Lec15 18 Shedding
Lec15 18 Shedding
Lec15 18 Shedding
WEAVING
WEAVING
Weaving is the most popular method of fabric
manufacturing and is generally done by interlacing
two orthogonal sets of yarns – warp (or end) and
weft (or pick) – in a regular and recurring pattern.
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Weaving mechanism
Primary motions
1. Shedding
2. Picking
3. Beat up
Secondary motions
1. Take up
2. Let off
Auxiliary motions
1. Warp stop
2. Weft stop
3. Warp protector
Weaving: Shedding
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Shedding
Shedding is the process by which the warp
sheet is divided into two groups so that a
clear passage is created for the weft yarn to
pass through it.
Shedding
One group of yarns either
moves in the upward
direction or stays in the
up position, thus forming
the top shed line.
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Shedding
Warp yarns are not controlled individually during the
shedding operation (except Jacquard shedding)
Healds are used to control a large number of warp
yarns.
The heald frame carries a large number of metallic
wires known as heald wires.
Shedding
Each heald wire has a hole, called heald eye, at the
middle of its length.
The warp yarn actually passes through the heald eye.
Therefore, as the heald moves, all the warp yarns
which are controlled by that heald also move.
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Shedding
The upward and downward movements of healds are
controlled either by cam or by dobby shedding
mechanisms and associated heald reversing
mechanism.
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The upward
movement is ensured
by the roller or spring
reversing mechanism.
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i. Grooved cam
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Grooved cam
When the cam rotates, the bowl moves upwards and
downwards and this movement is translated into sidewise
movement of lower end of tappet lever.
The heald is also raised and lowered by using levers and link
systems.
Matched Cam
When the shaded follower
is touching the minimum
radius of the corresponding
cam, the un-shaded
follower is touching the
maximum radius of the
corresponding cam.
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Open Shed
Ideal kind of shed and it minimises the wasted
movements of the ends (or healds).
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Numerical Problem
Calculate the throw (lift) of the cam controlling the back heald
from the following particulars:
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Numerical Problem
Numerical Problem
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Geometry of Shed
Geometry of Shed
As the healds move away from the warp line, the
warp takes a longer path.
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Geometry of Shed
If the length of the back shed increased, then yarn
extension is reduced (preferred for weaving delicate
yarns like silk)
Therefore, H = 2h
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Numerical Problem
Determine the ratio of strain created in the warp threads during
shedding by the front heald and back heald if the total shed
length (distance between the cloth fell and back rest) is 120
cm, front shed length for the front heald is 20 cm, distance
between the front and back heald is 4 cm, diameters of
reversing rollers are 5 cm and 6 cm.
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Numerical Problem
Timing of Shedding
One pick is equivalent to one complete rotation of the
crank shaft.
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Timing of Shedding
At 0°, the reed reaches the forward most position and
performs the beat up.
Loom Timing
Loom timing is defined as relative chronological
sequences of various primary and secondary
motions are expressed in terms of angular position
of crank.
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Loom Timing
Shedding (for early
shedding)
Loom Timing
Shedding (for late
shedding)
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Loom Timing
Picking and Checking
80°-110°:Picking stick
operates
105°-110°:Shuttle enters
in the shed
Loom Timing
Sley Motion
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Loom Timing
Take-Up
Early Shedding
The shuttle enters and
leaves the shed at around
110° and 240° respectively.
The shed is levelled (closed)
at 270° .
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Early Shedding
When the shuttle enters the shed (110°), more than half of the
dwell period is over. When the shuttle leaves the shed (240°),
the shed is about to close.
Late Shedding
Timing of shedding is delayed
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Late Shedding
The problem of abrasion
between warp and shuttle can
be minimised by adopting late
shedding
The beat up occurs when the
shed is levelled and healds are
yet to cross each other.
Therefore, this timing is not
favourable for weaving heavy
fabrics.
However, this kind of timing is
favourable for weaving delicate
warp yarns and the possibility
of abrasion with the shuttle is
very low.
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In this case, the length of two shed lines CUN and CDN are
equal which signifies that the tension in both the sheds (top and
bottom) is equal.
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This is clearly visible from the fact that length of the top shed
line CUR is smaller than the bottom shed line CDR. Thus the
tension in the top shed line will be lower than that of bottom
shed line.
At beat up (360° ), the shed is fully crossed i.e. the top shed
line of the last pick has now formed bottom shed line and vice
versa.
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The previous pick (the second circle from the right) will be
forced in the upward direction with respect to cloth plane but by
a lesser magnitude.
This process will repeat after the insertion of each and every
pick and as a consequence higher pick density in the fabric will
result.
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Bending Factor
Bending factor is defined as the ratio of depth of shed
in front of shuttle ( s ) and the actual height of the
shuttle ( h )
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Bending Factor
If it is greater than 1, then there will not be any
abrasion between warp sheets and the shuttle.
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Bending Factor
The bending factor changes continuously as it is
influenced by the following two factors.
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Bending Factor
For late shedding (where
the shed levels at 0), dwell
occurs between 120°-
240°. Therefore, during
this period, the healds are
stationary. So, the depth of
shed in front of the shuttle
varies only due to the sley
movement.
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Bending Factor
For early shedding (where the
shed levels at 270°), dwell
occurs between 30° -150°.
Bending Factor
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Heald Staggering
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Heald Staggering
The two cams of same group can be arranged in such
a way that there is some phase difference (say 5-10°)
between them
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Heald Staggering
This ensures that even when two healds are rising,
they do not reach the middle of shed depth at the
same time
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Diameter of follower
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Example 1
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Each of the two dwells will be spanning over 2/3 ×180° =120°.
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Step 1
Draw a circle
having its centre
at O and radius
OA of 4 units (cm
or inch).
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Step 2
Add d and l (4
+6=10). Then
draw another
concentric circle
having radius of
OB (10 units).
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Step 3
Divide the circle in
four segments of
60°, 120°, 60° and
120°, for rise, dwell
1, fall and dwell 2
respectively. Here
∠COB = ∠DOE =
60°.
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As the span of the rise and fall (60° for each) has
been divided into six equal parts i.e. 10° each, the
distance between the centres of cam and follower
would increase by 1/6 × 6 unit = 1 unit after each
10° rotation of the cam during the rise.
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Step 6
Draw small circles
having diameter of 2
units, representing
the follower,
considering Q1, Q2,
…., Q6 and B as
centres. Also draw
small circles, having
diameter of 2 units,
considering R1, R2,
…, R6 and D as
centres.
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Example 2
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90
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Step 1
Draw a circle
having its centre at
O and radius OA of
4 units (cm or
inch).
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Step 2
Add d and l (4 +
6 = 10). Then
draw another
concentric circle
having radius of
OB (10 units).
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Step 3
Divide the circle in
four segments of
80°, 40°, 80° and
160° for rise, dwell
1, fall and dwell 2
respectively.
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As the span of the rise and fall (80° each) has been
divided into four equal parts i.e. 20° each, the
distance between the centres of cam and follower
would increase by ¼ × 6 unit = 1.5 unit after each
20° rotation of the cam during the rise.
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Step 1
Draw a circle
having its centre
at O and radius
(OA) of 3 units
(cm or inch)
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Step 2
Add d and l (3 +
6 = 9). Then
draw another
concentric circle
having radius
(OB) of 9 units.
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Step 4
Similarly, divide
∠BOD is divided
into six equal parts
by radii OQ2, OR2,
OS2, OT2 and OU2.
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Draw perpendicular on
diameter CF from points
H1, H2, H3, H4 and H5.
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Step 7
Draw small circles
having diameter of 2
units of the follower,
considering 14
centres C, J1, K1, L1,
M1, N1 and P1 while
the follower is having
a fall and B, J2, K2,
L2, M2, N2, and P2
while the follower is
rising.
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Similarly, the total displacement of the follower after 40, 60, 80,
100 and 120° rotation of the cam will be given by the distances
CI2, CG, CI4, CI5 and CF respectively.
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Keighley Dobby
Keighley dobby is known to be a double acting
dobby as most of the operations is done at half
speed as compared to the loom speed (picks per
minute).
Stop bars
Baulk
Hooks (two per heald)
Knives (two for the entire dobby)
Pegs on pattern chain
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Keighley Dobby
The motion to reciprocating
knives (K1 and K2)
originates from bottom shaft
of loom.
Keighley Dobby
The peg pushed right end of
feeler 2 in upward direction.
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Keighley Dobby
In next cycle, knife 2 will move
inward and knife 1 will move outward.
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When the heald is in lower position for two consecutive picks, the top
as well as the bottom end of the baulk will be resting on the
respective stop bars. So, the midpoint of the baulk will not have any
significant movement.
If the heald is in raised position for two consecutive picks, then one
end of the baulk will move away from the stop bar and another end of
the baulk will move towards the stop bar.
Thus the middle point of the baulk will not experience any significant
movement.
Thus the amount of wasted movement is very nominal. Therefore,
the system will produce open shed.
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System of Pegging
Twill weave (3/3/1/1) which repeats on eight ends and
eight picks considered for demonstrating pegging
plan.
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System of Pegging
The selection for heald movement is controlled by
wooden pegs which are inserted within the circular
holes made on the wooden lags.
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System of Pegging
The presence of a peg within the hole results raised
position of the heald and vice versa.
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Positive Dobby
In Keighley dobby, knives and hooks
cause movement in the baulk and as
a result, the heald is raised. The
lowering of heald is done by the
reversing motion.
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Positive Dobby
This gear can be rotated either
by the top or by the bottom
gear which are having teeth
only over the half of their
periphery.
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Positive Dobby
The selection mechanism
presents cylinders of different
diameters for different pick.
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Positive Dobby
The heald will retain its lowered
position as long as cylinders with
lower diameter will be presented
by the selection mechanism to the
lever.
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However, whether a
hook will be lifted or not
will be decided by the
selection mechanism
which is basically a
punched card system
mounted on a revolving
cylinder.
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This will happen because one of the hooks will descend and
the other hook will move up and they will cross at the middle
of their vertical path.
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Number of cylinder
rotation or turn and
number of reciprocation
cycle of knives is half
as compared to that of
SLSC.
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Jacquard Harness
It is the system by which
the ends are controlled
during jacquard shedding
with the help of nylon
cords, heddles (heald eyes)
and dead weights (lingoes).
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Jacquard Harness
If the hooks of the
jacquard are arranged in
six rows and each row is
having 50 hooks.
Jacquard shedding
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Thus the loss of lift is around 16% with respect to the warp
end positioned vertically below the hook.
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Electronic Jacquard
In recent times electronic jacquards have become very
popular.
Electromagnet
Hooks
Knives
Double roller
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Electronic Jacquard
If the electromagnet is activated
by the signal pattern, then it can
briefly retain the upper end of the
retaining hook once the latter is
pressed on the electromagnet
due to the upward movement of
the hook.
If this happens then the hook is
not retained by the retaining hook
when the former starts to
descend with the knife.
On the other hand, if the
electromagnet is not activated,
then the hook is retained or
caught by the retaining hook.
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Electronic Jacquard
Position 1:
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Electronic Jacquard
Position 2:
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Electronic Jacquard
Position 3:
The hook 1 has been raised to the
highest position by the knife 1 and
thus the hook 1 has pressed the
top end of retaining hook 1 (R1)
against the electromagnet.
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Electronic Jacquard
Position 4:
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Electronic Jacquard
Position 5:
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Electronic Jacquard
Position 6:
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