mm
40, s 6mm
50, s 5mm
60-80, s 4mm
Tension in yarn can be calculated by using following formula
Tension (G.P.M) =total ends/1.69*Ne.
Tension meter can check tension.
EQUALIZED THREAD TENSION
The pretensioners installed by BENNINGER automatically compensate the thread tension differences occurring due to the variation in thread length from the rearmost to the foremost package, permitting a uniform thread tension and winding over the entire warp width.
The automatic pretensioner is set so that a corresponding wrap compensates the difference in tension between the front and rear threads.
EFFICIENT BALLOON LIMITING
Due to their structure, rotor yarns have special balloon dynamics. Ballooning is three times greater with rotor yarns than with ring spun yarns and has its maximum elongation in the spaces between package and tensioner. Two round metal rods with a smooth and friction-resistant surface achieve effective balloon reduction.
STOP MOTION SENSOR:
It feels the breakages of yarn. As the yarn breaks this sensors sends the signals to stop the loom. So brakes are applied on the warper’s beam, pressure drum & on the guide roller.
A UNIVERSAL STOP TENSIONER
OPTOSTOP has been specially developed for the direct beaming of staple fiber yarns at high speed and an application range from 5 to 170 Tex. The shape and the large jaw area treat the yarn surface gently and avoid twist push-back with resulting snarling.
HIGH SPEEDS WITH LOW THREAD TENSILE FORCE
The jaws of the thread tensioner open automatically shortly after the start of the beamer. Thread tensile force from the package is the sole determining factor for a steady and dependable thread run. This ensures that the tensile load on the threads is low, even at high beaming speeds.
BACK BEAMS WITH NO MISSING ENDS
The optoelectronic stop motion integrated in the OPTOSTOP tensioner monitors the thread run right from crawl speed. It detects an end break at once, whether this occurs on the package or at the comb of the beamer. In the event of a thread stoppage, it responds in milliseconds, so that no ends are lost.
BENEFITS OF OPTOSTOP
HIGHEST QUALITY
• No loose ends shooting forwards when stopping
• No snarling caused by twist pushback
• Stop motions are self-activated by pushbutton
• Warning display after repeated breaks on the same end
• Continuous display of number of running ends
• No threads lost at end break
HIGH PRODUCTIVITY
• Wide application range
• Low thread tensions for high speeds
• End breaks are rapidly located
HEAD STOCK:
TRAVESING COMB:
It is used to separate the threads to overcome entanglement of yarn.
Filling of comb is always start from center to sidewise .the comb has vertical as well as horizontal movement. Vertical oscillations of comb are necessary for avoiding cutting of comb needles from fast moving threads. Horizontal oscillations of comb are to prevent the groove formation on guide roller and also for uniform winding of warper beam. The comb opening is adjusted according to no. of ends required on beam. Every strip of comb represents every vertical column of creel.
The height of needles is different because spindles are not at same height from floor level.
SIMPLE INSERTION OF THE THREADS INTO THE COMB
The stepped comb is moved apart to simplify lying in the ends. The lateral alignment of the comb on the beam and the setting to the exact warp width are motor-driven. The horizontal comb movement guarantees uniform yarn build-up on the beam. The traverse can be set steplessly. Thanks to the vertical movement, the life of the comb is increased.
Expandable comb
EFFECTIVE COMB BLOW-OFF
This acts intermittently over the entire width. Intervals and blowing intensity are adjustable individually. Adequate turbulence is assured by a special technique. Despite low air usage the effect is optimal, and the comb remains free of dust.
Effective comb blow-off
BENEFITS OF EXPANDABLE COMB
HIGHEST QUALITY
• Exact thread guidance
• No crossed threads
• Cylindrically wound beams – no slip between press roller and yarn package
• Warp length accuracy within 1 per thousand
• No cutting-in by threads on the comb
• Fewer rolled-in ends through short braking distances
HIGH PRODUCTIVITY
• Short braking distance
• Simple insertion of threads into the comb
• Workplace designed according to ergonomic principles
WIND SHEET:
The function of wind sheet is to prevent the fly to reach the beam.
Figure shows wind sheet.
PRESSING DRUM:
Figure shows the pressing drum
Pressing drum has a ply wood layer on its surface to increase the friction b/w beam and drum. It is the only length-measuring unit on m/c, which measures the length of warp sheet having complete no. of ends on warper, s beam.
Whenever the brake is applied the pressing drum moves instantaneously away from warping beam and stops.
Package density is controlled by presser drum on beam threads pressure varies from 200(10-30 Ne) 300 (40_60Ne) daN. Pressure is inversely proportional to yarn counts.
INDIRECT PRESSING WITH ACTIVE KICK-BACK:
The presser roll is of hard paper and has strong end rings to prevent damage. The increasing yarn diameter on the beam forces the press roller back against the resistance of the pre-set pressing force. Thanks to this indirect pressing action the winding is always perfectly cylindrical. Upon braking, the press roller is immediately swung away hydraulically. All friction between roll and yarn is avoided.
WARPER BEAM:
The warper beam is positively driven from motor and its surface speed remains constant through out. Beam width was 2400mm. The beam has brakes on both sides, which stop it.
Whenever any thread is broken inching/creep/crawl speed is used for repairing of broken threads, this speed is 1-2m/mins.
BEAM HOLDING SYSTEM
The beam has brackets in its ruffle outside on both sides called “CHUKS” with exactly turned cones. These cones must be GUDGEN type or JOURNAL type with a toothed internal degree of 40degree taper. The journal type guarantees the easy beam centering as well as torsion less drive. The loading, unloading and gripping of beam is done hydraulically with automatic system
FLUFF REMOVAL FROM PARTS OF MACHINE
Fluff is one of the main problems in warping. It is avoided or removed at 3 important sections in warping machine.
AT CREEL
Fluff can cause problems on creel if it is stuck in the sensing devices, which very quickly sense breakage and are necessary in warping. Hence fluff is removed from them by blowing air at pressure of approximately 5 bar.
AT HEAD STOCK
Fluff is accumulated in the warping comb could vary tension of warp and also make the yarn fluffy causing yarn faults in next processes. Hence it is removed by blowing air through the comb by a blow pipe. The pipe moves up and down instantly and exerts air pressure through the perforations. Its timing is set before.
PLC FEEDINGS ON WARPING MACHINE:
Ø Rod movement for tension
Ø Speed of machine
Ø Pressure of pressing drum in daN.
Ø Set length
GENERAL MAINTENANCES OF WARPING MACHINE ARE:
Ø Checking the hydraulic system for brakes.
Ø Checking the all brakes as warper beam, pressure drum & guide roller.
Ø Checking the drive belts
Ø Checking the hydraulic pressure bolts to avoid the loss of pressure.
Ø Check flanges
Ø Check all connection nuts
Ø Check that the pressure of pressing drum is uniform.
TABLE OF DIFFERENT SETTINGS
Count Tension Drum force Speed
(s) (Mm) (daN) (m/min)
7 14-16 350 700-1150
10 14-16 350 700-1150
12 12 350 1066
16 5-6 250-320 950-1166
20 3-8 250-300 900-1050
24 3-6 250 900-950
30 3-6 250 900-950
40 4 200-220 650-900
60 2-3 200-220 650-900
80 1-2 200-220 600-850
DIFFERENT SETTING PLANS AND PROGRAMMES
We plan different sets according to the no. of bags available. Total no. of beams calculated is adjusted according to the no. of ends / beam. If the no. of ends per beam is more, we reduce the no. of ends per beam by increasing the no. of beams so as to avoid the yarn breakage due to more friction.
HUMIDITY AND TEMPERATURE FOR DIFFERENT COUNTS
Normal, range of humidity is 45-70%. But we use in the range of 65-68% for cotton. The R.H value is less for coarser counts and more for finer counts.
For PC and CVC, R.H value is kept below than 65 %.
The temperature range is 25-40 C depending on the yarn count, quality & external environment. We normally keep the temperature in the range of 35-37 C.
MAINTENANCE SCHEDULES
The maintenance schedules are as follow
Ø After 100 hours
Ø After 1000 hours
Ø After 5000 hours
Ø After 10000 hours
After 100 hours maintenance
· Clean the m /c.
· Clean the wind shield.
· Clean the pressing roller
· Clean the guide rollers
· Check the oil level
· Check the screwed connections
· Check the drive belt
After 1000 hours maintenance
· General maintenance work
· Check the beam position
· Check the wrapper beam
· Check and clean comb traversing chain.
· Grease cylinder pressing device
After 5000 hours maintenance
· General maintenance work
· Oil change
· Inspect brakes pad
· Release drive belt
· Check the beam clamping device
After 10000 hours maintenance
· General maintenance work
· Release pressing drum bearing
· Release serrated cones
CONE REMAINDER % AGE AND YIELDAGE %AGE
Normally we take 1 – 2 % for a yarn of count range of 1-60.
And for 60-80 count we take 2.5-3 %.
But if the yarn quality and paper cone quality is not good, we take more cone remainder %age.
In simple words we take 98.5 – 99 % yarn from a cone in order to avoid any shortage of yarn.
So
Length taken from a cone = total length x 98.5/100
OR
Length taken from a cone (meters) = 3152.68 x count
COUNT CONE REMAINDER %AGE
16 1.6 – 2.01
20 1.26 – 1.41
40 3.31 – 2.36
60 3.11 – 3.16
80 3.13 – 3.16
SOME USEFUL FORMULAE:
Cone Length = cone wt(lb) 840 count 0.9144
Total No of Ends = Warp Density Cloth Width
No of Beams =
Ends per Beam =
Beams per Creel =
No of Creel =
Total No of Bags =
No of remaining Cones = Decimal Value No of Cones in one Bag
NO OF WORKERS ON ONE WARPING MACHINE:
Warper = 01 Assistance = 01 Creeler = 01 Helpers = 03
WARPING PROGRAM:
You are given with quality 32.16/94.48=63 2″ and beam length 4035m.
Prepare your Warping plan.
Cone Length = = 61440m
Total No of Ends = Warp Density Cloth Width = 94 63 2= 11844
Beams per Creel = = =15
No of Beams = = =15
Ends per Beam = = = 789/98 Ends/Beam
No of Creel = = 01
Total No of Bags = = =19 Bags
No of remaining Cones = Decimal Value No of Cones in one Bag= 0..74 40= 30Cones
TABLE OF DIFFERENT QUALITIES
Quality Beam length Cone Length Beams per Creel Total No of Ends No of Beams Ends per Beam No of Creel Total No of Bags
21.16/128.60=63 22150m 67205m 03 8064 09 896 03 336
16.8/84.28=110 3350m 51204m 15 9240 15 616 01 385
21.16/128.103=63 22150m 67205m 03 8064 09 896 03 336
16.8/84.28/=105 4580m 51204m 11 8820 11 801/10 01 367.5
40.40/100.80=104 11410m 128010m 11 10400 11 945/50 01 433.3
SIZING
OBJECTS OF SIZING:
The functions of the sizing operations are:
Ø To lay the protruding fibers in the body of the yarn and to cover weak places by encapsulating the yarn by a protective coating of size film. Too thick a coating will be susceptible to easy shed-off on the loom.
Ø To increase the strength of the spun yarn without affecting its extensibility. This is achieved by allowing the penetration of the size film into the yarn. Excessive penetration is desired.
Ø To make a weavers beam with the exact no. of warp threads ready for weaving.
Ø And finally to increase the weave ability.
TOTAL NO OF MACHINES = 02
SPECIFICATIONS OF MACHINES:
Specifications M/C # 01 M/C # 02
Creel Capacity 32 Warper’s Beams 32 Warper’s Beams
Company Name BENNINGER ZELL BENNINGER ZELL
Made in GERMANY GERMANY
Model 2000 2002
Order No A0015808 A0016347
Ambient Temp. Max. 45°C 45°C
Voltage/Frequency 400V 50Hz 400V 50Hz
Main Fuse 20A 25A
Control Voltage 24V/DC 24V/DC
Barrel Dia. 220mm 220mm
Beam Dia. 1000mm 1000mm
BLOCK DIAGRAM OF SIZING M/C
CREELS (UNWINDING ZONE)
CAPACITY 32 BEAMS
The primary function of the creel is to allow smooth and steady unwinding of the warp yarn sheet without the side to side swinging of the warper beams and without entangling two adjacent warp sheets being unwound, for this purpose modern creels are equipped with ball bearing to support the end shafts of the war per’s beam.
Over / under creel is most commonly used for slashing spun yarns of cotton and synthetic fibers. The warp passes over one beam, under the next beam, Again over the next beam , and so on. For heavy to medium construction fabrics, where two size boxes are used in industrial practice, all top beams in the creel may be threaded over and under and then straight to the first size box, like wise all bottom beams are threaded over and under and then straight to the second size box. It is the first zone of tension as Z1 a/b, a to 1st size box & b to the 2nd size box.
Figure shows Creel
There are 32 stands for the warper beams in 8 sets , each set having 4 stands.
In a set 2 warper beams rotates in clock wise direction and 2 rotates in anti-clock wise direction.
There are 32 guide rollers to guide the warp sheet.
Each beam is placed on the hubs of beam support of stand.
Each beam is connected through a pneumatic brake system on both sides of the beam, having a belt and compression system.
Type of brake is
Pa / 80321 w /50
The maximum displacement by the piston of pneumatic brake is 50 mm.
The pressure is 80 bar and temperature is 80 C
The warper beam moves freely on the hub of stand.
There are 5 BUTTONS ON THE CREEL PORTION.
· Full stop
· Temporarily stopped
· Very slow speed
· Slow speed (5 mm)
· Maximum speed (given)
The range of maximum speed is up to 160 m/ min but we use up to 125 m/min.
WARPING BEAM BRAKING SYSTEMS:
These systems are required for preventing the over –running of the beams, especially during the reduction of the speed of the slasher at the time of break or during the doffing of the weavers beam. Also the braking system allows control of yarn tension b/w the size box feed and creel during the normal constant speed operation. An automatic pneumatic braking system in which a sensor is placed b/w the creel and size box for measuring the tension in the whole warp sheet. The air pressure in pneumatic cylinder is automatically adjusted in proportion to the tension fluctuations registered. During acceleration or deceleration, and also from start to finish of the warper’s beams.
BAND BRAKES:
The back beams are mounted in the back beam unit with insertable journals. Pneumatically loaded and automatically regulated band brakes impart the unwinding tension. Width adjustments up to 400 mm are possible with the ZB band brake.
Brake
SIZE BOXE (SIZING ZONE)
1. PRE-WET ZONE:
Prewettig
Ø It is used for coarse yarns to increase the absorption of sizing materials in the body of yarn. For this purpose the yarn sheet is first pass through the pre-wet, containing hot water (40-50) in a stainless steel tray before main size box. After that the warp sheet is squeezed by passing through pair of squeezing rollers, 100 shore for top and 65-80 shore for bottom roller and the lower squeezing roller is driven by motor, its minimum dia. Is 260 mm. Main results due to pre-wet sizing are
OBJECTS
· Yarn hairiness is removed
· Abrasion resistance power of the yarn is increased
· Tensile strength is increased
· Adhesion of size recipe is increased
· Sizing cost is reduced
· Tensile power is increased
2. SIZE BOX
TYPE DOUBLE DIP DOUBLE NIP
Model 2002
It is also called sow box having two main rollers
Size box
1- Immersion / dipping roll
2- Squeeze rollers
The basic function of the warp sheet is to impregnating the yarn sheet in the size liquor at a predetermined application temperature and to squeeze out the excess size liquor before the yarn sheet reaches the drying zone. The amounts of size that will be picked up by the yarn sheet depend upon the depth of the immersion roll and the level of size liquor in size box. The lower the positions of immersion roll, the greater the pick up of the size by the yarns while remaining constant level of size in box.
The size liquor in the size box is normally heated by steam supplied through steam coil placed at the bottom of the size box. The top roller is made from cast iron material covered with rubber while bottom roll is made up of stain less steel. The top roller is usually under pressure in addition to its own weight of around 180-250 kg. The pneumatic pressure is applied on the top rollers, in KN.
As speed increase pressure will have to increase. At low speed there is more size percentage as compared to high speeds. The contact area b/w top and bottom squeezing rollers is called nip immersion.
Harder the squeezing roller, more penetration and less coating. Hardness of squeezing roller is measured in term of degree shore, value is 65-75 O shore temperature of size box liquor for cotton is 85-95°C.
Figure shows Size Box
SQUEEZE ROLLER PRESSURE
Take up within size box depends on
1- Squeeze roller pressure.
Figure shows Squeezing rollers
2- Speed of yarn sheet
3-Tension in sheet
4- Viscosity of size liquor
5- Type of polymer and temperature
DEGREE OF SIZING:
The degree of sizing is dependent upon many parameters, which can change depending on the article, from batch to batch and/or change within batch depending on time.
More over the degree of sizing is dependent on several factors e.g; Parameter of the warp
LIQUOR CONSUMPTION
The liquor level in the size box is measured with a sensor, unsusceptible to contamination and regulated to the specified level. This measurement serves to measure liquor consumption and calculate the actual size pick-up.
SIZE BOX HEATING:-
Two heating systems are matched optimally to one another. The indirect heating in the double bottom compensates the heat loss by radiation and the direct steam heating responds quickly and effectively. High circulation and low liquor level ensure an homogeneous liquor.
UNIFORM THREAD TENSIONING AND CONTROLLED STRETCHING:-
BEN-SIZETEC sizing machines always leave a high residual elongation in the warp for the following weaving process, hence reducing warp thread breaks on the weaving machine. This is rendered possible by the control and regulation technology with individual motor drive in the sizing machine's 5 tensioning and stretching zones. In the wet state the yarn is particularly susceptible to excessive tension or stretch, so 2 control possibilities are provided here as standard. Either the stretch is controlled and the resulting tension displayed, or a tensile force is programmed as setpoint, and only the resulting stretch is displayed.
Benninger Size Box
DRYING CYLINDERS:
1. MINI DRYING CYLINDERS:
There are four mini drying cylinders. There temperature is 100 o C. These are used to prepare the wet yarn sheet so that it can be PER-DRIED. These are Teflon coated which prevents the yarn from stickines
2. MAIN DRYING CYLINDERS:
The temperature of drying cylinders was 125c to 140c. The drying cylinder temperature is used to dry the yarn by keeping the moisture at required level. The number of drying cylinder is 14. 4 are for one size box, other 4 are for 2nd size box & remaining for both sheets. The tension in this zone is called Z3. All cylinders are coated with Teflon coating except last 3.
WAXING DEVICE:
After drying cylinder the yarn sheet is passed through the waxing device to soften the yarn.
MAHLOMETER:
It is after the waxing device. It used to check the moisture in the yarn sheet.
Moisture meter
There are two size boxes and yarn sheet is double dipped in the size box.
Each size box has following parts
· Pendulum roller
· Immersion roller 1
· Lower roller
· Upper roller
· Immersion roller 2
· Lower squeezing roller
· Upper squeezing roller
MOTORS FOR SIZE BOX
There are following motors
· Size return pump 4 kw
· Size pump 1.5 kw
· Tow rollers for immersion 0.25 x 2 kw
· Squeezing device motors 0.25 x 3 kw
· Drive of lower squeezing roller 6.3 kw
· Temperature range of size box 90-100 C
The maximum range of size liquor in size is 200 mm but safe value is up to 135 mm and minimum value is up to 55 mm.
The water level in the size box and pre wet section is determined by measuring pressure difference with the help of pressure transducer.
LEASE SECTION:
The tension in the lease section is termed as Z4. The number of lease rods used is one less than the number of beams.
This is a guide which guides the warp sheet from drying cylinders
There is a mahlo moisture meter having three small rollers attach to a rod which detect the residual moisture in the warp sheet
The moister is adjusted ands set in panel on head stock
There is a waxing device having a wax box and a waxing tray
In waxing tray a roller is moving
The wax from waxing box is guided to the waxing tray where the wax is attached to warp sheet by roller
The wax roller is attached to the Nor-green pressure device
The piston of the Nor-green can be displaced to maximum value of 12mm
In leasing section , there is one large rod which splits the warp sheet of two size boxes in to two parts.Then there are small leasing rods .
The total number of rods is one less than the warper beams .
In leasin portion the warp sheet from individual warper beams is separated.
HEAD STOCK
After this yarn sheet is passed through expendable comb to separate each thread then through drag roller and finely wound on the weaver beam. Tension on the weaver beam is controlled by servomotor. The density of package is controlled by press force.
Benninger Size machine Headstock
PARTS IN HEAD STOCK
There are following parts in head stock.
· Guide roll
· Adjustable and expandable comb
· Feed roller
· Pendulum roller
· Weaver beam
· Pressing trolley
· Protecting cover sheet
· Tapping device
· Beam clamping device
The comb can be expanded and contracted by motor
Also the comb can be raised and lowered by the motor
The number of ends / dent and no. of pieces of comb are calculated for a specified quality.
MOTOR ATTACHED TO THE HEAD STOCK
The following motor are attached to the head stock
· Main motor for feed rollers 15 kw
· Two black motors for the drive of weaver beam 22 kw x 2
· Two motors for pressing trolley 0.75 kw x 2
· Two motors for beam clamping device 0.55 kw x 2
· Tapping device motor 0.11 kw
· Comb expansion 0.06 kw
· Vertical comb expansion 0.09 kw
· Comb and cover sheet 0.12 kw x 2
· Speed range 0-160 m/min
· Usual speed range 0-125 m/min
The tension in the warp sheet is maximum at winding portion
THE DIAMETERS AND HARDNESS OF DIFFERENT ROLLERS
The diameters and hardness of different rollers are following
Rollers Diameters (mm) Hardness (shore)
Feed roller 200 70
Pre wet squeezing roller 288 90
Lower roller of pre wet 260 100
Pressure roller of pre wet 188 75
Squeezing roller of size box 225 75
Upper roller of size box 200 65
Lower roller of size box 200 100
Immersion roller of size box 188 75
Press roller of size box 130
Pendulum roller of pre wet 139
Feed roller of head stock 240 65
Pendulum roller of head stock 133
Press roller of head stock 188
Main drying cylinders 800
Mini dry cylinders 186
TENSION FEEDING IN SIZING:
First of all the G.P.M for the warp is calculated by this given formula
TENSIONS AT DIFFERENT PLACES IN SIZING:
Formula:
Creel G/m 4
Size Box G/m (10 or 20 or 30)
Drying Section G/m (12-13)
Winding G/m (17-19)
Pressing G/m (15-16)
TEMPERATURE:
Cooking 190°C
Size Box 90°C
Drying Cylinders 120-145°C
SIZE PERCENTAGE:
Formula:
TABLE OF DIFFERENT QUALITIES:
Quality Beam Length Empty Beam Weight Weight of Sized Beam Calculated Warp Weight Size %
20.16/128.60=63 2150m 169Kg 745Kg 511Kg 12.72%
10.8/70.40=63 2300m 154Kg 790Kg 584Kg 8.9%
21.16/128.60=63 2 2100m 245Kg 1292Kg 952Kg 9.98%
16.12/108.56=63 2 2100m 220Kg 1375Kg 1041Kg 11%
10.8/70.40=63 2 2200m 251Kg 1490Kg 1157Kg 7.8%
SIZING RECIPIE:
CHEMICAL COMPOSITION:
?MAIZE (CORN) STARCH
034010 (Net Weight = 50kg), 34 Rs/Kg
?ELEVANOL (POLY VINYL ALCOHOL)
Net Weight = 25Kg, 139.79 Rs/Kg
Made in = U.S.A
?CLARIANT (TREFIX-605)
(Net Weight = 25Kg), 121.79 Rs/Kg
?ACRYLIC
Ø Avrnt 33.79rs/kg
Ø Acr140 87.7 rs/kg
?SOFTENER (SOLID CONTENT=100%)
· Makes the Sizing process Economical & Easy
· Imparts the excellent softness in the Warp Sheet
· Improves the lives of Rubber Covered Rollers & Teflon Coated Cylinders
· Eliminate the problem of Excessive Material Handling
COOKING METHOD OF SIZE RECIPE
There are three tanks
COOKING TANK
This is used for cooking the size recipe.
The mixing fan has flat type of arms
The number of the arms attached to mixing fan are 6 in set of 2 .
The motor for mixing fan is of 6 kw
The capacity is 1250 lit.
TRANSFERRING TANK
This cylinder is used to transfer the size recipe to size box
This cylinder has a \mixing fan having oval type of arms
The number ofd arms are 6 in set of 2
The motor for fan is of 0.37 kw
Capacity of cylinder is 1300 lit.
STORAGE TANK
This is used to store to recipe after cooking
RECIPE COOKING METHOD
First of all we add required amount of water according to size recipe
Now we add the PVA to it and start the fan to mix it in cold water.
The stirring time ranges 8-25 minutes depend on the amount and type of PVA
Normally this is 15 minutes
Now the fan is on and starch is added
Then softener and acrylics if any.
Now we stir the solution for 35 min. at 90-95C
The steam does the heating.
Now we store the recipe in storing tank to reach the stable form but maintaining the temperature at 80-85 C.
TESTING THE SIZE SOLUTION
VISCOSITY
A visco cup and stop watch are simple methods to check the viscosity of the size solution. Checking should be made periodically in cooking tank, storage tank , and in size box. Viscometer is also used for this purpose.
CHECKS AND CONTROLS WHICH HAVE TO EXECUTE REGULARLY
ON SIZING LIQUOR
· Size concentration By Refractrometer
· Size viscosity By Viscometer
· Temperature By Thermometer
NO OF WORKERS ON SIZING M/C:
Helpers=02 Mixer=01
Back Sizer=01 Sizer=01
Technician=01
GENERAL MAINTENANCES:
Before the starting of new batch
Ø Check the beam brakes.
Ø Check the pressure valves.
Ø Check the warp beam damages.
Ø Check the hardness of squeezing roller.
Ø Check all bearings.
Ø Check the belts.
Ø Check the Teflon coating on the drying cylinders.
Ø Check the crane loading equipment.
Ø Check all guide roller surfaces.
Ø Check all controlling equipment as given earlier.
RECIPES USED IN RELIANCE
QUALITY WEAVE WATER STARCH TREFIX SIZE%
10 8 70 40 63 1\1 775 50 4
10 10+70D 76 41 63 3\1 775 50 4
14 10 OE 76 29 114 HP 775 60 0.5 6
16 12 108 56 63*2 3\1 775 80 0.5 7
16 12 108 56 63 3\1 775 50 0.5 5
16 10 88 25 96 HP 775 60 0.5 5
20 16 128 60 63 3\1 775 60 0.5 7
20 20 108 56 65 3\1 775 50 0.5 6
20 PC 20 PC 98 48 64 1\1 700 60 0.5 8
20 10 118 52 63 3\1 775 55 0.5 6
20 16 101 47 69 2\1 750 50 6
20 16 108 59 75 3\1 775 60 0.5 6
20 12+70D 121 60 67 3\1 775 60 0.5 7
20 16 108 59 101 3\1 775 65 0.5 7
20 16 84 28 60*2 HP 700 60 0.5 6
20 10 OE 58 33 77 1\1 775 50 0.5 6
20 30 122 83 63 2\1 775 60 0.5 6
20 20 122 56 63 1\1 700 60 0.5 9
20 20 97 67 63 1\1 750 60 1 8
20 20 75 50 68 1\1 750 50 0.5 6
20 16 114 60 65 725 60 1 8
24 PC 150 D 120 68 59*2 4\1 700 85 2 12
30 30 130 70 63 2\1 775 70 1 9
30 20 130 80 63 BFC 750 65 1 9
30 30 110 74 63*2 750 80 0.5 8
30 30 112 63 87 750 80 1 8
30 PC 30 PC 96 86 61*2 4\1+1\4 725 80 0.5 9
32 20 138 93 63 800 65 1 7
40 40 110 90 98 1\1 750 75 0.5 10
40 30 160 68 100,116 4\1+1\4 700 80 1 11
40 40 127 79 116 4\1 750 80 1 9
40 50+70D 128 102 68 800 70 1 9
40 40 122 74 63*2 750 80 2 11
40/2 16 128 64 63 3\1 775 60 0.5 7
40/2 20 105 58 64 3\1 800 50 0.5 6
40 CVC 40 CVC 110 60 100 1\1 730 80 1 10
40 CVC 40 CVC 130 64 105 1\1 700 85 1 12
40 PC 40 PC 100 76 84 1\1 750 70 1 10
MAINTENANCE SCHEDULES FOR SIZING MACHINE
· CREEL PORTION
Before each new batch
Clean and degrease the the warper beam brake discs
Every 50 hours
Check the rail for dirt and foreign material for good working
Every 200 hours
Check the pneumatic brakes of warper beam
Every 500 hours
Check the brakes of cylinders
Check the belt and shoes for wear and also roughen its surface if it is softened
Check the beam support hubs
Check the axial guides
Check the crane
Pendulum and measuring roller
Every 500 hours
Check for correct functioning
Check roller bearing
Sizing center
End of shift
Clean the immersion roller bearings
Clean pressure trasducer of level of measuring (with maximum of 10 bar pressure)
Before each new batch
Replace and clean easy change filters
Every 200 hours
Check for leakage
Check safety valves
Every 500 hours
Remove all size residue from lower roller
Check drives
Check roller bearings
Check the squeezing roller
Check temperature and control system
Check steam and size valve
After 1000 hours
Check nip of roller
After 2000 hours
Remove oil from cones in variable speed gear box
Drying cylinders
Every 24 hours
Clean insulator and sensor roller for moisture contents
Check vacuum valve in steam piping
Every 200 hours
Check Teflon coating
Check safety valves
Check steam system
Every 500 hours
Check drives
Check coupling
Check slip clutch
Check drive shaft; drive gear wheel, universal joint shaft, chain and bolts
Check tensioning of chain and belts
Check cylinder bearing
Check hydraulic chain tensioner
Check cylinder
Check correct function of temperature control system
Check drive split rods
Every 1000 hours
Check vent pipes
Check fans
Headstock
COVER FACTOR
Quality Cover factor
16x12/108x56-63 34
20x16/128x60-63 35
40x40/88x54-122 31
40x40/110x16-93 35
40x40/110x90-98 35
40x40/120x53-114 48
40x40/130x55-106 45
20x10/1187x62-63 35
32/2x32/2 /81x56-63 31
40x40/88x42-108 31
30x30/108x81-94 35
40x40/127x89-98 41
20x8/42x40-115 19
60x60/183x91-115 56
60x60/183x54x2-100 49
60x60/183x56x2-124 59
60x60/160x63x2-118 53
30x24/88x77-68 23
40x40/130x55x2-114 48
DRAWING IN
PURPOSE OF DRAWING
The beam come from sizing section is then passed through the drawing section in which they made different pattern no weaving beam. For this purpose they use healed shaft and dropper. This work is done manually. It can also say that
“In drawing in process, the design of the fabric is prepared for weaving.
Working is done on sized waver beam.
PROCESS FLOW OF DRAWING IN:
PARTS OF DRAWING IN:
• Warper Beam
• Warp yarn
• Dropper- A drop wire
• Healed frame
• Healed/Heddle
• Healed eye
• Reed
Ends of sized warper beam are passed through healed frames, then through dropper. At the end ends are passé through reed dents.
DROPPERS:
The function of droppers is to stop the machine in weaving process whenever warp yarn breaks. Different types of droppers are used according to the yarn count. Droppers are classified according to their types i.e. 02, 03, 05. For fine count we use small droppers.
HEALD EYE:
These only pass out the yarn further. The number of droppers and heald wires are same in an article. The central hole of heald wire is called heald eye.
Two types of heald wires are used. These are classified according to their lengthwise size.
i. 11.5”
ii. 13.5”
HEALD FRAMES:
Heald frames carry the heald wires in them. These frames move upward and downward on loom and make the shed. These are of three types:
§ 190 CM (CARBO SPEED)
RUNS AT 1000 RPM
§ 210 CM (NEW LIGHT)
RUNS AT 800 RPM
§ 280 CM (GROB)
RUNS AT 700 RPM
§ 340 CM (GROB, SCHMEING)
RUNS AT 500-600 RPM
REED:
The function of reed is to complete the beat up process on loom. It also contains warp sheet in its dents. Dents per inch of reed are very important in warping planning. Reed has also three types:
a. 190 cm
b. 210 cm
c. 280 cm
d. 340 cm
BASIC CONSIDERATIONS
Basic considerations are
�� Warp count x Weft count / EPI x PPI Width
�� Type of weave (plain, twill, satin, sateen)
�� Reed (dents / inch), (end per dent)
�� Reed space
�� Selvage (selvage width and ends in selvage)
�� Total ends (body + selvage)
�� Total heald frames
IMPORTANT FORMULAS:
End / inch-(weft contraction)
Reed count in inch = ----------------------------------
Ends/dent
Total ends
Reed width = ----------------------------------
(Dents /inch) × (Ends/dent)
Ends /inch
Ends /dent = -------------------------------
Reed Count
Total ends
Reed space = -------------------------------
Reed Count × Denting order
Reed Count × Selvedge width (mm)
Selvedge Dents (dent of knara) = -------------------------------------------
25.4
Selvedge Ends = Selvedge dents × Selvedge denting order
Body Ends = Total ends − Selvedge ends
KNOTTING IN
DEFINITION:
The purpose of knotting is to knot the new warp sheet with the previous that has been processed on loom and is finished.
When the weaver beam becomes empty & the same quality is to prepare then the knotting in is used. For this purpose the weaver beam is taken off & knotting in frame is placed at weaver beam side. The both old & new warp sheets are kept in tensioned & in parallel form with the help of this frame. So the knotting in is started. The knotting in speed of this machine is 400 knots/min. company is ‘Poege Fischer”
MACHINE PARTS:
Ø Main Head
Ø Gripper
Ø Cutter
Ø Catcher
Ø Knotter
Ø Push Hook
Ø Lever
Ø Filler
Ø Wall Pressure
Ø One Lever Cam
ACCESSORIES USED IN KNOTTING
· Knotting Frame
· Brushes to tight the yarn sheet
· 1 rod of inside sheet
· 8 tension valves
· 4 used for upper sheet
· 4 for lower sheet
· Stand clamp to clamp the yarn
· Tightening rods
KNOTTING FAULTS:
o Tar loose in frame
o More size
o Sheet yarns
o Needle tension not accurate
o Wrong needle
o Head don’t works properly
o Gripper or Knotter has garbage
o Knotter becomes straight
o If cutter is not working properly, ends brake
o If knotter hook moves upward & downward
o If knotter size is not ok
o If frame is not ok, we adjust fillers.
COUNT WISE NEEDLES & SPEED OF M/C
COUNT NEEDLE NO. SPEED / MIN
6 32 250
7-8 30 250
10 26-24 250
12 18 250
14 16 250
16 14 250
20 12 250
24 12 250
30 9-10 200
35 8-9 200
40 8 175
45 7-8 175
50 7 175
60 7 175
80 5 150
100 4 150
120 3-4 150
WEAVING
SPECIFICATIONS:
TOTAL LOOMS 204
COMPANY TSUDAKOMA
DOBBIES 16
RPM 500-750 DOLBY
750-1000TAPPET
EFFICIENCY 96-98 %
LOOM MODELS ZAX, ZAX –E AND ZAX-P
LOOM SIZES 190 CM, 210CM, 280CM, 340CM, AND 340CM
Model Rpm Shedding Type
ZA 600 -IVE
ZAX 800 +VE
ZAX-E 900 +VE
ZAX-N 900 +VE
ZAX-P 1100 +VE
LOOM DESCRIPTION
Loom type Width(cm) No. of looms
Zax 190 76
Zax professional 190 48
Zax-e 210 28
Zax 280 4
Zax-e 280 9
Zax 340 12
`zax-e 340 27
SHED LAYOUT
MACHINE DRIVE
· One motor for main shaft
· One motor for take-up motion
· One motor for let-off motion
· One motor for leno device
· One motor for leveling the frames when cams have been adjusted
· One motor on drum feeder to wind the required number of turns
· One motor for lubrication to feed the lubricant material to different sliding parts
SHEDDING
Cam dobby of staubli is in operation for positive shedding.
Cams
AL-10 (It is used for Low Cover Factor and High speed)
AL-20 (It is used for Average Cover Factor)
AL-40 (It is used for High Cover Factor and Low speed)
TECHNICAL DETAIL
Repeat gear
Bevel gear
Cams of desired weave
Link lever
Healed frames
TSUDAKOMA ZAX-P have positive shedding mechanism. Motion through motor is transmitted to main shaft. Then through main shaft, the motion is transmitted to Bevel gear and then to the Repeat gear of cam dobby
For different weaves the rpm of cams are adjusted with the help of repeat gear & Bevel gear. The teeth of repeat gears are fixed as 60.
REPEAT GEAR
TYPE OF REPEAT GEAR
· R4
· R5
· R6
R4 is used for Weaves 1/1,2/2, 3/1, 1/3
R5 is used for Weaves 2/3, 3/2, ¼, and 4/1
R6 is used for Weaves ½, 2/1, 2/4, 4/2, 3/3, 1/5, 5/1 and Sateen or Satin
BEVEL GEAR
For Repeat gear R4, teeth are fixed that is 60 and the teeth of the bevel gear will be,
BEVEL GEAR TEETH=60/4 =15
For Repeat gear R5, teeth are fixed that is 60 and the teeth of the bevel gear will be,
BEVEL GEAR TEETH=60/5=12
For Repeat gear R6, teeth are fixed that is 60 and the teeth of the bevel gear will be,
BEVEL GEAR TEETH=60/6=10
SHEDDING OPERATION:
After the decision of Bevel gear teeth, the motion from repeat gear is transmitted to cams. Cams give required movement to treadle levers, which raise the required heald frames with the help of link lever.
Also remember that the remaining heald shafts are moved to downward direction simultaneously providing positive shedding.
PICKING:
As picking mechanism is through jet of air, different types of nozzles are used for weft insertion.
The passage of weft through different nozzle is explained as
PICKING FLOW DIAGRAM
DRUM FEEDER:
Now the yarn is wound on a drum feeder. It stores the yarn for picking. It reduces the tension in the yarn. So breaking of weft yarn reduces due to low tension. The pick length is measured by fabric width &weft crimp %age. So number of coils is decided by pick length that should be wound on drum feeder before picking. Here an unwinding sensor is present on the drum feeder that controls the proper unwinding of yarn for picking.
On drum feeder the band-measuring device measures the pick length.
Figure shows drum feeder
TENDOM NOZZLES:
These nozzles are located after the drum feeder . their main object is to unwind the yarn from drum feeder. So main nozzles require less pressure for weft insertion.
MAIN NOZZLES (M1, M2):
These are the nozzles those perform the main picking operation. It is desired that the pressure through nozzle should be laminar or straight flow for perfect picking.
It is in the range of 250 to 450 kPa. From fine (80s) to coarse (14s)
SUB NOZZLES (SUB):
These are the number of nozzles that are present along the reed & fitted on the reed. These nozzles are at a distance of 1.5” to 2”from each other.
It is in the range of 400 to 500 kPa. from fine to coarse counts.
Their number depend on
Ø Yarn count
Ø Fabric with
Ø Pressure of each nozzle.
STRETCHING NOZZLE (STRETCHING)
After the pick has been inserted then the pressure of this nozzle keeps the yarn in stretching position. It is in the range of 400 to 500 kPa from fine to coarse counts.
WBS(WEFT BREAK SYSTEM)
This device consists of the WBS main body including the WBS motor that drives the push lever and the
WBS amplifier, and the WBS controller to control their operations.
OPERATION OF THESES NOZZLES:
The operation of these nozzles is very important w.r.t timing. It should be noted that these nozzles work individually. Their timing is controlled through synchronize solenoid valves. Operation, time wise, can be explained as
Ø Unwinding the yarn from cone.
Ø Winding of the yarn on feeder.
Ø Unwinding of the yarn from feeder with the help of tendom nozzle.
Ø Pick insertion through main nozzle.
Ø Sub nozzle pressure for gentle picking.
Ø Stretching through stretching nozzle.
Ø Main breeze pressure to control tension at beat up.
Ø Cutting of pick with the help oh cutter.
PRESSURE OF DIFFERENT NOZZLES FPR DIFFERENT QUALITIES IN KPa
S.N QUALITY MAIN SUB STRETCH Mb Mc
1 24*14/112*58/67” 400 500 500 40 40
2 60*60/90*80/67” 300 470 400 80 40
3 39*30/76*68/116” 440 430 530 70 44
4 60*80/244*194/120” 230 400 520 73 47
5 16*12/108*56/63” 400 240 200 60 40
6 60*80/244*194/108” 280 460 400 80 44
7 40*40/88*86/122” 250 400 400 74 45
GENERATION OF HIGH PRESSURIZED AIR FOR PICK INSERION:
The high-pressurized air is generated with the help of compressors. These are the reciprocating compressors that generate the high-pressurized air
Air consumption depends upon width of loom.
Pressure drop during insertion=0.3-0.4bar
Pressure of main nozzle ranges from 1.0-5.0bar depends upon
1.Count
2.Speed
3.Width
pressure of sub nozzle=4.0bar
The flow of air for generating high-pressurized air is shown in the figure.
Out side Air à Air Filter à Low pressure Reciprocating compressor à High Pressure Compressor à Drier à Piping à From regulator valve to each loom
BEAT UP:
Main shaft of the weaving machine drives sley crank gear on both sides of machine. Driving arm transmits the crank to sley tube, which moves back & forth, is mounted on sley tube. The reed is made profiled to make confined channel for passage of warp
Soft and hard beating up:
Beating up can be made softer by raising the backrest while lowering the backrest can lower it.
It depends upon weave
Soft beating hard beating
2/1 1/3
3/1 1/4
4/1 1/2
1/1
WARP LET OFF:
This motion is responsible for
Ø Proper warp let off
Ø To control the tension on the warp sheet.
The load sensor measures warp tension it is corrected by servomotor, which adjusts the rpm of let off beam.
FABRIC TAKE UP:
This motion is responsible for proper take up of fabric at require PPI. In this motion take up roller is driven by servomotor. So frequency-controlled servomotors control weft density. Here pressing roller is used to prevent the fabric from slipping back depending on the type of fabrics one or press rollers are used.
ELECTRONIC TAKE-UP
Weft density settings can be entered from the function panel (single pick density type). This system can also change weft density during loom operation (multiple pick density type).
WORKING OF LET OFF & TAKE UP MOTION:
Their motion is very important w.r.t timing.
Both motions in air jet weaving loom are inter connected through servo pack or servo amplifier. Their working can be under stand with the help of this diagram.
EXPLANATION:
First of all the tension in the warp sheet is feeded.it is parameterized value of tension.
During weaving, as the beat up completed, the tension in the warp sheet is measured by load sensor. Actually the load cell is checking point of warp tension. This load cell transfers this information to servo amplifier. There are the two main objects of servo amplifier.
This servo amplifier measures the current rpm of let off beam & take up roller.
It also compares the current warp tension with feeded warp tension. Servo amplifier corrects the difference in tension. This servo amplifier adjusts the new rpm of let off & takes up roller. So tension is maintained at require level.
FABRIC WINDING UP:
In air jet loom the fabric wind up is controlled by directly driven with the servomotor. The rpm of wind up roller are adjusted with the servomotor to control the tension in the fabric.
WARP STOP MOTION:
It is electrically controlled. As the yarn breaks then dropper falls on the dropper rail. So electrical circuit is closed & the weaving machine stops. The six rows of rails are present in JAT710.
WARP EASING MOTION
This motion releases warp sheet, as shed is open and pulled back the sheet as shed is closed.
EASING TIMING
Easing timing means the timing when the tension roll is shifted backward to its maximum extent.
The standard easing timing is the same as the shed opening timing of the shedding motion.
When the shed opening timing has a phase difference, take an earlier timing
The major parts involved in this motion are
· Crank stroke
· Joining arm
· Easing block
· Easing roller
EASING AMOUNT
The easing amount is determined by the position
of the easing arm of the easing rod.
Easing amount (mm) when the eccentric amount
of the eccentric boss is 4.5mm:
STANDARD EASING AMOUNT
When the pick density is high or the shedding amount is increased, the easing amount should be increased.
SENSORS IN LOOM:
Major types of sensors, which are used in air jet loom of JAT710, are
Ø Encoder
Ø Eltex sensor
Ø Magnetic pin
Ø Leno sensor
Ø Winding sensor
Ø Reserve sensor
Ø Oil sensor
Ø Leveling sensor
Ø WF1
Ø WF2
Ø Load sensor
Ø Feed sensor
ENCODER:
To show the Crank degrees at any instant
ELTEX SENSOR:
In double pick insertion quality when two yarns are fed from single color, out of two one yarn is passed through Eltex sensor because in case of breakage, it stops the Loom, while breakage of other weft is shown by winding sensor.
MAGNETIC PIN(F.D.P):
It allows the required length of weft yarn for pick insertion.
LENO SENSOR:
It shows the breakage of leno thread.
WINDING SENSOR:
It shows the breakage of weft thread before winding on drum feeder.
RESERVE SENSOR:
It controls the required number of turns to be wound on to the drum feeder.
OIL SENSOR:
It shows the level of oil in cam box.
LEVELING SENSOR:
It shows the level of heald shafts.
H1 FEELER
The main object of this sensor is stopping the loom in case of if yarn is not present in the reed .it is located before the stretching nozzle. It consists of a laser transmitter & receiver. Transmitter transmits the laser light towards the receiver. If yarn is present then laser does not reach towards the receiver & loom runs continuously. if yarn is not present then laser reaches towards the receiver which stops the loom.
H2 FEELER
This sensor has opposite function as compared to WF1.if yarn is present then laser does not reach towards the receiver & it stops the loom. The main object of this sensor is to stop if the yarn is present. Actually it controls the lengthy pick. it is located after the stretching nozzle. So it stops the loom if pick is very large about 50mm.
The location of these sensors is shown in the figure below.
LOAD SENSOR:
It measures the tension on warp sheet.
CONSTRUCTION OF H1 & H2
LOCATION OF H1 & H2
LOAD SENSOR:
It is very important sensor of the loom. It measures the tension of the loom. It sends its in formation to servo amplifier, which correct the tension.
FEED SENSOR.
It is present on the feed drum to measure number of coils require for picking.
MOTORS:
There are different types of motors used in an air jet loom.
These are AC motors & given below.
Ø MAIN MOTOR
Ø WEFT FEEDER SERVOMOTOR
Ø LET OFF SERVOMOTOR
Ø TAKE UP SERVOMOTOR
Ø FABRIC WINDING SERVOMOTOR
Ø EASING MOTOR
MAIN MOTOR:
It is the main motor, which supplies the power to the loom. It is 3-phase 400volts & 50Hz frequency motor.
.
WEFT FEEDER SERVOMOTOR:
It is servomotor, which is present in the feeder. It controls the rpm of feeder for proper storing of yarn. The number of servomotors depends on the number of feeders used. The length of yarn stored depends on the width of fabric.
LET OFF SERVOMOTOR:
It is connected to let off gear to control the let off speed.
TAKE UP SERVOMOTOR:
This motor directly drives the take up roller. It takes the fabric according to required ppi.
FABRIC WINDING UP SEVOMOTOR:
It is used for fabric winding. Its speed is synchronously control with the speed of take up roller.
SELVEDGE:
Two types of selvedge are formed in roomy fabric. These are formed according to requirement. These are
Ø LENO SELVEDGE
Ø TUCKED IN SELVEDGE
1- LENO SELVEDGE:
Air jet weaving machines typically produce cut selvedges called leno selvedges. The ends of filling yarn on the receiving side may be fixed with the additional yarn fed from a special creel & cut off edge is fed into a waste box.
A mechanical device called leno device forms these leno selvedges. This device contains the reels of yarn, which binds the picks on both side of fabric to produce a firm selvedge. The reels of yarn are also called the leno yarn. The count of leno yarn should be less than the ground yarn. The leno device is shown in the figure.
Two types of leno selvedges are formed on air jet loom. These are
2- TUCKED IN SELVEDGE:
It is a selvedge in which the cutting end of the pick is tucked in the edge of the fabric. A special blow of air & tucking needle is used for tucked in selvedges.
When the cutter cuts the pick then blow of air passes the pick through hole of tucked in needle. This needle dips the yarn in the shed & moves back empty for next pick.
I-BORD FEEDINGS ON LOOM FOR A NEW QUALITY:
Ø Tension on the warp sheet in kilogram force.
Ø RPM of loom.
Ø Require PPI
Ø Require width
Ø CUT LENGTH:
Length of warp sheet on weaver’s beam
Ø Timing adjustment of primary motions as
· Shedding.
· Picking.
· Beat up
These were shown earlier.
Ø Pressure of all nozzles as
· Tendom nozzle
· Main nozzle
· Sub nozzles pressure
· Stretching nozzle pressure
· Main breeze pressure
· Main cut pressure.
Ø Timing of pressure of pressure of all these nozzles during picking. ( these are usually already feeded ).
DURING WEAVING I-BORD SHOWS:
Ø Current loom RPM.
Ø Efficiency of the loom.
Ø Efficiency of the loom per day
Ø Production in meter per minute.
Ø Remaining cut length which is the length remaining on the weaver’s beam.
Ø Cloth forecast length which is the length of cloth that has been woven.
Ø Current tension on warp sheet.
Ø Number of stoppages of loom.
Ø Number of warp breakages.
Inside these PLC shows wide range of in formations as year production
TENSION FEEDING ON THE WARP SHEET:
The formula for finding the warp sheet tension in kgf is given below.
Friction ranges from .65 to .8 depending on weave
MAINTENANCE SCHEDULE
1- SHEDDING MOTION
Check the barring of connecting lever
Check all bushes of connecting levers
Check all adjustments
Check all moving parts of cam box
Check joints of healed frame
2- PICKING MOTION
Check positioning of EDP pin
Check EDP pin bushes
Check weft accumulator alignment
Check cushion gum
TANDEM MAIN AND SUB NOZZLES
Check air leakages of all pipes of main and sub nozzles
Check working and positioning of all these
SOLENOID VALVE
Overhaul solenoid valve
Check sub valve coil
Clean solenoid valve
3- WEFT INSERTION MOTION
Check all jet start
Check the blade surface
Check the blade arrangement degree
4-BEAT UP MOTION REED AND SLAY
Clean total reed and slay
ROCKING SHAFT BRAKES
Check wear ness of bushes
Clean all parts
Check lubrication nipples
EASING ARM
Check the easing arm rod ends
Check easing lever pin and bushes
Check easing rod bearings
5-LET OFF MOTION
Backrest tension roller assembly
Check all bearings
Check all bushes
Check and clean oil nipples
Clean all parts
GEARS
Check teeth of gear of let off
Check proper play between gears
YARN BEAM HOLDER
Check that there are no stains on the surface of bearing housing
6- TAKE UP MOTION
Check chain and gears
Clean and lubricate where necessary
Check teeth of bevel gears
Check fly dust accumulated in driving belt
Check tension of belt
7- WARP STOP MOTION
Check warp stop motions
Check fly and dust accumulation
8- WEFT STOP MOTION
Check the weft feelers
Check there are no stains n the light emitting and receiving devices
9- LENO
Check that sensor plates work correctly
Check leno bobbin rod and bushes
Check tensor arm bushes
Check bobbin holder
Check bobbin rod stopper
Check binding eye4s
Check tension spring for deformation
Check rachet finger
Check leno shaft and gears
Clean every part of leno motion
10 – OIL CHANGE
Change oil from
Right and left hand gearboxes
Tappet cam box
Let off drive box
11- LOOM LEVELING
Check leveling of the loom
Check all foundation bolts
TROUBLESHOOTING IN WEAVING
TIP TROUBLE
The loom stops as the weft end is entangled at
the right selvage due to weft delay, shortage of
weft feeding force, selvage looseness on the RH,
or defective shedding.
BENT PICK
The loom stops as the weft bends in a U-shape
due to shortage of feeding force, weft delay or
defective shedding motion.
KINKY YARN
When weft has strong twist or twist looseness in
the storage section, the weft folds in an Z shape.
This problem is common with high twist weft.
WARP TIE-ON (OTHERS)
The loom stops as the shedding is defective due
to too low warp tension or defective warp, so weft
is caught by warp.
VARIANCE OF MEASURED LENGTH, SHORT PICK OR ONE TURN SHORT PICK
(1) VARIANCE OF MEASURED LENGTH
This is caused by a defective yarn supply
package, or lack of stability in storage and of weft
feeding force.
(2) SHORT PICK
When there is too much variance in the
measured length or the main nozzle is clogged
with lint, short pick results and the loom stops.
(3) ONE TURN SHORT PICK
The loom stops as the inserted weft length is
short by one turn on the drum.
BLOWN-OFF TIP
Air pressure before weft insertion is too high or
weft is too weak, so tip is blown off.
The loom stops due to short pick.
Weft tip is not cut sharply.
BLOWN-OFF (AT THE MIDDLE)
1) Yarn feeding force is too strong during weft
insertion or supply yarn is weak.
2) Yarn feeding force is too strong when the hook
pin stops the weft.
The above 1) and 2) happen at the same time
resulting in frequent weft breakage.
LOOSE PICK
1) Weft is loosened when it is caught by the hook
pin because of shortage of feeding force, weft
delay, improper warp line, or defective shedding.
2) Looseness on the RH is caused by weft
repulsion
MIS-CUTTING
Weft is not cut with the cutter on LH.
FALSE STOP
Weft arrives normally, but there are problems
with the posture of weft, selvage, catch cord or
electrical parts. A weft signal is not entered due
to the above problem and the loom stops.
LONG PICK
Inserted weft length is longer by one turn of the
FDP drum.
BLANK PICK
Weft is stored on the FDP drum when no weft is
inserted.
REPULSION PICK
When the weft selection is for 2 or 4 colors,
additional weft is inserted by one turn of the FDP
drum into the next pick.
INSPECTION
It is the department where the grade to the fabric is given by checking the points of fabric. There are 19 inspection frames and 11 rechecking frames. There are the different types of faults that occur in the fabric these can be classified as
Ø YARN FAULTS
· Long thick places
· Slub cockled yarn
· Count variation
Ø SIZING FAULTS
· Hard size
· Sizing stain
· Kinks
Ø MECHANICAL FAULTS
· Starting mark
· Repping mark
· Reed cut
· Weft Loose
· Defective Selvedge
Ø OPERATION FAULTS
· Miss pick
· Double pick
· Double end
· Short end
· Float
· Wrong drawing
GRADE CALCULATION STANDARDS:
There are two standards, which are widely used in inspection.
These are
· AMERICAN SYSTEM
.It is the system in which 4 points are given to fabric. It is called four point system.
· JAPANESE SYSTEM
It is the system in which 10 points are given to faults. It is called 10 point system.
AMERICAN SYSTEM:
It is used in Reliance Weaving Mills. Its specifications are given below
FAULTS LENGTH POINTS GIVEN
1"-3" 1
3"-6" 2
6"-9" 3
Above 9" 4
INSPECTION FRAME
GRADES GIVEN TO FABRIC:
Specific value of points/sqr yard gives grade value.
These values are given below in table
GRADES POINTS/SQRE YARD
A1 10
A2 15
A3 20
B Above 20
WHERE
TOTAL POINTS = X1+2X2+3X3+4X4
X1 = TOTAL POINTS OF 1 POINT FAULTS
X2 = TOTAL POINTS OF 2 POINT FAULTS
X3 = TOTAL POINTS OF 3 POINT FAULTS
X4 = TOTAL POINTS OF 4 POINT FAULTS
There the some faults called continuous faults
These are
Ø Double warp
Ø Reed mark
Ø Wrong denting
Ø Wrong drawing in
These fabrics are accepted as b-grade
PACKING
There are three types of packing.
· Roll packing
· Bale packing
· Pallet packing
These are according to customer requirement.
SPECIFICATIONS
ROLL PACKING M/CS……………………………………02
BALE PACKING M/CS…………………………………....03
PALLET PACKING M/CS…………………………………..01
ORDERS SPECIFICATIONS FROM A PARTY
Main specifications are
Ø Warp count
Ø Warp yarn type
Ø Weft count
Ø Weft yarn type
Ø Ends per inch
Ø Picks per inch
Ø Width
Ø Weave
Ø Selvedge type (leno or tucked in)
Ø Fabric length with allowances
Ø Time in which order is to be placed
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