1. Presented by:Md. Nazmul Hassan RayhanDepartment of Textile
EngineeringDaffodil International University
2. WARPING:Warping:The parallel winding of warp ends from many
winding packages (cone or cheese) on to a commonpackage (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
3. TYPES OF WARPINGBeam WarpingA weavers beam may have up to
10,000 ends and if this were to be produced directly itwould be
necessary to have up to 10,000 creel packages. Such an arrangement
wouldbe very difficult to accommodate and manage ;consequently it
is normal practice toproduce wrappers beams which may contain up to
about 1000 ends and these arecombined at the slashing stage.
Because of the difficulties involved in combining theends
,patterned warped beams are seldom produced on the direct system
and anypattern that is produced is achieved by combining beams of
various colors at the laterstage of slashing.This imposes
limitations which can only overcome by changing to pattern
weaving.Sectional Warping ProcessIn sectional warping sections are
made sequentially and because of this the process israther slow ;it
is the practice therefore to produce no more than is required to
fill a singleweavers beam. The result is that the sectional warping
is used mainly for short runs orfor complex color patterns.
4. QUALITY OF A GOOD WARPThe essential features of a good warp
are as follows:1. Sufficiently and uniformly strong.2. Uniform in
cross section.3. Uniform warp tension.4. Uniformly sized.5. Less
hairy and clean.6. Minimum no. of knots .7. Proper or standard size
and types of knots.8. Free from naps, slobs and loose fibers.9.
Parallel arrangement of warp yarn in the weavers beam.
5. IMPORTANCE OF WARPINGImportance 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
knotsetc.4. Winding the predetermined length of yarn.5. Combination
of small packages.6. Finding long length of warp yarn.7.
Accelerating the next process.
6. OBJECTS OF WARPINGObjects of warping:The object of warping
is to convert a predetermined number of single end packages,such as
cones or cheeses into a sheet of yarn of specified length &
width. Theindividuals ends in the warp are uniformly spaced across
its full width. The warp yarnscomprise one of the systems of yarns
required to produce a woven fabric & also forwarp knitting. The
objective at warping, as erroneously considered by many is not at
allto remove yarn faults, the breaks due to these being only
incidental.
7. WARPING ELEMENTS & MOTIONEach warping m/c has the
following warping elements & motion:1. Warping creel for
accommodation the bobbin.2. A builder motion.3. A guide reed.
Uniformly spreading the yarn over the warp width.4. A measuring
motion registering the warping length.5. An automatic knocking off
motion to stop the m/c up on achieving the required length
ofwarping in case of yarn breakage.6. A drive7. A starting &
stopping motion.8. Warping m/c is furnished with package doffers
signal devices, blowers. Fluff -exhaustsystem.
8. WARPING PROCESS INVOLVES
9. CHECK LIST BEFORE PRODUCTIONCheck List Before
Production:With the production before data control operator will
call-up the following forrecording:1. Warp length shift.2. Down
time.3. Efficiency.4. No. of thread breaks.5. No. of warp beam
doffed.6. Time for thread repair.7. Time for beam change.8.
Operator must check yarn quality in term of count, material, and
colorwith customer demand.9. Operator must check yarn quality in
term of strength and record yarnbreak rate. Standard for good
quality yarn 10 breaks/10,00,000 meter.
10. COMPONENTS OF WARPING MACHINEHEAD STOCK:1. Guide Reed :
Uniformly spread the yarn over the warp width.2. Adjustable V-Reed
: Guides the yarn to follow the fixed path.3. Speed Controller :
control the speed, crawl speed or full speed.4. Pressure Roller :
Exert required pressure to the warp yarn.5. Measuring Device :
Measures the length of the yarn.6. Beam Bracket : Holds the warp
beam.7. Emergency Stop Device: For emergency stop.8. Automatic
Knock Off : Stop m/c at achieving required length of beamor in case
of9. Yarn breaks.10. Electrical Panel Board : To give the automatic
controlledfunction.
11. Hi-speed warpingMd.Monirul IslamId:- 133-23-3651Section
AB.Sc. In TE
12. High speeded warpingIn this process, the threads are being
directlywinding on a beam while unwinding the yarnfrom creel
13. HI-SPEED WARPING MACHINE
14. YARN PATH DIAGRAM OF MACHINEMain Parts:1. Yarn cone or
Chase2. Balloon Breaker3. Yarn tensioner4. Yarn guide5. Ceramic
guide6. Auto stopper7. V-reed8. Lease rod9. Roller10.Pressure
Roller11.Pre-beam
15. Major components of Warping Machine:Warping machine has
three major components:1. Creel2. Head Stock3. Pressure roller4.
Control DeviceCreel:Parallel creel with travelling packageCreel
capacity of SIM fabric directwarping m/c:oNo. of warping m/c: 2oM/c
no 1: Both side: 756
16. Symmetric diagram OF DIRECTWARPING MACHINE
17. DIRECT I HI-SPEED WARPING MACHINE
18. HI-SPEED WARPING MACHINEDispoYarn from
storeCreelingWarping
19. Working principle of H.S. Warping At the beginning so many
beams are preparedas the following equationNumber of beams = In
which way threads are assembled showsthe number of beams
20. DIRECT I HI-SPEED WARPING MACHINE
21. COMPONENTS OF WARPING MACHINECREEL:1. Cone Holder : Hold
the cone or arrange the cone in the creel.2. Yarn Guide : To guide
the yarn.3. Tension Rod : Maintain yarn tension by upper &
lower disctensioner.4. Ceramic Guide Disc : To guide the yarn from
creel to warping m/c.5. Auto Stop Sensor : To sense the breakage
yarn.6. Creel Panel Board : Display where the yarn break
22. Creel:
23. FUNCTION OF COMPONENTS OF CREELFunction of components of
creel:1. Cone or cheese spindle for high speed warping.2. Thread
guide: To pass through the yarn in the reqd way.3. Tensioner: To
keep the yarn always in a uniform tension.4. Yarn cleaner: To
remove various faults of yarn like slubs, neps etc.5. Suction fan
or blower: To remove the dirt & dust from the yarn.6. Breakage
indicator: To indicate breakage in package.7. Stop device: To stop
the m/c when yarn will be broken.
24. Control device:Similar to winding, warp yarns are threaded
through tension devices , stopmotions, leasing rods and the reed.
The stop motion electrically links each warpend to the warper
braking system; when a warp end breaks, the warper stops. Alight
indicates the location of the broken end. The warping process is
generallyirreversible, unwinding, of the beam would cause yarn
entanglement. The stopmotion device which can be mechanical or
electronic for quick response, is usuallylocated near the
creel.Fans are used to prevent lint accumulation when warpingstaple
yarns.
25. High Speed Warping m/c Setting:
26. Use of High-Speed Warping Machine Producing one color
fabric like gray fabric For producing one/single color fabric For
the same count of yarn Example: Shirt , Pant , Polo Shirt etc.
27. Sectional Warping m/c.
28. Sectional warping is a process of preparing warp beam over
two stages.First, yarns are wound in narrow tapes on a large
drum.Second, the rewinding of the warp onto a beam is
performed.Sectional warping machineMain parts :CreelDrum or
dresserWarping combWarping carriageLeasing and splitting devices
for sizingBeam carrying chuckGuideLevelling roller
29. Features of sectional warping To produce fancy fabric of
different colors. Hand weaving used in sectional warping. To
produce weavers beam from small amount of warp yarn. To produce
weavers beam from twisted yarn. To produce weavers beam from which
do not required any sizing material tobe applied before weaving.
Weavers beam can be formed immediately after. Production is less,
so it is costly process. Yarn tension can not be kept uniform. A
tapered beam or drum is used.
30. Process Flow Chart Sectional Warping MachineProcess Flow:
DispoYarn from storeCreeling(According to warp plan)Machine
setupSection wise warpingBeamingWarp width:Total Ends Warp
WidthBelow 7200 1800 mm7200 2000 mmAbove 7200 2100 mm
31. SCHEMATIC DIAGRAM OF DIRECT WARPING MACHINE
32. HEAD STOCK OF SECTIONAL WARPING MACHINE:
33. HEAD STOCK OF SECTIONAL WARPING MACHINE:
34. CREEL DIAGRAM
35. Requirement of warping
36. REQUIREMENT OF WARPINGShould meet the following
requirement:1. The tension of all wound ends must be uniform and
possibly constant during all thetime of withdrawal from supply
packages, otherwise the rate of breakage will beincreased & the
structure of the ready cloth will be impaired.2. Warping should not
impair the physical & mechanical properties of yarn. The
tensionshould 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.
37. REQUIREMENT OF WARPING1. 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.
38. Faults & Remedies of Warping:Warp off centre of the
beam:Due to not carefully placing of creel wraith and flanged
beam.Remedy: Beam and wraith placed properly.Ridgy or uneven warp
beam:This effect due toWinding of small no of ends on larger
beam.When the dents are bent or the spacing between dents is
uneven.Mixed count.Remedy: Higher no of ends be used.Crossed
ends:Due toFaulty knotting after yarn breakage.Tying of broken
ends.Loose warp.Remedy: Knotting and tension controlled.
39. Faults & Remedies of Warping:Snarl formation in the
warp:Due toOver tension.Improper twist.Position of guide.Remedy: By
proper tension and twist.Missing ends:Due toFaulty stop
device.Exhausted cone or bobbin.Absence of cone or bobbin on
creel.Remedy: By correct stop device is usedHard beam:Due to high
tension.Remedy: Tension and pressure maintained.
40. Faults & Remedies of Warping:Unequal length :Due to
faulty measuring device.Remedy: correct measuring device.Broken
ends:Remedy: To be joined carefully the yarn.Warp ends round the
creel peg.Unequal length of warp.Unequal size or weight of cone or
cheese in the creel.Lapped ends.Piecing.Soft end on the warping
beam.Warp ends round the creel peg(spindle) and results broke.
41. Causes of yarn breakage in warping:Causes of yarn breakage
in warping:1. Weak yarn.2. Sloughing off.3. Over lapping.4. Knots/
bad splice.5. Slubs.6. Loose yarn.7. Pig tail.8. Cut yarn.9. Bad
tip cone.10. Short cone