project abuzar final

7/30/2019 Project Abuzar Final

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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

project abuzar final

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