Time required for tying-in process won’t be a headache anymore in weaving

Kaisul Kabir       
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Tying-in is the process of tying the ends of a new warp beam to the corresponding ends of the old warp beam after the depletion of a warp beam on the weaving machine, if there is no change in design. During the tying-in process the weaving machine needs to be stopped which discontinues the weaving process. As a result, time for producing fabric is increased, at the same time, loss of yarns is also an issue.

Figure: A Tying-in machine (left), an accumulator (center) and the weaving machine (right).
Figure: A Tying-in machine (left), an accumulator (center) and the weaving machine (right).

Previously, tying-in process was done manually, which consumed a lot of time. But thanks to technology providing automatic tying-in machine, which can knot single or ply yarns of cotton, wool, synthetic and blend warp yarns as well as of different thickness at a speed of 60-600 knots per minute. TOPMATIC and MAGMA of STAUBLI are such kinds of warp tying machines in association with TPF3 tying frame provide high performance warp tying.

A small portable robot is also used to turn on or off the weaving machine for tying-in. However, these machines and gadgets provide a cut in the production time but still the looms have to be stopped for tying-in and cause yarn wastage. An investigation from NC state textiles researchers indicates that depending on the size of the beam 4-8 hours of downtime is observed for about 40 looms. As time is a precious thing in terms of production, it became a headache for the weavers. In spite of improvements in yarn quality and high-speed weaving machines, manufactures haven’t been able to solve the problem of long stops in production to replenish the warp sheet.  Weavers are in search for a solution of this issue for hundreds of years.

However, Abdel-Fattah M. Seyam and Willam Oxenham of NC State University College of textiles invented a nonstop tying-in process. They have tested a prototype of a new accumulator and tail beam support in the weaving lab on campus.

The researchers have estimated that this nonstop tying-in process could result in a 4-6 percent increase in weaving process efficiency and cutting the downtime to 1-2 hours. “The next step is finding a machine manufacturer to build full-scale versions. After that, full-scale trials can take place at P&A Industrial Fabrication in Roxboro, a frequent corporate partner that welcomed two NC State industrial engineering students for assignments this year”, says Oxenham.

The invention will be a game changer if it comes to play in the industry by reducing downtime incredibly and by saving yarns and labor. As a result, downtime, the headache of the weavers will be reduced a lot.

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