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Wing Cam
There are several different independent traverse systems, but the simplicity
of the wing cam makes it a useful example to describe. As shown, the end, A,
of a yarn guide bar moves the yarn while the other, B, is made to move
around the periphery of the cam, traveling one circuit of the periphery per
revolution of the camshaft. As B makes one circuit of the cam, A
reciprocates, moving the yarn through a return traverse (i.e., double
traverse) along the length of the bobbin. The reciprocating yarn guide limits
the winding speed because of the inertia on reversals. A very high rate of
traverse is impeded by the mechanics of the guide system, since forces of 16
to 64 times the weight of the yarn guide can be present during the
reciprocating action. The reciprocating guide can be replaced by a spirally
grooved traverse roller, which moves the yarn along the traverse length. In
this case, only the yarn undergoes reversal as it is held in the traversing
groove of the rotating roller, and speeds in excess of 1500 m/min can be
achieved. A further advantage of the grooved traverse roller is that, as a
result of tension, the yarn being wound enters the groove without the need
for threading up as is required with the independent traverse system.
Grooved Drum
With the grooved drum system, the surface speed of the drum, and the
traverse speed are kept constant. A continuous helical groove (i.e.,
interconnected clockwise and counter clockwise helical grooves) around the
drum circumference guides the yarn along the traverse length as the yarn is
wound onto the bobbin. A continuous helix has points of crossover of the
clockwise and counter clockwise helices. To retain the yarn in the correct
groove during its traverse, particularly at the intersections, one groove is
made deeper than the other, and the shallower groove is slightly angled.
2.)precision winders
They are also known as Spindle driven Winders. the Principle of precision
winder is as shown in figure.
With precision winders, the package is mounted onto a drive spindle, and a
reciprocating yarn guide, driven by a cylindrical cam coupled to the spindle
drive, is used to move the yarn along the traverse length. The reciprocating
yarn guide limits the winding speed because of the inertia on reversals.
The term precision refers to the control of positioning each layer of yarn as it
is wound onto the bobbin. There is a precise ratio of spindle to traverse
speed. Therefore, as the package diameter increases, the wind and TR are
kept constant.
a) Cone taper
The steeper the cone taper the greater the freedom of yarn withdrawal and
therefore a reduced tendencies to peak tension. But as the cone angle is
increased there is a strong possibility of slough off at high unwinding speed
So proper selection of taper must be made for the end use.
e.g. In knitting the winding speed is slow .and uniform and yarn should be
capable of being unwound at low tension. Hence a steeper cone angle may
be suitable.
For selecting best taper, cones with different taper should be wound and
should be unwound under similar conditions as it s end use the taper that
gives minimum stops due to slough off and peak tension is the best paper for
that end use.
B: Package length and diameter:-
For optimum continuity of yarn supply in the subsequent process to winder
one would think to go for longer package with grater diameter. so tests are
conducted in which packages are wound with different package length and
diameter combinations. they are then unwound under similar conditions of
the subsequent process and the unwinding characteristics is studied. The
package length and diameter range(empty PKG to full PKG) that gives the
best unwinding characteristics such as uniform unwinding tension,minimum
tension picks, slough off should be selected.
1package density
2:package stability and characteristics such as tension peaks,slough off etc.
the no of winds per single traverse for a given package length decides angle
of wind with law wind the angle is more and visa versa. Low wind means
less coils in each layer.
In winding a dye package few wind is used to get openness required for
easier and free flow of dye liquid.
For knitting purpose relatively low wind should be used. low wind gives
higher coil angle and the degree of yarn across face of package is minimized
so yarn unwinding at low tension becomes possible.
Knotting
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Among the various types of knot, the weavers knot and the fishermans
knot, illustrated in Figure 1, are the two types that may be used. The latter is
suitable for most yarns. The weavers knot is more appropriate for short-
staple yarns, as it is a smaller knot, but it slips more easily when
under tension.
The advantage of a knot is that its strength will be several times that of the
yarn strength so, if properly tied, it gives reliability to the piecing. However,
the knot has many disadvantages for the end user of the yarn and may be
seen as one fault replacing a worst fault. Its main drawback is size, i.e., its
thickness and tails. The weavers knot is two to three times the yarn
thickness; the fishermans knot is three to four times as large. Often,
therefore, it may be preferable to accept a thick place in the yarn as a
compromise on the final fabric quality, even if it is of comparable thickness,
since no tail ends will be present and, as it is less firm than the knot, it could
be less visible in the fabric. In processes subsequent to winding, knots can be
problematic. When passing at high speed through a tension device (e.g., a
disc tensioner), a knot can give rise to a sudden high peak tension, causing a
yarn break. Although smaller and hence preferable for finer yarns, the
weavers knot is susceptible to untying when tensioned. In weaving, then,
the alternating stresses on the warp yarn can cause slipped knots, especially
with plied yarns. With densely woven fabrics, knots and tails can rub
neighboring warp ends, hampering shedding and causing yarn breaks. The
size of the knot can disturb weft insertion on air-jet looms, leading to fabric
faults, and, in knitting, difficulty in passing a knot through needles can cause
holes in the fabric because of dropped stitches or needle breaks.
The development of the splice has made a major reduction in the size of
pieced ends and has therefore eliminated many of the processing difficulties
mentioned above and greatly improved fabric quality. Consequently, splicing
is seen as the industry standard and, although not all spun yarns can be
spliced, the great majority of winding machines are fitted with automatic
splicers.
SIZING
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The primary purpose of sizing is to produce warp yarns that will weave
satisfactorily without suffering any consequential damage due
to abrasion with the moving parts of the loom. The other objective, though
not very common in modern practice, is to impart special properties to the
fabric, such as weight, feel, softness, and handle. However, the
aforementioned primary objective is of paramount technical significance and
is discussed in detail herein. During the process of weaving, warp yarns are
subjected to considerable
tension together with an abrasive action. A warp yarn, during its passage
from the weavers beam to the fell of the cloth, is subjected to intensive
abrasion against the whip roll, drop wires, heddle eyes, adjacent heddles,
reed wires, and the picking element, as shown in Fig.1 . The intensity of the
abrasive action is especially high for heavy sett fabrics. The warp yarns may
break during the process of weaving due to the complex mechanical actions
consisting of cyclic extension, abrasion, and bending. To prevent warp yarns
from excessive breakage under such weaving conditions, the threads are
sized to impart better abrasion resistance and to improve yarn strength. The
purpose of sizing is to increase the strength and abrasion resistance of the
yarn by encapsulating the yarn with a smooth but tough size film.
The coating of the size film around the yarn improves the abrasion resistance
and protects the weak places in the yarns from the rigorous actions of the
moving loom parts.
Fig 1:- Parts of the loom and major abrasion points.
2. To increase the strength of the spun warp yarn without affecting its
extensibility. This is achieved by allowing the penetration of the size into the
yarn. The size in the yarn matrix will tend to bind all the fibers together, as
shown in Fig. 4.18. The increase in strength due to sizing is normally
expected to be about 10 to 15% with respect to the strength of the unsized
yarn. Excessive penetration of the size liquid into the core of the yarn is not
desirable because it affects the flexibility of the yarn.
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Most of the common packages on which the yarns are wound can be divided
in to two groups.
(1)Parellal wound packages
Cone taper
(semivertical
angle) End uses
330 General purposes
42 Wet processing (e.g., dyeing)
55 Weft knitting: at final diameter taper may increase to 10
91 Weft knitting: at final diameter taper may be 14 to 18
Comparison of cross and parallel wound package
Sr
no. Cross wound Package Parallel wound package
1 Self supporting Package Flanges are required to support the yarn
2 Overhead Unwinding Side-end Unwinding
Package is Stationary during
3 unwinding Package rotates during Unwinding
The yarn doesnot stop unwinding as
The yarn stops immideatly the the package continues to rotating due
4 unwinding Stops to inertia
Suitable for High speed
5 unwinding Not suitable for high speed unwinding
yarn is laid at an angle to each
6 other The yarn is laid parallel to one another
7 eg., Warpers Bobbin Eg, Cone, Cheese & Spool
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4 Votes
Windings : In the process, the yarn from a number of ring frame bobbins or
hanks is put in a long continuous length on to a bigger packages such as
Wrapers bobbin, cone or cheese. During this process, the objectionable
faults are removed from yarn. For the use of dyed yarn, ring frame bobbins
may be taken to reeling process to obtain hanks. These hanks are dyed 2 &
then sent to winding. The yarn is dyed in cone/cheese form also. Thus,
winding packages ( wrapers bobbin, corn or cheese ) are taken to next
process of wraping i.e. Direct Wraping or Sectional Wraping.
Wraping :
( DIRECT WRAPING OR BEAM WRAPING )
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To achieve this quality of warp and weft should be good. Poor quality of
warp and weft causes frequent breakages. So loom has to be stopped
frequently which badly affects productivity. Poor quality of warp and weft can
lead to production of fabric with inferior quality. SO FOR THE BEST RESULT
IN WEAVING , THE BEST QUALITY OF WARP AND WEFT IS THE MUST.
WARP:-
1. To produce fabric of uniform quality, the tension of warp threads across
the width should be same i.e if there are 500 ends, tension of all of them
should be same. Similarly the tension of warp sheet as it is unwound from
weavers beam should also be same.
2. The end should be free from any place that can cause breakage
during weaving or can give bad appearance to the cloth. E.g.
(a)A weak place can cause breakage during weaving.
(b)A thick place can cause breakage and give bad appearance.
(c)A thin place can cause bad appearance. Particularly thinner place
continuing over a long distance, say 1 or 2m will give bad appearance, as in
that portion a fine crack like appearance may be seen.
3. During weaving warp threads are kept under considerable tension and are
subjected to the abrasive action of the healds, other moving parts and also
of the neighbouring threads of warp. The warp threads should be strong
enough to resist these actions without breaking.
WEFT
(a) For shuttle looms weft is wound on pirns. The pirn fits in to a shuttle. The
shuttle is projected into the shed. So supply of weft is in the form of pirn
wound with weft.
(b) For shuttle looms fitted with UNFIL loom winder, pirn winding is done by
a special mechanism on loom itself. So supply of weft is in form of cones or
cheese.
(c) For looms in which insertion of weft is not by shuttle carrying pirn are
called shuttle-less looms. In these looms (generally) weft insertion takes
place from one side of the loom. The weft is withdrawn from the packages
such as cones or cheeses and it is inserted into the shed by some carrier
(gripper, rapier or air jet or water jet).
As Stated above pirn or cone or cheese can be the package of weft supply.
Here also the unwinding tension should be as uniform as possible to produce
the fabric of uniform quality and also any factor, such as slough off,
entanglement etc., that can cause breakage of weft, should be taken care
off. The weft thread should be free from weak places, thick places, thin
places, etc., that can cause breakage or give bad appearance to the fabric
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2 Votes
To obtain satisfactory weaving performance, it is essential to have not only a
correct yarnpreparation, but also an efficient organization which permits to
have warps available at the right moment, thus avoiding any dead time with
style or beam change. All these prerequisites aim at ensuring to the weaving
mills a sufficient flexibility and at permitting them to cope promptly with a
variable market demand.
Currently several weaving mills have installed weaving machines which
enable to perform the quick style change (QSC), leading to a considerable
reduction of the waiting time of the machine.
The following chart presents the possible alternatives for the preparation of
the weaving machine:
Changing style means producing a new fabric style, weavers beam changing
means going on weaving the same fabric style just replacing the empty
beam with a full beam of same type. Drawing-in consists of threading the
warp yarns through the drop wires, the healds and the reed (fig.1).
Depending on the styles of the produced fabrics and on the companys size,
this operation can be carried out manually, by drawing-in female workers
operating in pairs (a time consuming activity which requires also skill and
care), or by using automatic drawing-in machines.
Fig. 1 Drawing-in
Fig. 2 shows one of the most established heald drawing-in machines. The
drawing-in begins by placing the weavers beam, the harness and the row of
healds on the proper anchor brackets, then the drawing-in program is typed
in on the computer and the machine is started. A sort of long needle picks up
in sequence the threads and inserts them with only one movement into the
drop wires, the healds and the reed dents, which are selected each time and
lined up to that purpose. The computer controls the different functions and
supervises them electronically, ensuring the exact execution of the operation
and interrupting it in case of defects. The machine can be used with the
usual types of healds, drop wires and reeds and can process a wide range of
yarn types and counts, from silk yarns to coarse glass fibre yarns. The
drawing-in speed can in optimum conditions exceed 6,000 threads/hour.
Fig. 4:- A harness and a reed with drawn-in threads ready to be moved to the
knotting station.
The piecing-up of the warp yarns (Fig. 5) permits to the weaving mills which
are in a position to use it (not many mills at the moment) to simplify and
speed up considerably the loom starting operations in case of warps which
were drawn-in or tied-up outside the weaving machine. The warp threads are
laid into a uniform layer by the brush roller of the piecing-up machine and
successively pieced-up between two plastic sheets respectively about 5 cm
and 140 cm wide, both covering the whole warp width.
The plastic sheet can be inserted into the weaving machine simply and
quickly, avoiding to group the threads together into bundles; the threads are
then pieced-up on the tying cloth of the take-up roller.
Fig. 5 Piecing-up
Taking out of the loom the prepared beam with the harness
Transport of the beam into the weaving preparation department
Fastening of the heald frames and of the reed on the proper frame
Knotting
Passing of the knots by proper drawing
Warp piecing-up
Temporary maintenance of the new warp with the harness
Transport of the new warp inclusive of harness with proper carriage
Loading of the weaving machine and start of the weaving process using
plastic sheet (fig.7)
Weaving
Fig. 6 A knotting machine in operation on a warp with colour sequence,
tensioned on the proper frame.
The automatic knotting machines can process a wide range of yarn types
and counts at highly reliable and rapid operating conditions (up to 600
knots/minute), with mechanical or electronic control on double knots and on
the sequence of warp patterns in case of multi-coloured warps. Fig. 6 shows
a knotting machine in operation on a warp with colour equence, tensioned
on the proper frame.
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Sample Warping
DECEMBER 14, 2011 TEXT-TEAM LEAVE A COMMENT
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