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CERTIFICATE OF APPROVAL
THIS IS TO CERTIFY THAT THE PROJECT WORKENTITLED AUTOMATION IN TEXTILES IS BONAFIDE
RECORD OF PROJECT WORK DONE BY,
ANSARI ABUZAR (2010009)
&
GHASIT ZUBAIR (2009010)
IN PARTIAL FULFILLMENT FOR DIPLOMA IN TEXTILE
TECHNOLOGY.
GUIDED BY H.O.D.
Prof. A.S. Deshmukh Mr.H.V. Ramteke
Date: 17-05-2013
Place: Mumbai
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SUBMISSION
WE THE STUDENT OF THIRD YEAR OF THE
COURSE OF DIPLOMA IN MAN-MADE TEXTILE
TECHNOLOGY HEREBY SUBMIT THAT WE HAVE
COMPLETED THE PROJECT WORK AS DESCRIBED INTHIS REPORT BY OUR OWN SKILLS AND STUDIED IT
FROM TIME TO TIME DURING THIS PERIOD AS PER
THE INSTRUCTION OF OUR GUIDE Prof. A.S. Deshmukh
AND WE HAVE NOT COPIED THE REPORT, OR
ITS ANY APPRECIABLE PART FROM ANY OTHER
LITERATURE IN CONSIDERATION OF THE ACADEMIC
ETHICS.WE HAVE MADE THIS PROJECT WITH
DEDICATION AND LOT OF HARD WORK.
DATE: -17-05-2013 SIGNATURE OF STUDENT
ANSARI ABUZAR Signature
GHASIT ZUBAIR Signature
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ACKNOWLEDGEMENT
We wish to take this opportunity in expressing my sincere thanks
to the people, we are obliged to, for their encouragement and
inspiration that they had shown thought this project.
We express our deep sense of gratitude to our revered guide MR.
A.S. Deshmukh. His guidance throughout the preparation of this had
led us to complete this project successfully.
We also to the very of thanks to entire staff of SASMIRA
specially all the librarian, who have deterred us from helping in
Collecting the information and data require for our project and wefinally thank our parents and friends for giving their Co-operation.
Finally, once again we want to express our deed hearted thank for to
my most Respected guide MR.A.S. Deshmukhfor giving moral support
throughout this project.
And also We want give thanks to all our well wishers
for seeing us throughout this project.
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Behind every success there is a source of inspiration, in our
case Mr. A.S. Deshmukh whose inspiration and constant
incouragement late us to complete this project report to the satisfaction.
Inspite of very short schedule of academic work, he spread to his
valueable time to us, and acted as friend and guide and not as mere
conventoinal guide, therefore take oppurtinity to thank prof. A.S.
Deshmukh whole heartedely.
Secondary we would like to regards all the SASMIRA staffspecially librarian who giving us the idea about project and also
providing us the material for the same.
Last but no least we would like to thanks our all the friends for
giving us constant incouragement and co-operate us from time to time.
[DMTT]
ANSARI ABUZAR
GHASIT ZUBAIR
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INDEX
TOPIC Page No.
1. Introduction 6-10
2. modern yarn preparation 11-18
a. winding
b. warping
3. Automation in warp sizing 19-28
4. Shuttle less wave machine 29-41
a. sulzer weaving machine
b. air jet loom
c. water jet loom
5. Application of computer in textile 42-44
6. Conclusion 45
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Chapter 1
INTRODUCTION
The textile manufacturing process from fibers to yarn and yarns to fabrics
involves many processes the fiber when undergoes treatment of opening, carding,
drawing, roving and spinning is converted into yarn which then undergoes yarn
preparatory treatment that is winding warping then the warp yarn goes for sizing
treatment to be ready for being woven into fabric. Automation has been nearly
applied to all the machinery involved in the manufacturing from the fabric. The
amount of automation being done depends upon the possibilities the need and the
available means, while the priorities of these factors already varied. The degree of
automation machine to machine and from one processor to another. Automationas always been carried for certain purpose. It may be to reduce the labour, to
increase the production, to increase the quality of product and many other reasons
are involved. The following description will consider the automation done in
various fields of textile.
Materials Handling
One of the most fertile field for mechanisation is heavy of material. One
day of manually handling large packages such as bale of cotton are
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gone.Moterised or electric jeeps and jeeps load and unload. Stack, and distribute
faster and more economically, then can be done by hand. Throughout the plants
hoise conveyers and mechanics dollys.Transport material between operations
more easily and more cheaply than can do man power.
Opening And Fitting:
Improved opening and cleaning have resulted in saving areas other than
labor specifically when modern equipment are used, a low grade raw stock is
capable of yielding an in product equal in quality to that obtain with older
machineries and more expensive raw materials.
At the end of blow room, automatic lap changers make things very easier,
but also increase the efficiency and quality, especially in conjunction with
weaving and storage. These replaced manual cleaning machines like trutzschler
yield qualities, which previously attainable only after laborious manual blendingin a hand struck.
Carding
The improved methods of opening and cleaning have festered and
encouraged the development of better carding techniques. However the majordevelopment in carding namely vacuumed stripping has resulted independently of
these changes.
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Normally each card required one to three stripping in a shift of eight hours,
depending upon the stop being processed. The advantage of vacuumed processing
stripping is the work of two labors. To be done by the six or eight man with brash.
Not only it faster and cheaper to strip by vacuumed, but working condition are
improve and more uniform production is possible.
With heavier laps have come conveyors to replace human tracking and
hanging on cards with power laps to lay card tenders assignment can be increase
ten to thirty percent.
Drawing
The operation of drawing, disregarding the larger supply package and
finished package is notable for improved speed with reduced variations. Todays
modern draw frames are six to eight time faster at the rate five hundred meter per
minute approximately. More micro dust is extracted in drawing operation. Autodoffing and can change is introduce auto draft levelling is applied on draw
frames.
Roving
Now days single process roving is offered whereas the older manremembers the short draft slobbers, intermediate and speeders.
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The processing improvement in converting raw cotton to finish the fabric is
not independent unit developments. It operation is depends on its quality and
operating characteristics. Not only at preceding steps in preparation but also in
how the material are to be handled insufficient operation thus the waste
improvement in opening blending carding and drawing laid the ground work for
reducing roving processes and tremendous strides in the utilisation of high and
super draft in spinning made it practical. No sacrifices in quality have resulted
and the saving has been tremendous. Automation has been carried out in limited
extend due to greet strides of operation before and afterrovings, direct slivers to
yarn processing is beginning to eliminate the roving frame.
Spinning
Spinning has always been small package and low production, high
operation cost upon the success of which rested much of the manufacturers
ability to produce quality goods for market. Any substantial contribution to theseoperations under the way of not sacrifices in quality has been needed for years.
Spooling and Warping
Automatic spoolers and high speed wrappers exemplify the strides taken by
the manufacturers in utilizing the mechanical application to reduce labour cost
and improve handling.
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This process at a little to product value. Wears spot and yarn defects are
corrected to a limit extent, but basically the operation nearly transfer the yarn
from bobbin to beam through the intermediate package.
Winding, spooling and related operations have become automated.
Automatic winding and warping have certainly festered. Many of the
improvement in spinning packages.
Weaving
Generally speaking, the conversion of fibers into finished product
involves three steps, preparation conversion to yarn and weaving.
Weaving itself involves two step of preparation the warp and feeling
followed by the weaving process. That combined the warp and feelings
to make the finished fabrics.
Weaving is perhaps of the first of the any textile operation to have
experience. Automation in recent years the three steps in weaving
process filling preparation; warp preparation and weaving of fabrics
have experienced tremendous automation.
The uni-fill loom winder has combined the filling operation with
weaving the uni-fill loom attachment combines many operations, hence
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eliminating labours, transportation and material cost in addition to
improving both quality and quantity of the finished products.
CHAPTER-2
MODERN YARN PREPARATION
WINDING:
AUTOMATIC M/C:
The first successful automatic winder was the Barber Colman
spooler which still effectively processing substantial proportion of the yarn
wound in the world today. Some 50 years after its commercial intro. It is
sometime described as semi automatic winder as the broken end on the
unwinding ring tube is not relied but ejected for refeeding. Barber Colman
Spooler belongs to large group winder.
The term group winder has evolved as a result of the development of
winding m/cs with progressively smaller no of winding position per automatic
knotter. Several m/cs are now available with an automatic knotter and a bobbin
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change mechanism at every winding position. So the BC Spooler with up to 306
positions to one travelling knotter clearly warrants inclusions with a large
category.
Developments in small group winding m/cs have continued on well
defined line throughout the last 20years. Three features appeared to have received
most attention in design, the configuration and the no of wind position to be
serviced by one knotter, the degree of automation or the transfer of skill from
separator to m/c and equipment flexibility. 3 main configurations have emerged
there are rectilinear and stationery wind position and travelling knotter and 10-12
wind position/knotter of which the schlafhorst autoconer is typical circular with
travelling spindle positions and stationery knotter and similar wind position to
knotter ratio, of which the schweiter call is typical and one knotter per spindle
rectilinear of which the savio RAS, the morata no 7-11mach coner and the
leesona uniconer are typical.
AUTOCONER:
Automatic wind m/c has been adopted mainly for 3,reasons:
1. Reliability2. Economic viability3.
Excellent uneinding properties of quality package.
Quality and economy are the standard feature assumes package
quality due to:
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Electronic monitoring of the running yarn
Sensitive tension device
Electronically tested yarn joints
Precise build up of package
High production & low Wind cost due to:
(i)Electronically controlled splicing or knotting
(ii)Automatic package doffer
(iii)Favorable material flow due to inline construction
Amendable and easily supervised working area simple maintenance
& operation.
Due to the facility of having various types of supply creel for
processing and bobbin spinning flange bobbins full package or the package
remains versality of the autoconer is unsurprised.
Autoconer package quality package
Electronic tested yarn joints either spliced or knots Even package density
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Excellent unwind properties due to adjustable displacement of yarn layersand antique patterning
Constant package diameter Constant yarn length Measured transfer tail
Flexibility:-
The textile mill can specify for its autoconer either an automatic
splicer, fishermens knotter or weavers knotter, depend on yarn and nature
of process. As the autoconer splicer is suitable for all yarns it is now
standard feature of m/c.
THE AUTOCONER PACKAGE DOFFER:
ASSURED HIGH PRODUCTION:
The automatic package doffer ensures constant high production. As
full package do not have to wait for manual doffing. Bobbin creeling is the most
frequent task of the operative, waiting package lead directly to production lossess.
The automatic doffer relieves the operative of this task moreover it contributes to
the achievement of a more human working environment. Correctly wound on
starting layers are essential for achieving a complete run off the yarn from the
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package in subsequent processing. Provision of a transfer tail with adjustable
length by the package doffer cost neither time nor money. Producing a transfer
tail manually requires 6 min of time. And a package runs time of 50 minutes. The
increase in production is about 6% when the packages are doffed automatically.
KNOT PROBLEMS:
The thickness of the fishermans knot is 3-4 times and that of the
weavers knot 2-3 times, more than the yarn itself. The bulkiness of knot and tails
are the friction point during withdrawal of yarn over the end of the package yarn
layers may be dragged along.
To overcome all the difficulties , spliced join has been carried out ,
the advantage of spliced joint are adequate strength and diameter is nearly equal
to yarn with practically not thickening.
SPLICING METHODS
Two different splicing systems which operate with air and refinement have
succeeded in automatic winding up to now. The fibers in the yarn are
intermingled by air and coupled together in such a way that great many yarns
value of 80-100% of the basic yarn strengths are achieved.
On the automatic splicer the ends to be joined are presented to the splicing
chamber by the guide elements after closing the cover of splicing chamber and
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positioning the feeder for sufficient over lap , the actual splicing procedure start
with the actuation of the cutters. Almost synchronously with the cutting of the
end, the compressed air impulse is released by a magnetic value. This
electronically controlled compressed air blats initiates three operations in
sequence.
WARPING
The objective of all wrapping system, beam , sectional , tricot ,
etc are to be present continuous length of yarn to the succeeding process with all
the ends continuously present with the integrity and elasticity of the yarn as
wound fully preserved, this is a deceptively simple concept , the creel package
changed dimensionally as the process continues , the beam increase in diameter
and provision must be made for constant yarn speed either by contact drum or
variable spindle speed .
It is also necessary to adjust the packing density of the beam for
different applications .the warping machine has evolved as a highly sophisticated
machine . The creel design the down time associated with creel changes and
there are several stages in automation between a simple and single creel and so
called automatic creel which reduces creel change time . to absolute minimum
and permits over all beam wrapping efficiencies of over 50 %
THE WRAPPING CREEL
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The creel is no longer merely a convince method of holding the yarn
packages in position for wrapping but it an integral part of the machine, no single
type of creel is capable of giving high beam efficiencies of all yarn material and
linear densities, set lengths and final applications, there are for general purpose
types of creel In common, use truck, continuous, magazine, chain and automatic
with specialist creel for tricot, and sizing machine service continues chain creel.
This principle was first successfully applied by the Barber Colman
Co. Over fifty year ago, but many designs, such as Beiger GCA creel, has
adopted this basic design feature. The two wings of an acute angled creel are each
served by endless chin which moves the column of yarn package holders and
tension units round and endless track, transfer in the expanded packages from the
position outside the creel wings to the creeling position inside the creel and the
creel packages into the running position. Creel changes can be completed using
such a system in less than 15 minutes, and significant reduction of this creel
change time are unlikely without considerable mechanical complexity which the
relatively small potential savings are unlikely to justify. Fig 1 Shows the Beninger
creel GCA with the package frame mounted on an endless chain in each wing of
the creel. A Creel is being transferred from the creeling position to the running
position. The pegs shown as empty will normally carry cone residue from the
running position. Into the creeling position where they are replaced by full
packages for the next creel. Fig.2shows the GCF creel with Beninger ZDA
beamer.
AUTOMATIC CREEL:
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The Schlafhorst automatic creel Z25 is one of the most highly developed
creels currently available. It is essentially a truck creel with automatic chain
loading and with two features to reduce creel change time. The first is yarn
threading. The creeler threads. The yarn from the package simultaneously.
Through tension device and break detector and collects all the ends from
one tension column and twists them together before locating them in a holder on
the threading truck. As the truck is pushed forward it automatically threads and
separates the ends according to creel tiers and column.
The knotting carriage work is conjunction with creel Z25 has the shortest
creel change time of any available system. The carriage stands at the rear of the
creel during beaming, and is released when running yarn packages are almost
expended. As the carriage moves along the creel every end is cut between
package and tension devises the live end being secure in the clamp. When the
knotter carriage reaches the front of the creel, the operative operates the chain
conveyor and remove the creel truck from the creel. The creel trucks are designed
with special pegs with clamp at their extremities so that when each cone is is
loaded the ends is located in the clamp. The knotter carriage has the separate
knotter head for each tier on each side of the creel. When the full creels trucks are
correctly assembled by the conveyor chain, the knotter carriage ties one column
each side simultaneously. This takes 5 seconds, with seconds traverse time to the
next column thus 576 and creel with 48 column per side of 6 tiers will take 5-6
minutes to complete the knotting all the ends.
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Chapter No. 3
AUTOMATION IN WARP SIZING
OBJECTS OF SIZING
To improvewearability of the warp and to overcome inherenet deficiencies
of the yarn to with stand the stresses and strains of weaving. This can be attained
by improving primarily the abrasion resistance of the yarn. This is turn is
achieved with the formation of a film around the yarn along with some
penetration of sizing ingredients.
To improve abrasion resistance of the yarn.
To reduce hairiness of yarn.
To reduce generation of static charge for polyster blend yarn
To improve breaking strength of cellulosic yarn.
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Gamataxsnc of Itlay showed a sizing machine which as and automatic
control on speed/ tension, sqeezing, humidity and temperature, so that the values,
ones set, are maintained during-production cycles with remarkable guarantee of
precision and reliability sizing and squeezing boxes are separate to suit different
requirements.
Tsudakoma of Japan exhibited spun sizing machine (HS-2011) which has
many optional devices to suit her users requirements.
The machinery two-size boxes and the touch-free vertical yarn sheet
pullout system. The letter system reduces full and yarn breakage. It pneumatic
band brake, which ensures optimum yarn tension control for irregular diameters
of back-beams.
The sequence of he sizing process and the objectives of automation.
Figure shows the functions of warp sizing. There are basically five
processing areas involced in the production of a sized warp namely.
Size preparation including storage and supply to the machine, in which
chemical or natural products are made up into aquarius liquor and prepared for
the sizing machine.
Running-off the yarn from the section beams.
Sizing of the warp yarns ile application of the size liquor to the yarn
Drying of the yarn.
Winding the warp onto the warp beam.
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In sizing preparation, problems of size quality & process control are the
primary reasons why certain functions in the process are assigned to control
systems. In unwinding from in the sections beams the aim is to improve warp
quality by reducing end break frequency and also the increase, sizing machine
output by high unwinding speeds. In the wet zone,, the prime considerations in
automation are uniform optimum size application and economy of size usage. In
dryer design, greatest importance is attached to maximum throughout, energy
sawing, heat recovery and economy development in beaming machines on the
others hand involve improvement of warp beam quality combined with a
significance reduction in the operatives work land.
Manual duties can be carried out automatically by suitable mechanism as
explained below:
With some degree of standardisation in size agents, feed stock supply can
be automated by silicons and metering devices. The operative then only has to
preselect addition of size in according with a prescribed recipe and set the
matering system.
One important function in size preparation is meeting the quality
specification, as incorrectly made up size liquor can create problems in weaving.
The risk can be overcome by using boiling up system incorporating process
control. The boiling up process then follows a programmed sequence combined
with continuos measurement of velocity temperature and time. As soon as the
present values are reached and the size thus attains the intended quality, the
formation is realeased for transfer into the reservoir.
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The size is stored in reservoirs which should be situated in the vicinity of
the sizing machine and away from size kettle. The transfer system allows
monitoring of the reservoir contents from the size kitchen by remote display and
automatic filling immediately as need arise. The operative can thus monitor
requirements and replenishment of the sizing machine centrally from the size
ketches.
Transfer of size from the reservoir to the size box can be automatically
controlled in accordance with size usage in conjunction with a measuring and
matering system without the need for operative involvement.
A combination of all four of the above solutions ensures constant size
quality, resolves loading and transfer problems and provides maximum
convenience to the operative. The operative is only left with monitoring duties
which take up relatively little time.
SIZE INGREDIENTS:
A warp yarn should be strong, elastic, extensible and smooth. The
ingredients used in sizing are usually starches and gums and fatty or oily
substances. The two type of ingredients tend to have apposing effects on the yarn
and a compromise has to be made to yield the lowest end-breakage rate. Other
ingredients are commonly added to the size, including anticeptics, antimidew
agents, etc.
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Typical ingredients for water based liquors are shown in table-1 ingredients
for water based sizes.
Adhesive Lubricants Additives
Potato starch Mineral waxes Salicyclicacidf
Starch from cereals
(corn, wheat, rice
etc.)
Vegetable waxes
animal fats
Zinc chloride
phenol
Carboxy methyl
cellulose (CMC)
Mineral oils Emlusifiers
Polyvinglealconol
(PVA)
Vegetable oil
Polyvingle
chloride
It is possible that non-aqueous liquors will be used increasingly in the
future, but there is as yet little experience in this area.
Consequently, only a queous solutions are considered in the text. [typical recipes
are given in table-2]
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The adhesive usually in granule form is mixed with water and heated to
form a paste which ultimately becomes a viscous fluid. Starch is a complex
carbohydrate which combines with water, this causes the materials to swell &
change character. The viscosity of the boiled starch is controlled to a great extent
by the amounts to which the surface of the granule is dissolved. This in turn is
affected by the recipe, the degree of mechanical mixing, the temperature and time
of boiling.
[typical viscosity curves are shown in fig-3]
It will be seen that under certain conditions prolonged boiling will cause a
decline in the viscosity. Similar effects can be obtained by over-vigorous
mechanical working. In both cases, this is caused by breakage of the fairly weak
hydrogen bonds formed during the gelatinizing phase.
Although viscosity is important, there are other factors to be considered in
relations to feeding, if for instance, the size particles are affected by heat alone
(e.g.melting of the waxes), the material might clump together and not feed
properly. Similarly, in a wet feed system, trouble might be caused by premature
gelatiniziation of the material before it reaches the place where it is boiled.
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Lubricants, soaps, and waxes, are commonly used, the letter acting as
softeners. Without such softeners, the yarns would not be sufficiently extensive
further more, the size would crack and particles would drop away from the yarn;
this in turn; would create local stress concentrations and encourage end breaks.
The most important factors in choosing size ingredients
are:
a) The recipe should be that which givesfewest and end-breaks inweaving.
b) The recipe should be that which givesthe least amount of exfoliations(dusting off)
c) The recipe should be that which permit easy size removal in a lateroperation.
d) The recipe should be that which gives good fabric characteristics,e) The recipe should be comfortable with the machinery.f) The recipe should not cause any heald hazard.g) It should not cause any degree of textile material.h) Cost of sizing plus cost of weaving and finishing should be
minimum.
FACTOR WHICH AFFECT PROPERTIES OF SIZED
YARN
1. The percentage of lubricant to adhesive material.
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2. The amount of size put on yarn.3. Technique of sizing, such as yarn speed temperature of dying, tension etc.
The ingredient and techniques must be chosen to full-fill the requirement
metntioned earlier.
Warp Sizing Machine:
1. Cylinder drying.a) Two cylinder type
b) Multi-cylinder type
2. Hot air drying3. Combined system.
Machines may be further classified according to method of yarn
supply as indicated in figure. A sizing machine contain a number of
components sections.
The beam creel is a frame which carries some 8 to10 warper beam
which may be arranged in various ways. The arrangement shown in
figure can give equal tension in all sheet but it requires most space of
three alternatives the arrangement shown in figure reduce the space
required but it is at the expenses of tension uniformity. The third
alternative is a compromise. Negative let-off is normally used
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because of its simplicity but occasionally the beams are directly
driven and control to
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Chapter 4
SHUTTLE LESS WEAVING MACHINE
A) AS SULZAR WEAVING MACHINE
INTRODUCTION
The idea of gripper type weaving American inventor Mr. Salisberry in
1901. Latest swizer machine are consider best all modern weaving machines due
to their excellent technical and commercial performance. They can produce
various type of weaves using a very wide range of natural and synthetic yarn.
General Description
Shorter run more varied production and need for increase productivity have
late to situation in weaving where by setting up a weaving loom. And a particular
executing style changes quickly and efficiently have become of paramount
importance. Sulzer projectile weaving see the need to approach the problematic
nature of style changes has been essentially one of logistic and judicious
calculations. In order to organize man power expenditure , machine down time,
material flow and order processing for optimum economic efficiency.
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The quick style change ability of sulzer projectile weaving machine is
helping cut down time needed for style changes and at the same time is helping
increase productivity time. Additionaly it create potential to protect extra order
and generate increased profit ability.
In this m/c the weft yarn introduced into shed by means of projectile the
high performance low number of thread break short time required for warp and
weft changes mimimum setting work low wear and high reliability are the reason
for up the particular good relationship between the cloth output and labor input on
sulzer projectile weaving machine.
All the above advantages which positively influences the performance ratio
of the machine. Thus this several function have made sulzer projectile weaving
more and more profitable over the automatic and conventional looms.
PREPARATION FOR SHUTTLE LESS WEAVING MACHINE
Shuttle less loom require a high standard or yarn preparations.
This requirement is vital if highly expensive shuttleless looms are to be
run at a higher efficiency and with a reason allocation.
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WARP PREPARATION
Warp preparation of standard comparable with those acceptable for
automatic looms are used there will be less warp breakage per pound of yarn than
when same yarn is woven in automatic looms preparation changes have been
found for improvement associated with the change of weaving principle.
The remarks apply to carded yarns, medium count combed yarns are found
to present less difficulty than yarn is count range 12s to 20s whichis emerging as
most economic field of application for this type of weaving machine.
The object of all warping systems beam, sectional or other specialist type,
is to present a continuous length of yarn to succeeding process with all the ends
continuously present and with integrity and elasticity of yarn as would fully be
preserved.
WEFT PREPARATION
Weft insertion rate is high and unwinding is intermittent on projectile
weaving machine. So it is essential to have anti patterning device to prevent the
slough off the fabric.
On the projectile weaving machine the weft is unwounded from on
stationary packages creeled on the machine frame. Thsu no weft reserve is carried
along the shed as in shuttle and multiphase weaving. Due to this large size yarn
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packages, considerably large then the main advantages of projectile weft insertion
system because it considerably reduces the amount of labor connected with the
weft supply to the weaving machine.
PRINCIPLE OF SULZER PROJECTILE WEAVING MACHINE
In common with all high performance shuttle less weaving machine the
Sulzer differs from a conventional automatic loom in two respects, viz. the
method of weft insertion into shed and method of moving reed including
projectile track other motions including shedding. Take-up and let-off are simply
variants of known mechanism. This chapter contributes to information on
working principles of Sulzer weaving.
The basic mechanical principles of Sulzer projectile weaving machine are
to be considered as follows:
1. Shedding2. Beat-up mechanism3. Take-up and let-off mechanism4. Weaving with than one color in weft5. Selvedge formation.
Apart from this principles other mechanical principles are also include in this.
SHEDDING:
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in Sulzer projectile weaving machine, the shed can be produced by means of
tappet, dobby and jacquard. These units are precision built to meet high speed
requirements of weaving machines. The depth of shed produced. On produced on
Sulzer loom is about 2-5 inches or 6.35cm where as this depth of shed in much
larger in conventional and automatic bobbin changing looms, hence warp threads
are subjected to less straing in Sulzer weaving machine. But warp breakages are
high owing too much greater than speed of loom.
PICKING SYSTEM:
In Sulzer projectile weaving machine. Picking is done with torsion bar,
several gripper projectiles are employed for the sulzer shuttleless weaving
machine. They are return to the picking side by conveyer fitted below the warp
ends. The gripper carries the pick of weft through the shed using shear strain
energy, which is stored in the torsion bar. Shear strain energy it derived by
twisting torsion bar to a predetermined extent and triggering off to provide themeans of propulsion. This principle has several considerable advantages. As the
energy available for picking depends only on the angular displacement of free end
for a particular design of torsion bar the strength of picks is completely
independent of the speed of the machine. Secondary the energy can be used to
attain very high velocity, as the mass being projected is very small.velocities
approximately twice as great as those commonly used for shuttles i.e. 80 feet/sec.
as the gripper si returned to the picking side by a slow moving conveyer operating
between the receiving box and the picking unit and fitted below the shed, it can
be lifted accurately into the picking position so that shed picking always
commences from a previous pick. This means that a constant picking force is
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consistently applied to the gripper to the gripper. The gripper projection energy is
about 1/3 to of that normal experienced in conventional shuttles.
TORSION BAR PICKING MECHANISM
The picking arrangement in the sulzer shuttle less weaving machine may as
seen in fig. the drawing illustrates the torsion bar picking system of this loom.
The torsion bar (A) has its splined end (B) rigidly constrained in and
adjusting the twisting angle and hence the gripper projection velocity. The other
end of the torsion bar is splined into the picking arm (C), which carries the
picking shoe (D) at its upper extremity. The gripper (E) is shown in the shuttle
lifter with the gripper spring opener (F). the conveyer is not seen in the fig. but it
is placed under the warp shed at the back centre picking position.
The bevel wheel drive (G) rotates the picking cam shaft (H) which carries
the picking tappet (T). the pivoted lever (S) is rigidly connected to the torsion bar
and through a short linkage to the toggle plate (R). theaction of the cam is for the
small bowl (P) to bear against the toggle (Q), rotating anticlockwise about the
centre (O). thus withdrawing the picking shoe to its nearest position.
In this position the three centre of toggle arrangement are in line and thetorsion bar is twisted to its maximum. The nose of the picking cam then bears
against the bowl carried between the toggle plates and moves the central pivot, of
the toggle arrangement off the line of centres. Thus permits the whole of shear
strain energy to be transmitted instantaneously to the gripper. The gripper leaves
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the shoe after about inches of travel at 78 feet/sec2at a point about 0.6 from
the gripper rest position. The residual energy in the picking system is absorption
by the hydraulic system about 62.5% energy is dissipated in the picking unit
break. The body (m) are also shown in the figure. The gripper guided (k) are also
shown.
After the gripper has come to rest under the shuttle brake it is returned 1.6
inch to 1.8 inch in a fixed position in relation to the receiving side selvedge prior
to being ejected into the receiver the dropped on to the conveyer. The picking
track is locked between the picking and receiving units at the back centre and the
pick is delivered across the stationary sley race. The forces acting on the gripper,
other then gravity are picking force and yarn tension both acting along its major
axis. The guide blades are lubricated with oil, picked up from the gripper. As a
result, the
B) AIR-JET LOOM
THE ELIMINATION OF the ubiquitous shuttle has for many years
exercised the minds of many who have come in contact with the weaving process.
The first recorded attempt at substitution of the shuttle by a jet of compressed air
appears to have been made by J.C. Brooks, a native of accrington, Lanchashire,
who emigrated to the U.S.A and was granted a patent in 1914. Fifteen years later,
in 1929, E.H. Ballou took out a patent for a method of air jet weft insertion which
differed from that of Brooks in providing, among other details. A suction which
differed from that of Brooks in providing, among other details, a suction nozzle in
addition to the blowing nozzle. Finally Mr. Max paabo, an Estonian by birth, who
went to sweeden as a refuge sometime around the end of the war, developed the
air jet loom known as MAXBO
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ESSENTIAL REQUIREMENTS:
An essential feature of air-jet picking is the provision of a device which
will serve, prior to or during weft insertion to measure off a length of weft
sufficient for the width of cloth being woven. With gripper shuttle and repier.
System such a device is unnecessary, the carrier on the former type of loom,
being checked at the end of its flight, while on rapier looms, the rapier with weft
attached, is moved positively a predetermined distance. With the air jet system,
however, the air, as it passes though the nozzle entrains the weft and drags it
through the warp shed. If unrestrained, the weft would be prepelled at a speeddependent on the drag-force acting upon it due to the friction between the jet and
the weft. This force acting upon it due to the friction between the jet and the weft.
This force is in turn, a function of nature and velocity of the air jet of the
characteristics and dimensions of the weft. In addition, the changing dimension of
the weft package tend to cause disturbance of the conditions behind the nozzle.
Not only therefore is an efficient meter necessary to counteract these varying
factors, but without such a device uniformity of weft thread length from pick
could not be guaranteed. It is also important that, the requisite length having been
measured. The weft should be released without restraint, so that on emerging
from the nozzle, the maximum velocity dependent on the drag-force developed
can be rapidly achieved.
The character of the issuing jet of air is of it will be evident that an ever-
present problem of pneumatic picking is air-stream control and that some method
of confining the stream is necessary. But, no matter how effective such a control
system may be, there are so many factors contributing to undulation of the weft
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that some form of straightening device is necessary, particularly at the receiving
and.
The following items may therefore be considered as essential requirements
for successful air-jet weft insertion:
i. A pre-measuring deviceii. A short quick air blast
iii. A nozzle preferably not attached to the sleyiv. Air-stream control andv. A suction device at the receiving end.
THE MAXBO LOOM:
The MAXBO air-jet loom does not differ in principle from a conventional
loom except for the method of weft insertion. Elimination of the shuttle has
resulted in several modifications in the traditional design of the loom. Thus, it isno longer necessary to arrange for the closed shed-line to be in an approximately
horizontal position, the warp-stop motion can be modified, shedding dwell can be
dispensed with and other changes made in the general design. That advantage has
been taken of these possibilities in the design of the maxboloom will be evident
from fig. which shows schematically the passage of the warp. The loom consists
of a simple cast iron framing with a fixed flange warp beam located at the back
and occupying about 24 sq.ft. of floor space. The warp sheet passes vertically
upward
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to the intermediate roller and over a tension roller which is approximately 5ft.
above floor level. The yarn is then passed over the back and front guide rollers,
with the warp stop motion situated between the two. From the front roller the
warp descends at an angle of 150
to the vertical (increased in later to almost 450)
is
drawn through the healds. The heald frame ends being mounted in slides, which
make and angle of 150 with horizontal. The reed immediately below the healds
has its metal baulks in the top and bottom reed cases fastened to the sley by set
screen.
SCHEDDING:
Positive shedding can give approximately simple haromonic
motion to the healds shaft without dwell at speed of 310 ppm. The time
for sheet crossing is to facility of nozzle in the event of weft break.
The picking machenism consist of
1. weft measuring device
2. blowing nozzle
PICKING SEQUENCE
The weft is drawn from stationary supply package mounted at floor level at
the LHS of the loom. Then passes underneath a nylon tension wheel over the
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surface of measuring drum and into the drum through a guide eye situated at the
centre of drum the projecting pin on the surface of measuring drum is withdrawn
by a cam action at the same time.
(C) WATER JET LOOM
The first loom to make a use of water jet for insertion of weft was
developed by Czechoslovak engineer vladimisvaty. When the loom was first
shown in western Europe at the Brussels. Textile mechinary exhibition 1955
largely regarded as a cureocity. The participants in an international symposium of
shuttle less weaving where able to visit in installation of more than 150 water jet
loom. It becomes clear that a development as taken place which could not be
ignored.
Technically this is an extremely interesting weaving machine which
deserve close and careful study. The purpose of these chapter is to study basicphysical principle underline hydraulic weft tension.
GENERAL DESCRIPTION
Apart from methods of its weft insertion the water jet loom does not differ
in principle from a conventional loom and a brief out line only of its mainmechanism will therefore the suffice the warp beam is of conventional size but is
mounted considerably higher than on conventional loom is can be seen in figure.
It is possible to rotate warp beam forward and backward by means of handwheel
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situated at front of loom. The warp passes over a single loaded roller. Which
takes place of back roller in a conventional loom.in additional advantages of these
slopping warp line is saving of floor space.
1)SHEDDINGShedding is carried out by negative dobby. Can sure crane motion which in
most of the looms are for B shaft. The selvedge is formed by a conventional type
of leno motion. The heal shaft moves at right angle to the warp line. The picking
operation is carried in fully open sheet.
2)PRINCIPLE OF WEFT INSERTION
The weft supply in the form of cone of bobbin is situated at the LHS of
loom. The four main stagesof weft insertionis shown in figure.
THE WEFT SUPPLY SYSTEM
It is illustrated in figure has four main portion.
1) to apply tension on the weft before it is wound on to measuring device.
2) To measure required weft reserve on each pick.3) To apply tension to the weft during picking.
4) To pull the protruding end of weft back into the nozzle after the operation of
cutter.
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OPERATION OF WEFT SUPPLY SYSTEM
The sequence of operation by which the weft supply system functions can
be explained with reference to the figure.
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CHAPTER 5
APPLICATION OF COMPUTER TEXTILES
LOOM MONITORING
The heart of mill is weaving shade where much of the advance
process control development has taken place by linking a computer to a
loom for monitoring purpose computer maintained direct and
continuous contact to via sensing device which a loom the computer
automatically polls each loom sensor one every minute and legs of on
to a magnetic disc records the on off condition. The warp stops, weft
stops and any other stop by mechanical reasons.
COLOUR MATCHING
For a mill man computer color matching is most important and
profitable area in textile industry.
Computer matching of color for virtually any type of substrate
and all kinds of fabric is a fast maturing science. The computer is
reducing color matching time from days and weeks to hours and
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minutes. But there is an also impressive pay out in more accurate
matchs better color quality, dye stuff cost saving and saving in dye in
inventory investment.
The principle involved in the color control system can be out line
in three stages.
1. Determination of di characteristics
2. Recipe formulation of computer
3. Recipe correction if necessary
COMPUTER IN TEXTILE DESIGNER
The increase variety of available fibers and textile manufacturing
method make it imperative for new methods of textiles designs to be
developed, both in order to achieve optimum solution to design
problem and because the traditional ground rules no longer apply in
new situation. Computer Added Design is the key to the new situation.
Furthermore it offers a chance of bringing a designing much close to
the production process which is important both in itself and as a means
of reducing significantly the tile leg between appreciation of need for a
new design and its appearance in the shops.
The designer can display the design on a grid with different ratio
of horizontal and vertical lines. They can also vary the number of warp
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yarn per inch to see the design good look if woven with different
degree of coarseness. They can even repeat the design with different
spacing between center or specify different lines of symmetry and thus
develop a full design from a small segment.
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CHAPTER 6
CONCLUSION
The modest step towards automation here altered the production sequence
in spinning mills it is also evident however that keeping up with its technical
evaluation and achievement. Automate isnt easy specially when the cost are
consider automation has only just started it will continue to gain ground both in
purely technical process and also specially in splitting the possibilities opened by
microprocessor.
The desirably of perusing the technical change has been recurrent them in
the textile industry for many decades.
The guiding force and we find seeing reliance on technology as a means of
copying todays problem and creating tomorrows opportunities.
Impelled by general progress technical advance and economic expansion.
Machine engineering has quickened its face of development and wideled its
scope.
Undoubtedly the shuttle less weaving machine now has the greatest
important in overall pictures with nearly all leading weaving producers engaged
in development new or existing shuttleless design.
Thanks to economic flexibility and ability to follow fashion sulzer machine
holds a dominating position in weaving.
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REFERENCE
1. Indian textile general 1996.
2. Weaving conversion of yarn to fabric.
3. International textile bulletin
4. Bitramono graph series on winding
5. Process control in winding
6. Autoconer system 283