Multiphase, a new concept of weaving

Multiphase: A new Concept of Weaving

Md. Ishtiaque Parvez Ibne EmdadId NO: 2014-2-2-005

Classification of Weaving Machines

Single-phase weaving machines Machines with shuttles (looms):Hand operated (hand looms)Non-automatic power looms (weft supply in shuttle

changed by hand)

Automatic weaving machinesShuttle changing[Rotary batteries, stack batteries, box

loaders or Pirn winder mounted on machine (Unifil)]Pirn changing

Shuttle less weaving machines:ProjectileRapier (1. Rigid Rapier 2. Flexible Rapier)Jet Loom (1. Air Jet Loom 2. Water Jet Loom)

Classification of Weaving Machine:

Multiphase weaving machines Wave shed machines (Weft way multiphase)Weft carriers move in straight pathCircular weaving machines (weft carriers travel in

circular path)

Parallel shed machines (Warp way multiphase)RapierAir jet.

Development of multiphase loom

1. Shed progresses in waves 2. Sheds from in succession across the width of the loom3. This type of machine may be flat or circular.

Wave shed machines (Weft way multiphase):

Circular Multiphase Loom: 4 to 10 Shuttle Pass in a circular path.

Widely used for producing Circular fabric for sacking or packaging material (like Polypropylene circular fabric for heavy loading).

Wave shedding

Starlinger Circular Loom

Optimized design and production of cam drive mechanism, to ensure the stability of the machine and the long-running reduced power consumption;

Selection of the most advanced automatic latitude compensation system to improve machine efficiency and reduce the incidence of rejection;

Longitude and latitude detection devices, real-time monitoring of warp, weft usage, break through, the weft, to achieve position-indicating when the weft end, and automatically shut down;

Intelligent boost control to replace the traditional mechanical weft density gear change

Repairing broken weft is tough.

Wave Shedding Mechanism

Warp shed is divided into segments

Each shuttle runs in its own shed

Cam controls the heald frame or wire segments from inside via pushrods.

Only plain and twill weave are possible.

Heald is connected elastically, by way of an elastic traction element locked to the fixed part of the loom.

Healds of each section are lowerlylocked to a single connection block which is connected by a spring catch connector, which is itself connected to the end of a cam-controlled operating lever

Each cam controls a independent set of connecting block thus a independent part of a heald frame.

Filling Insertion of Circular Loom:Mechanical Shuttle drive Oscillating reed: It moves the shuttle and

also simultaneously beat up the inserted weft thread.

Striking lever type elements: They push the shuttle through the warp ends of the shed.

Rack and pinion system: The drive of each shuttle is given through two especially designed gears. One of which is attached to the revolving cylinder, has teeth of special profile to accommodate small groups of warp ends as it mashes with the second pinion attached to the shuttle within the warp shed.

Pressure rollers: The act on the warp ends of the inner shed and through them on the shuttle.

Electromagnetic Shuttle Drive

Magnetic field: This is set up in the form of a magnetic field by which the shuttle is moved.

Rotating Electromagnet: this holds the shuttle firmly through the warp ends of the inner shed and caries it when it rotates.

Beat Up In Circular Loom Spiked Wheel: They

reacting through the warp ends follow the circulating shuttle and press the weft thread against the fell of the fabric.

Oscillating Drop wires: They reach through the warp ends, after the shuttle pass and push the weft threads against the fell of the cloth. They are pushed down by the next shuttle.

Flat Multiphase Loom

Shed Formation In flat Multiphase loom:

Weft Insertion In Flat multiphase Loom

The Contis C2 and NuovoPignone TZP looms use positive drive from the roller on an endless chain track fitting into the depression in carriers.

In Ruti 6000 the weft carrier is driven by reed dents which applies pressure to the rear inclined surface of the weft carriers. Fig: Weft carriers are driven by Oscillating

Reed Dents (Ruti 6000)

Beat up In Flat Multiphase Loom: Beat up is done by rotating or oscillating reeds in

case of flat multiphase loom. These kind of reeds also aid in the weft carrier drive.

Fig: Rotating Reed for weft Carrier drive and also for beat up.

Parallel shed machines (Warp way multiphase)

a series of individual parallel sheds are formed across the warp direction, one behind the other along the warp each extending the whole width of the warp sheet

These shed approach the fell of the cloth

This concept is called Sequential Shed principle or multi-linear Shed Principle.

Fig: Parallel shed (Warp Way multiphase loom).

Shedding Mechanism of Warp way multiphase Loom

A shedding rotor is used to form successive parallel sheds.

The rotor is consists of shed forming element and Beat up Elements.

The weaving shed-forming elements consist of lamellas which are provided with seating on their top sides in which warp threads can be received. They form Upper shed

The yarn which miss this position and take place at the right side of the lamellas create bottom shed.

The position of the warp yarn is selected by a position selection element.

Position selection elements with thread guides for the respective warp threads, whereby these thread guides can be laterally moved between at least two positions

The number of position selection devices and no of heald frame for a design will be equal. And threading of the guide of the position selection devices will be same as drawing order of the design.

Picking mechanism of Weft Thread in warp way multiphase loom

The Picking mechanism for the warp way multiphase loom is of two types.

By Rapier (GentiliniRipomonte Loom).

By Air Jet (Sulzer TextilM8300).

Filling Insertion By Air Jet (Sultex M8300)

The yarn insertion system consists of a fixed part on the one hand and of a part rotating along with the weaving rotor on the other hand.

In the fixed part are provided yarn feed- through ducts, in this case four, respectively, for the respective weft yarns with fixed entries. Their outlets open laterally into the part which rotates along with the weaving rotor.

The Weft conveyor ducts formed by recesses in the weaving shed-forming elements.

several relay nozzles are preferably provided, spread over the length of the weaving rotor, which promote the conveyance of the weft threads through the conveyor ducts.

Beat up of Warp way multiphase loom:

Beat up in warp way multiphase loom is done by the beat up elements on the shedding rotor. It pushes the newly inserted weft yarns into the fell of the cloth.

Multiphase: The future of weaving System:

Fastest Weaving machine in the world:

Sulzer textil has developed multiphase weaving machine and brought it to maturity. The M8300 multiphase weaving machine is the most cost efficient of all weaving systems.

The advantages of the multiphase machine make their full impact when warp densities remain unaltered for a prolonged period of time.

Printing ground fabric, bed linen, work apparel, light denim styles can be produced in this machine.

warp density of 114 ends/ inch or 45 ends/cm can be produced in this machine and yarn count 8-40 Ne.

Fastest Weaving machine in the world:

The M8300 will be used wherever 25-30 % lower production cost as compare to single phase air jet machines.

M8300 was used exclusively for staple fibre yarns count range 14.5-70 tex (8- 40 Ne). The European and American customers were using cotton, polyester, viscose, and blends of these as raw materials, and producing fabrics in basic weaves and less elaborate designs. Filament yarn can also be woven in range of 50 to 330 dtex.

Fastest Weaving machine in the world:

With the weft insertion rate up to 2800 picks per/ min (5400 m/min) are possible meaning that up to 1500 linear meter of printing ground fabric can be produced daily.

On the basis of practical observation it is known that a complete style change on M8300 is possible in less the 3 hrs.

References Behera, BK , Hari PK, Developments in weaving machine, Indian Journal of Fiber and Textile

Research Vol. 19, September 1994, p 172-176. Sartorius C. The Fastest Weaving machine in the World, Sulzer Technical Review 99/3. Corain L, Heald Control System for a Travelling Wave Shedding Loom, US patent no.4,538,648 Sartorius C. A market breakthrough of multiphase Weaving system. Sulzer Technical Review. Gokerneshan N, Jegadeesan N, Dhanapal P, Recent Innovation of loom Shedding Mechanism,

Indian Journal of Fiber and Textile Research Vol. 35, March 2010, p 85-94. Strauss EH, Guide arrangement for Weft Thread Inserting Elements, US Patent no 3,683,969. A. Ormerod and W. Sondhelm; "Weaving Technology and Operating", The Textile Institute, p180

(1995) K. Chikaoka and M. Ishida; J. Text. Mach. Soc. Japan, 49, p62 (1996) Beitelschmidt M, Helfenstein A, Better Fabrics through Knowledge of Thread Forces, Sulzer

Technical Review 2/2001. Sondhelm WS, Technical Fabric Structures- Woven Fabric, Handbook of Technical Textile. P 78-

87. Shaw H, Weaving Machine as well as a method for forming a fabric by means of such weaving

machine. European patent no EP 1 497 487 B1.