DIRECT WARPING OR BEAM WARPING:-
Direct waping or Beam Warping process and percuation:-
Image of creel.
image of creel.
image of warper's beam.
In this method of warping, single color (mono color) in warping is used to prepare the warp of single-ply yarn. Multiple warp can also be used in this warping. The muti colored warp of simple pattern can also be made by this warping method. First of all warp yarn is wound on the many warper's beams . The warp yarn from these beams is transferred to the weaver's beam during sizing.
Structure & working of Direct warping or Beam Warping machine:-
The common components of Direct or Beam arping and their working are coming as below;
CREEL:-
The yarn package is mounted on the creel. It is a very important part of warping machine. Creel is also a frame round or square section pipes and iron channel in vertical columns on both of the creel, 50 columns of cone holder on each side of the creel are there in the creel of direct warping machine. The number of rows of cone holders varies according to the capacity of the creel. The number of rows in the creel may range from 4-8 according to requirement . The yarn packages are mounted on the cone holders. A yarn guide and a tensioner are provided in the creel for each warp end . The yarn coming from the package first of all passes through the yarn tensioner. The main function of the tensioner is to impact a sufficient amount of tension to the yarn. Normally inverted cups and dead weight washers types of tensioner are used in the warping machine . The number of washers and the weight depends on the yarn count used in warping process . As the yarn count becomes finer from coarser , the number of washers is reduced, its weight is also reduced, if necessary. Now the warp end passes through many ceramic guide which are arranged at equal distance upon the length of the creel. The main object of this guide is to keep separate each end and to prevent an end to end entanglement during warping . The second objective of this guide is to provide enough support to each end . The sagging problem creates in sufficient support to the yarn during warping a long yarn try to sag is due to its own weight. Thus enough support needs throughout the passage of the warp end the passage of the warp end. Now the next passage of warp end is drop wire. Its objective is to stop the machine immediately when end breakages occurs. The creel is equipped with fully automatic warp stop motion. The indication lamp on each row are provided in the creel , when ends breakages occurs the indication lamp puts on immediately and the machine is stopped. These indication lamps help the operator to identify the correct situation broken ends in the creel .
REED AND ADJUSTING ATTACHMENT:-
The reed is mounted over the head stock of the machine. The top side of the dents of warping reed is opened. A center mark is made in the center of reed . The warp ends are inserted into the dents in a definite sequence quickly without using any drawing hook. The reed used in the direct warping machine has the ability to change its width within the limit. An attachment is provide in the machine which helps to reduce or increase the reed width . This system also helps to move the complete reed. A threaded shaft across the width of the machine is used in this system, the clock wise threads are used at one end and anti clockwise threads are used at another end of the threaded shaft. The threads bracket of the same types of threads are fitted on both side of shaft . The ends of reed are mounted on the bracket. A hand wheel which is fastened at the one end of the shaft. Whenever the operator need to adjust the reed width, he rotates the wheel in the required direction. The threaded bracket mounted on the threaded shaft comes close or go away to each other, thus the reed width is adjusted. This system further moves in the left or right folitection with the help of a hand wheel and a threaded shaft, thus the operator brings the center of the reed in the center of the machine.
WARP STOP MOTION:-
This is an extra warp stop motion that is mounted over the headstock of the machine just after the reed . The drop pins are inserted into the electrode. Every ends passes through one drop pin. When an end breaks , it falls down on the electrode and the electrical circuit is completed. The machine stops immediately. This stop motion is more effective when a broken end is entangled with another end and starts to move with that. In this case, the stop motion situated in the creel does not stop the machine, but these extra stop motion does not fail and stops the machine immediately in this case.
WINDING DRUM:-
The function of warping drum is to revolve the warper's beam. The drum rotates the beam by surface contact . The drum rotates on the bearing . The beam mounted on the hydraulic arm is free to move in any direction because it is loose on its shaft. The surface of the beam touches the surface of the drum . When the drum rotates, it also revolves the beam in opposite direction due to frictional contact. The yarn passes between the surface of the drum , beam and is finally tied on the beam barrel . When beam rotates it is pulls the yarn and wound on to it.
WARPER'S BEAM:-
The warper's beam is cylindrical having flanges at both sides. The cylinder of beam barrel is made of good quality wood. An iron shaft is inserted inside it . Aluminium flanges are fitted at both end of the cylinder . The iron shaft is projected out side of the flange from 6-8 inches . The flange to flanged distance is always fixed as per the length of the warping drum .
BEAM LOADING SYSTEM:-
The beam lifting arms are mounted on the shaft which is fitted at the bottom of the machine in front of the drum. These arms are moved in upward and downward direction on the bushes fitted in them. The top end of a hydraulic cylinder. These hydraulic cylinder help to move the arm up and down and help to maintain pressure between drum and beam during operation. The warper's beam is mounted on these arm . Before mounting the beam on the arms , a self-alinged bearing at each side of the beam shaft is fitted . Now beam is mounted in the brackets of beam lifting arms and it is to tightened with a bracket cover. Now the beam is move toward the drum and touches the surface of the drum .
HYDRAULIC PRESSURE SYSTEM:-
A hydraulic pressure device is used to generate pressure to bring up and down the beam , pressure also helps to prevent the slippage between drum and beam during running . Hydraulic pressure breaks controls the compactness of the beam . Hydraulic pressure controls breaks the momentum of the rotating drum in case of machine stoppage. Generally a cuboid shape oil tank is used which is located at one side of the machine , 68 number hydraulic oil is filled in this tank . A geared oil pump is mounted on this oil tank. The inlet of the oil pump rests in the oil. The oil enters the oil pump through as oil filter which does filter the oil . The pump's shaft is connected to the electric motor . This motor rotates the oil pump . The out let-off the oil pipe at the other end . During machine operation, a certain amount of pressure is always mounted in the system. A three positions switch is use to select the position of arm . The center position keeps the arms in the rest position. The left side position provides downward movement and the right side position provides upward movement to the arms . Magnetic valves are used to start and stop the supply of oil into the cylinder at both ends . The position of cylinders comes out and go inside the cylinder again as per the position of the selection switch. The position of cylinder operates the arms in up and down direction . Lifting and lowering of beam take place in this way . A pressure regulator is used to reduce or increase the pressure during warping operation.
Full warp length stop motion:-
In today's machine electronic full warp length stop motion is used. The required warp length is entered in the digital counter meyer . A multiple pin is fitted near the circumference of the drum on one side . A proximately sensor is mounted just opposite this pin. When the drum rotates the proximitly sensor sense every rotation of the drum . The signals are sent to counter metre. The counter counts the rotations of the drum and converts them into meters . When warp length reaches to the completion, the counter meter sends a signal to the control unit and the control unit stops the machine immediately.
A C INVERTER:-
An inverter drive changes the speed of the warping drum withou replacing the motor pulley. A pot is provided in the machine which select the machine speed . The machine speed appears in the display of the counter meter
GENERAL SEQUENCE OF BEAM WARPING:-
The general working sequence of warping machine is described below;
The yarn received in form of cone or chesses from spinning mill or yarn stores. The yarn package are mounted on the cone holders . The number of package depends upon the number of ends required in the weaver's beam and number of warper's beam to be made. Now each end is drawn through a yarn guide and tension. Next each ends passes through many yarn separator guides. The ends are finally passed through the eyes of drop wires . Now operator draws these ends through dents of reed in definite order. The operator loads the empty warper's beam on the machine. The ends are passed between the drum and beam barrel surface. Three to four wraps of the ends are wound on the beam by inching the machine. The operator applied manual pressure on the end during inching to prevent slippage. Required warp length is fed into the counter meter . Now warping machine is ready to operate. An operator can run the machine by pressing push button .
Precuation to be taken in Direct or Beam Warping process:-
Following precautions should be taken durin the process of direct or beam warping;
1) The tension on every warp end should be proper.
2) The cleaning of the tensioner should be done at each creel change
3) The number of yarn separation guide should be according to the length of the creel.
4) The two end located at the rear side of the creel wind on both side of the beam . During sizing these ends get loose and create the problem on bowing in the fabrics. This tension of the end is maintained according to location . The rear ends require maximum possible warp tension . The middle ends require less warp tension than the rest ends . The front ends require minimum possible tension .
5) The tension should be selected in such a way that there is no false warp stop due to end slackening.
6) The number of tension washer and their weight should be always adjusted after change of warp count.
7) The drop wire should work properly.
8) The electrode of warp stop motion should be cleaned by any cleaning liquid to avoid failure of warp stop motion .
9) The warp ends should be drawn in creel in the correct sequence to avoide end breakages .
10) The reed width should be adjusted properly, proper adjustments causes loose ends at each side of the beam .
11) There should be no short end in the beam.
12) Short end in warp beam causes lappers and various end breakages during sizing process.
13) The warping pressure should be selected properly. If pressure is too high , it may cause yarn rupture,. If pressure is too low , it may cause warp slippage on the beam .
14) The short end should be mended during the process correctly.
15) Machine brake should be precisely and effectively .
16) The oil level in the hydraulic system should be maintained regularly.
17) The edge on beam flange should not be sharp and rough.
18) Skip denting order should not be used if possible. Theu should changed the reed.
19) The pitch of the creel should be selected precisely to avoide touching the surface of yarn package to each other.
Ref:-https://www.textilesdvisor.com
Comparison between Sectional and Direct or high speed Beam Warping machin:-
The difference between both warping are as below:-
Features of Direct or high speed Beam Warping :-
1) Uniform tension in this warping.
2) Single yarn is used in warping.
3) Warp beam is produced after completing sizing process.
4) It provides higher amount of production.
5) Large amount of warp yarn is required.
6) Cheese or Cone winding package are used.
7) This process is cheap.
8) Creel capacity is greater 1200.
9) The using of this process is very much.
10) Production speed is high.
11) It is used to produce warp beam for large amount of warp yarn.
12) Warping completes in one stage.
13) Cotton, linen, woolen and worsted yarn are processed by using this process
14) It is popular process of Warping.
Features of Sectional Warping machine:-
1) Uniform tension is not available.
2) Twisted yarn is used in warping.
3) Warp beam is produced after completion of warping process.
4) It provides low amount of production than a high speed warping.
5) Small amount of warp yarn required.
6) Flanged bobbin is used.
7) It is ultimately a costly process.
8) Creel capacity is ranging from 300 to 400.
9) It is not used as high speed warping.
10) Lower production speed than high speed warping process.
11) It is used to produce warp with small amount of warp yarn.
12) Warping process completed in two stages.
13) It is mostly used for man-made, filament and silk yarn.
14) It not popular as high warping speed warping.
The above given reasons is enough to differentiate both the warping.
Ref:-https://textiletutorials.com
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