ABOUT WARPING AND WARPING MACHINE
WARPING
Warping means winding the warp yarns parallel from package to beam with required
number, length & tension.
Good warping is as important as sizing. Because good warping good quality
of always ensure good quality sizing & weaving, as well as good quality
of fabric. Both efficiency & profit can be increased by a good warping.
OBJECT OF WARPING
? To prepare the pre-beam.
? To wind the yarn from the package (got from the spinning mill cone, cheese,
bobbin etc).
? To wind the yarn parallel to each other.
? To maintain the uniform length of each & every yarn.
WARPING MACHINE SPECIFICATION
Number of machines: 02
SUBJECT M/C NO. 01 M/C NO. 02
Name of the m/c Ben-direct Ben-direct
Manufacture of the m/c BENNINGER, AGCH-9240, UZWIL BENNINGER, AGCH-9240, UZWIL
Origin SWITZERLAND SWITZERLAND
Model no. 105350/177
Year of the construction 1998 2004
Creel capacity 540 (V-Type) 520 (V-Type)
No. of stand in one raw 45 52
Creel capacity in one stand 06 05
Length of accumulation on accumulator 06 meter 06 meter
Winding speed 350-1200 m/min 300-1200 m/min
Pitch of the m/c 350 mm 435 mm
Working width of the m/c 1800 mm 1800 mm
Maximum beam diameter 1250 mm 1250 mm
Air pressure required 5-8 bar 5-8 bar
Air consumption 2.5 m3 / hr 3 m3 / hr
Power required(voltage) 400 v / 50 Hz 400 v / 50 Hz
Power consumption 23 kw 21 kw
Density
Tension Below 16 Ne: 550 daN
Above 16 Ne: 500 daN
Beam weight 600-900 kg generally 600-900 kg generally
SOME MAIN PARTS OF WARPING MACHINE
In creel section:
? Bobbin stand / Package stand
? Holder
? Balloon breaker
? Yarn tensioner
? Break / Stop motion
? Yarn guide
? Cutter
In warping m/c section:
? Motor
? Main/Winding motor
? Traversing motor
? Comb shift motor
? Beam clamping motor
? Suction motor
? Hydraulic pump
? Comb
? Benvac section
? Accumulating zone
? Control board
? Beam clamping & de-clamping section
? Pressure roller
THE BENDIR (BENNINGE 540 (OLD), BENNINGER APTOSTOP 529 (NEW) MACHINE FUNCTIONS):
A. WINDING ON:
? Winding speed: 350-1200 m/min.
? Encoder: measure the surface speed of pressure drum.
? Motor speed gradually reduced with the increase of beam diameter.
? Inverter controls the motor speed.
B. YARN PARALLELIZATION:
? Each yarn is separated by comb.
? Each dent contains only one yarn
? Combs are traversed by motor
C. CLEANING:
? Combs are cleaned by compressed air automatically at a present interval.
D. BEAM CLAMPING AND DE-CLAMPING:
? By motor.
E. BREAKING FUNCTION: (By hydraulic oil)
? Breaking of beam.
? Breaking of pressure roller.
? Breaking of guide roller.
F. BENVAC:
? Collect the dusts flying in the winding zone.
? Collects dusts by creating vacuums by suction fan.
WARPING MACHINE MAINTENANCE:
Two types of maintenance are followed –
? Preventing maintenance.
? Breakdown maintenance.
Preventing maintenance:
? Daily (cleaning by air).
? Fortnightly (excess, lubricating, greasing)
? Monthly (greasing, parts replacement, belt tension, sharpening the teeth
of beam / flange ).
? Half yearly (oil replacement – due to reduction of their viscosity).
? Yearly (brake pad replacement (while its thickness is less then 2 mm) &
others).
Break down maintenance:
? Instantly when required.
CALCULATION OF WARPING MACHINE:
Waste percentage calculation:
WP%=(Waste / total gross weight) 100
Here,
Waste= weight of the bags+ Weight of the cone+ Remaining yarn weight
Problem:
Find the waste percentage –
Solution:
Let, weight of the bags =20 Kg
Weight of the cone= 100Kg (Generally a single cone is weighted as 50 gm
to 60 gm)
Remaining yarn weight: 10 Kg
Gross weight =8436 Kg
WP%= (130/8436) 100 = 1.54% (Generally WP% is 0.7%-1% tolerable).
Calculation for beam number:
Suppose a sample fabric having a structure of {(7 7) / (66 42)} 68.
Find the number of beam should be preferred for creeling in dyeing sizing
m/c. Suppose Creel capacity 540.
Total number of ends = (66 68)+16 (Extra warp)
= 4448 + 16
= 4464 ends
Creel capacity =540
So, Number of beam = 4464 / 540
= 8.26
If we use 09 beam =4464 / 9 = 496
Creeling should be done as 496 of 9 beam.
For Any machineries i.e warping, sizing, dyeing, weaving, finishing, boiler, Generator,
Chiller,of textile Email: sales@minmaxbd.com [ Europe, Asia ]
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