Warping Machine-1

WARPING

The parallel winding of warp ends from many winding packages (cones or cheese) on to a common package (warp beam) is called warping.

OBJECTIVE OF WARPING:

1. To convert a predetermined number of single end packages, such as cones or cheese into a sheet of warp yarn of specified feed and length.

2. The individual ends in the warp are uniformly spaced across its full width.

IMPORTANCE OF WARPING

    1. Construction of warp yarn beam.

    2. Construction of parallel yarn sheet.

    3. Winding the predetermined length of yarn.

    4. Modifying the faults of yarn like thick and thin places, large knots etc.

    5. Accelerating the next process.

REQUIREMENT OF WARPING

1. The tension of all wound ends must be uniform and possibly constant during all the       time of withdrawal from supply package.

2. Warp yarn should not impair the physical and mechanical properties of yarn.

3. The tension should be moderate to allow the yarn complete retain its elastic                     property.

4. The production of warp yarn beam should be high.

CLASSIFICATION OF WARPING

1. Beam warping

2. Sectional warping

3. Ball warping

BEAM WARPING

1. Yarn is directly wound from cone onto the beam.

2. This process is suitable for single colour weaving.

3. The end product is called warp beam and must send to the sizing                                     department for further process.

TYPE OF BEAM WARPING

A). Direct driven or spindle driven:

In which yarn winding speed on to the beam increases as the diameter of the beam increases. Beam size is limited due to the increase in yarn winding tension.

B). Surface driven beam warping:

In which beam gets its motion while in contact with a drum, revolving at fixed r.p.m.  in this case yarn winding speed remains constant throughout the build of the beam.

SECTIONAL WARPING

A). Yarn is wound on firstly wound onto a drum and then wound onto the beam.

B). This process can be used for both single and multicolour weaving.

C). The end product is called weavers beam and can be directly installed onto                       the weaving loom.

BALL WARPING

A). Ball warping is an intermediate process for storing yarn for transport, dyeing or            reserve.

B). It does not produce a beam. 

C). The usual form is a cross wound cheese in which multiple ends are wound at the             same time in a ribbon which contains perhaps 50 or a 100 ends.

FLOW CHART OF WARPING

CREEL

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CONTROL SYSTEM

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REED

⇩

MEASURING ROLLER

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WINDING ON A ROLLER OR BEAM

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DIRECT WARPING or SECTIONAL WARPING

MAJOR COMPONENTS OF WARPING MACHINE

There are two main components of warping machine.

1). Creel:

      A structure for holding for supply packages in textile process.

2). Headstock:

      The major component of the warping machine that actually rotates and winds         the warp sheet on package.(i.e. wrapper’s beam)

FUNCTION OF COMPONENTS OF CREEL

1). Cone or cheese spindle of high speed and peg for sectional warping.

2). Thread guide: To pass through the yarn in the required way.

3). Tensioner: To keep the yarn always in a uniform tension.

4). Yarn cleaner: To remove various faults of yarn like slubs, neps etc.

5). Suction fan or blower: To remove the dirt and dust from the yarn.

6). Breakage indicator: To indicate breakage in package.

7). Stop device: To stop the machine when yarn will be broken.

FEATURES OF COMPONENTS OF HEAD STOCK

1). Adjustable or variable v reed or wraith: To control the width of the warp beam.

2). Measuring and making device: Measure the amount of warp yarn on the beam and marks the yarn.

3). Yarn speed controlling device: To control the speed of yarn.

4). Pneumatic pressure unit: To press the warp beam with the surface contact of driving drum:

5). Break assembly: It stop the machine after required length is wound on beam.

6). Driving drum: Beam is in contact and control with driving drum.

7). Stop motion: Used to stop the machine after required length is wound on beam.

8). Beam bracket: To support and hold the beam.

9). Lease rod: Used for separation of yarn individually.

CREEL:

Independently of the warping system, the threads are fed from bobbins placed on creel. the creels are simply metallic frames on which the feeding bobbins are fitted; they are equipped with yarn tension device, which in modern machines are provided with automatic control and centralized tension variation. The no of packages in a creel must be decided on the economic merit of any given situation with warper's bobbins. its capacity from 400 to 600 packages; while with the cones or cheeses the range is wider, that is 600-1000 packages. In deciding about creel size, weight of yarn on supply package, floor space available and number of beams required must all be considered.

TYPE OF CREEL

1. As per the shape:

      a). H shaped (Horizontal ) creel

H SHAPED( HORIZONTAL CREEL)

         

    b). V shaped creel

V SHAPED CREEL

S.  No.	V- Shaped creel	H- Shaped creel
1	Wings/arms are placed at certain angle.	Wings are parallel to each other.
2	Yarns do not touch.	Yarns may touch each other.
3	Suitable for high speed warping,	Suitable for slow speed warping

2. AS PER THE CONSTRUCTION:

         a). Truck or trolley type:

There are many variants of the truck creel system but the principle is to use  `'truck', or mobile package carrier units, each consisting of a number of columns and tiers on either side so that when inserted on the axis of the creel frame it becomes a part of the creel.

The side members carrying tension units in positions corresponding to the package on the mobile unit when correctly installed in the frame can be moved outwards to provide working space between the tension device and the expended packages prior to running them out. the trucks have varying numbers of columns and tiers, generally in the range 6x9 per side, depending on the package size to be used and the corresponding creel gauge, which generally varies from 200 to 300 mm.

TROLLEY TYPE CREEL

     

b). Continuous chain creel

The two wings of an acute angled creel are each served y an endless chain, which moves the columns of yarn packages holders, and tension units round an endless track, transferring the expended packages from the running position outside the creel wings to the creeling position inside the creel and the creeled packages into the running position.

creel change inside cycle can be completed using such a system in less then; 15 minutes. A 'creel' is being transferred from the creeling position to the running position. The pegs shown as empty will normally carry cone residues from the running position to the creeling position where they are replaced by full packages for the next creel. This type of creel used in benninger direct beam warping machines.

CONTINUOUS CHAIN CREEL

  c). Magazine creel:
Each position is duplicated with one packages in the running position and the other in the reserve position tied nose to tail.
The package holders swivel to enable the empty cones to be removed and new cones tied to in nose to tail to the running package whilst the machine is in operation.
Drawback- It is normally a very long creel which greatly increased machine stoppages time per break. it is desired to avoid the knots in the body of the warp and thus preferable to rewind the yarn left on cones owing to the uneven yarn count from one cone to another.

MAGAZINE CREEL

  D). SWIVEL FRAME CREEL

This type of creel was designed as a variation of the mobile creel to enable the creeling up of bobbins which, owing to their heavy weight (5 to 25 kg), cannot be pinned on trolleys. each bobbin holder is double sided; the threads are unwound from one side, while a new series of bobbins is creeled up on the other side.

SWIVEL FRAME CREEL