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Modern Developments in Warping

OBJECTIVES

•Primarily aims at preparing the weaver’s beam to be set up on the weaving machine.

•It collects the ends from the set of wound packages and transfer them in a sheet form onto the warper’s beam(which is subsequently converted into weaver’s beam) or in some cases directly onto the weaver’s beam.

Basic elements of a warping line

1. Creel

2. Headstock

3. Control systems

Creels

Creels

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Creels used in modern machines

Headstock

Drive:-

1. Sectional warping:- direct drive to the drum

2. Direct warping:- surface friction drive or direct drive to the beam spindle.

3. Direct /spindle drive is preferred than drum drive. Reasons:-

• It facilitates braking problems on end-breakage.• The drum drive depending upon friction for its effectiveness has

deleterious effect on the yarn(especially fine/continuous filament yarns ) • The tension difference between the ends is also greater with a drum

drive.

Headstock

Design of the beam:-

1. Direct Warping:- Simple flanged beam

2. Sectional warping:- Tapered beam

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Control Systems

•Tensioning unit

•Stop motions

•Warp storage system

•Measuring and levelling rollers

•Air conditioning devices

•Humidification systems

•Anti-static aids

•Waxing devices

•Automatic cutters and knotters

•Microprocessor controlled online monitoring systems ,etc

Types of warping

1. Beam warping

2. Sectional warping

3. Ball warping

4. Sample warping

5. Direct beaming

Beam warping

Ben-direct

Sectional Warping

Sectional Warping

Sectional Warping

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Sectional Warping

Sectional Warping

Modern Sectional Warping

Computer controlled warp patterning on sectional warping machine

OOM-Sectional warper

Nov-o-matic-Automatic sectional warper

Direct beaming

Process control in warping

The following are the process control parameters in a warping department:

1. Minimising End breaks.2. Quality of warping beam3. Control of productivity

Importance of Minimising end breaks:

The stoppage of the machine due to an end break is likely to deteriorate the quality of the beam due to three reasons:

1. The rubbing of the beam by the drum which stops abruptly. 2. Owing to the difficulty in finding the broken end, there is a possibility of incorrect mending. It may lead to lappers during sizing.3. There is some loss in the extensibility of broken end when the machine is stopped, it increases the probability of breakage in weaving and sizing.

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Process control in warping

The following points should be noted to improve the quality of warping beams:

1. Condition of beam flanges:

If the beam flanges are damaged, the unwinding of yarn near the flanges will not be satisfactory. This will cause difficulties in sizing and weaving.

2. Stop Motions and Breaks:

Proper stopping of the warping machine after an end break ensures that the broken end on the beam can be traced easily.

3. Condition of the driving drum:

On most warping machines the beam is driven by fricitonal contact with the driving drum. In order to get a package of the correct density, the pressure between the drum and the warper's beam has to be kept at fairly high level.

Process control in warping

4. Barrel Diameter of the Beam

Beams of small barrel diameter give rise to high unwinding tension at sizing, particularly when the beam is about to become empty.

5. Cuts in Accessories in the path of yarn

Drop pins of stop motion, guide rollers, reed denting etc. should bot have any grooves.

6. Creel Fans

Fluff accumulated on the machine, particularly at thread guides, causes tension variations in the yarn. This fluff can pass on to the beam.

Process control in warping

7. Length Measuring Motion

The length measuring motion should be accurate, otherwise estimation of beam count would be wrong and subsequently will give incorrect values of size percent which is commonly determined from the weights of yarns on the warper's and the size beams.

8. Density of the Beam

The beam should be firm, inadequate pressure between the beam and the drum causes soft beam. Adequate pressure should be maintained by making suitable mechanical adjustments.

Control of Productivity

The productivity at warping depends upon the machine efficiency and machine speeds. The speed is governed by the mechanical condition of the machine and its design. Machine efficiency depends on several factors, such as the breakage rate, the time taken to mend the machine stop, set length, length of yarn on supply package etc.

Process control in warping

Causes of Low efficiency or Low productivity1. Increase in End breakage rate

The machine efficiency at warping is highly sensitive to the end breakage rate

2. Improper utilisation of magazine creel

If the creel boy does not keep the magazine creel ready to be used by the time the package in the running creel are over, the efficiency will fall.

3. Reduction in Average Set-length

Lower set lengths reduce the machine efficiency at warping

4. Number of Tenters per Machine

The number of tenters per machine determine the time to mend an end break. This is because by the time the warper finds a broken end on the beam, the creel boy brings the other end of the broken yarn from the creel

5. Stops due to Machine Breakdown, shortage of cones etc.

If the stops due to machine breakdown, shortage of empty beams or cones/cheeses etc. are high, the actual efficiency of the machine will be lower than calculated.

Warping defects

1. Lappers

2. Bulges

3. Yarn cut at the butts of the warp beam/ slackness of extreme yarns

4. Conical winding on the beam

5. Slacks & irregular yarn tension

6. Coarse knots

7. Fluff, oily ends & yarn of different density

8. Different length of sections, high wastage rate

9. Overlapping of the sections/Excessive gap between the sections

10.Excessive or insufficient number of ends in the warp

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Maintenance

Maintenance Check points at Warping

Machine

1. Clean with compressed air at every creel change-per shift2. Clean with compressed air and cleaning waste- weekly

Package Alignment at the Creel

1. Look for incorrectly aligned packages, correct if the non-alignment is too severe- regularly2. completely guage the creel with the help of a gauge- half yearly

Tension Weights

In case of high speed warping machine, check tension weights at every count change- regularly

Maintenance

Tension Level

Check the tension levels with tension meter- Monthly

Stop Motion and Brake

1. Ensure that the machine stops within 1 1/2 revolutions fo the drum in case of high speed warping- regularly2. Check with condition of drop pins and replace those with cut marks- regularly.

Guide rollers

1. Check for concentricity- half yearly

Maintenance

Beams1. Check for the conditions of flanges and beam shafts, repair damaged beams- regularly

Creel Fans1. Check that creel fans oscillate properly and are not chocked with fluff- regularly.

Parts in yarn path

1. Check for cuts in parts of machine in yarns parts regularly.2. repair/replace the parts with cut marks- weekly

List of Machine manufacturers

1. Benninger

2. SMH

3. Jupiter

4. Schlaforts

5. West Point

6. Robatex

7. Prashant Gamatex

8. Karl Mayer

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References

•Weaving conversion of yarn to fabric by Peter Reeves Lord, Mansour H. Mohamed

•Modern preparation and weaving machinery-A.Ormerod

•Textile reference book for weaving by the Italian textile machinery industry

•A paper on computer controlled warp patterning on sectional warping machine by P.K Hari & BK Behera,Department of textile technology,IIT,New Delhi.

•Karl Mayer website

•Google.com

Thank YOU!