Warping 140522102148 Phpapp02
Warping 140522102148 Phpapp02
Warping 140522102148 Phpapp02
WARPING:
Warping:
The parallel winding of warp ends from many winding packages (cone
or cheese) on to a common package (warp beam) is called warping.
Types of warping:
1. Beam warping direct warping.
2. Patterns band or drum warping Sectioned warping,
(Indirect warping)
3.
Ball warping
TYPES OF WARPING
Direct Warping Denotes the transference of yarns from single-end
yarn packages, wound packages, directly to a beam in a one step
process. This means that there are an equal number of packages in
the creel area as there are ends on the beam, except in the case of a
magazine creel. A magazine creel connects the tail of one wound
package to the beginning of a new wound package for an easy
package transfer. from the wound packages in the creel.
Beam Warping
A weavers beam may have upto 10,000 ends and if this were to be
produced directly it would be necessary to have upto 10,000 creel
packages.such an arrangement would be very difficult to
accommodate and manage ;consequently it is normal practice to
produce warpers beams which may contain upto about 1000 ends
and these are combined at the slashing stage.because of the
difficulties involved in combining the ends ,patterned warper beams
are seldom produced on the direct system and any pattern that is
produced is achieved by combining beams of various colors at the
later stage of slashing.
This imposes limitations which can only overcome by changing to
pattern weaving.
TYPES OF WARPING
Sectional Warping Process
In sectional warping sections are made sequentially and because of
this the process is rather slow ;it is the practice therefore to produce
no more than is required to fill a single weavers beam.the result is
that the sectional warping is used mainly for short runs or for
complex color patterns.
Pattern, Band or Drum Warping
Because many warpers beams are combined in the direct
system,this is usually regarded as a high speed process particularly
suitable for single color work .providing the warpers beams are of
single color ,it is possible to combine them to produce simple
patterns distributed over the warp width.
Ball warping
Ball Warping is an intermediate process for storing yarn for transport
,dyeing or reserve; It does not produce a beam.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 100 ends.
REQUIREMENT OF WARPING
Should meet the following requirement:
1. The tension of all wound ends must be uniform and possibly
constant during all the time of withdrawal from supply
packages, otherwise the rate of breakage will be increased &
the structure of the ready cloth will be impaired.
2. Warping should not impair the physical & mechanical
properties of yarn. The tension should moderate to allow the
yarn to completely retain its elastic properties & strength. The
yarn should not be subjected to sharp abrasive action.
3. The surface of warping package must be cylindrical.
Therefore, the spreading of yarn (density) throughout the
whole width of warping must be as uniform as possible.
4. A pre determined length of warping should be observed.
5. The production rate of warping should be as high as possible.
REQUIREMENT OF WARPING
1. The yarns in the sheet should be in uniform spacing.
2. The yarns in the sheet should be in uniform tension.
3. The yarns in the sheet should be of a predetermined
length.
4. The sheet should be containing a predetermined number of
ends.
5. There should be no broken ends in the beam.
OBJECTS OF WARPING
Objects of warping:
IMPORTANCE OF WARPING
Importance of warping:
1. Constructions of beam warp yarn.
2. Constructions of a parallel yarn sheet.
3. Modifying the faults of yarn like thick & thin places, large
knots etc.
4. Winding the predetermined length of yarn.
5. Combination of small packages.
6. Finding long length of warp yarn.
7. Accelerating the next process.
QUALITY PARAMETER
CHECK
RESPONSE
No ridge beam allowed, clean the
Homogeneous beam
uniformity.
Check the alignment of beam &
diameter
Yarn exhaustion
Yarn break
Operational Stuf
Operational Stuf:
1. SUPERVISING OFFICER.
2. OPERATOR.
3. CREEL MAN.
4. HELPER.
Operational Staf:
Section in Charge
Senior Executive
Supervising officer
Senior Operator
Creel man
Helper
OPERATION PROCEDURE:
The m/c operators and helpers and helpers open/break the yarn
cartons & place the yarn cones on the creel peg as per program &
draw the head end of each cone through pre-tensioner rods feeler
wire, yarn guide & then through expanded comb of beaming unit.
The basic creel data setting& m/c data setting are done according
for the required as pr m/c manufacturer instruction.
All the ends from the creel is warped around the beam manually
one round.
OPERATION PROCEDURE:
The m/c is then run slowly and checked for yarn alignment
with beam flange on both sides. To ensure perfect alignment
the expended comb may be moved either to the Right side
or Left side as required by switch.
WARPING PROCEDURE
WARPING PROCEDURE
6.
7.
8. Then by section alignment switch set the m/c ready for next
section. Repeat step-7, and 8 to finish the warping.
WARPING PROCEDURE
All the section thatare wounded up over the drum is doffed in the
beam from by beaming process as follows:
Run at crawl speed to see alignment either left side or right side
by drum alignment switch.
Hi-speed warping
Main Parts:
1. Yarn cone or
Chase
2. Balloon Breaker
3. Yarn tensioner
4. Yarn guide
5. Ceramic guide
6. Auto stopper
7. V-reed
8. Lease rod
9. Roller
10.Pressure Roller
11.Pre-beam
DIRECT
I HI-SPEED
WARPING MACHINE
Creeling
Warping
DIRECT
I HI-SPEED
WARPING MACHINE
Creel:
Parallel creel with travelling package
Creel capacity of SIM fabric direct warping m/c:
oNo. of warping m/c: 2
oM/c no 1: Both side: 756
Creel:
HEAD STOCK
Features of components of headstock:
1. Adjustable or variable v-reed or wraith: To control the
width of the warp beam.
2. Measuring & making device: Measure the amount of warp
yarn on the beam & 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 m/c after read length is wound on
beam.
6. Driving drum: Beam is in contact & control with driving drum.
7. Stop motion: Used to stop the m/c after read length is wound
on beam.
8. Beam bracket: To support & hold the beam.
Control device:
Similar to winding, warp yarns are threaded through tension
devices , stop motions, leasing rods and the reed. The stop motion
electrically links each warp end to the warper braking system;
when a warp end breaks, the warper stops. A light indicates the
location of the broken end. The warping process is generally
irreversible, unwinding, of the beam would cause yarn
entanglement. The stop motion device which can be mechanical or
electronic for quick response, is usually located near the creel.Fans
are used to prevent lint accumulation when warping staple yarns.
Stop motion
3
2
1
Tension
C
B`
A
Setting
Yarn Count
range
(Ne)
Coarse
Medium
Fine
4-30S
4-60S
15-120s
Range
Set value
400-600
As required
Warping Speed
1-1200 m/min
Warping length
1-999999 m
Shift selection
1-5
Beaming drum
1-11 mm scale
5 mm scale
1, 2, 3.
1 higher
Tensioner
A, B, C.
C higher
Depth of penetration
1-40 mm
As required
315 mm
Fixed
987 mm
Fixed
Beam width
1800 mm
As required
pressure
DIRECT WARPING
It is generally used to
Object / Use produce warp beam for
grey fabric or solid color
fabric.
Several Warpers beam are
Method of
produced here for getting
production
one weavers beam.
Ends/beam is less here.
No. of
Direct warping beams
Ends/beam contain 1/n no. of ends of
weavers beam.
(n=no. of warping
beam/set).
One stage Production.
Stage of
(Yarns are directly wound
Production on Warpers beam).
SECTIONAL WARPING
It is generally used to
produce warp beam for yarn
dyed (check/stripe) fabric.
One Warpers beam is
produced here for getting
one weavers beam.
Ends/beam is higher here.
Sectional warping beam
contains equal no. of ends as
weavers beam.
Yarn length on
beam
Creel Capacity
Sizing
Operation
Efficiency
DIRECT WARPING
Yarn tension is
comparatively higher
than sectional warping.
Higher length of yarn is
wound on a beam.
SECTIONAL WARPING
Yarn tension is
comparatively lower than
sectional warping.
Length of yarn in the beam
is comparatively lower than
direct warping.
Usually lower than
Usually higher than
sectional warping.
sectional warping.
One sized beam is
One sized beam is
produced from several
produced from one
no. of Warpers beam.
Warpers beam.
Efficiency is higher than Efficiency is comparatively
sectional warping.
lower than direct warping.
(Single stage operation). (One additional operation
beaming-off is required).
Creeling
(According to warp plan)
Machine setup
Beaming
Warp width:
Total Ends
Below 7200
Warp Width
1800 mm
7200
2000 mm
Above 7200
2100 mm
CREEL DIAGRAM
Ball Warping
Hard beam:
Due to high tension.
Remedy: Tension and pressure maintained.
Warping Calculation
Calculation:
For
construction(6815yds fabric)
Total number of yarn =7344 7250
Length of ordered fabric = 6815yds
Warping Calculation
Breakage calculation:
Number of total ends: 7500
Number of yarn per warper beam: 625
Number of creel: 12
Length: 9250 yards
Total breakage: 162
Now, total length: number of total ends length
: 7500 9250
: 72150000
Breakage in 72150000 yards length = 16
Breakage in 1000000 yards length
= 2.24
COMPANY
NAME
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
COUN
T
40/2
40/2
30/1
30/1
30/1
60/1
30/1
16/1
60/1
30/1
30/1
40/2
30/1
40/2
30/1
SPEED
350
350
350
350
350
350
350
350
350
350
350
300
350
350
350
BREAKAGE
RATE
1.01
1.8
1.92
1.95
2.65
2.1
1.25
2.13
3.31
1.13
1.24
0.45
0.73
4.04
1.41
Warping Calculation
Warping Calculation
Warping efficiency:
Efficiency is calculated depended on worker working shift
Actual Production: (200003) +14000 = 74000 yards
Machine speed= 350 yards/min
Production time= 74000 yards 350 = 3.32 hour (total length
speed)
Creel time= 1.00 hour
Breakage= (962) = 3.23 hour
Cleaning time = 0 hour
Electrical = 0 hour
Mechanical= 0 hour
Total time used= 7.44 hour
Idle time= 0.16 hour
Calculated production= total time machine speed
= 8.00hour 350 yards/ min
= 480 min 350 yards/ min
=168000 yards
Warping Calculation
Warping Calculation