Recent Developments: Weaving Technology
Textile World Asia presents some recent technologies that provide improved efficiencies in the weaving mill.
Jürg Rupp, Executive Editor
F
abric manufacturers are under pressure more than ever. Weavers around the world are
fighting against higher costs in terms of labor, raw material, production time and reduced energy
consumption to remain competitive. In turn, the machinery suppliers are challenged to provide
up-to-date machinery.
In times of increasing energy costs, it is of utmost interest for fabric producers to use weaving machines that offer reduced energy consumption.
Adaptive Relay Valve Drive
Picanol NV, Belgium, provided the following information about its Adaptive Relay Valve Drive, which is featured on its OMNIplus 800 air-jet weaving machine:
Adaptive Relay Valve Drive (ARVD) automatically adapts the closing timing of the relay nozzle valves to the behavior of the filling yarn. Instead of applying one setting for all the different picks, ARVD applies the best relay valve timing for each individual pick, thus reducing the overall air consumption.
At each insertion cycle, the winding timings from the prewinder are compared with a reference value by the machine's microprocessor. Since the filling insertion speed varies from one pick to another, it is not necessary for the relay nozzles to blow for the same amount of time at each pick. Consequently, the machine adapts the closing timings for the relay nozzle valves automatically. For a fast pick, the relay nozzle valves do not stay open very long. ... For a slow pick, they stay open longer. ... This is done from the second relay nozzle valve onwards.
Picanol notes that decreased air consumption reduces energy costs, and reduced blowing on the filling yarn reduces the number of broken picks. Also, Pick Repair Automation has a higher success rate because the type of filling stops changes.
The Adaptive Relay Valve Drive (ARVD) for Picanol's OMNIplus 800 air-jet weaving machine lowers air consumption and thus reduces energy costs.
Air-Jet Weaving
Italy-based Itema Weaving has recently upgraded its Sulzer Textil™ L5500 air-jet weaving machine, suited primarily for applications such as quality apparel and home textile fabrics made with natural or man-made fibers or blends.
Key benefits of this machine are said to be the fabric quality and low running costs. According to Itema Weaving, the L5500's strength is its competitiveness in terms of its capacity to conveniently weave fabrics that comply with superior quality standards, while also maintaining a high degree of efficiency even at top performance levels. The company adds that "conveniently" also means producing with reduced off-quality rates and reduced air consumption per meter of fabric, which improves profits. The L5500's RTC (Real Time Controller) function enables the machine to adapt to various weaving conditions, thereby obtaining significant air-consumption savings.
Targeted customers are weavers interested in superior production to enable entrance into new, highly profitable markets. The L5500 can be adapted to different production requirements. Easy operation, widest range of application and shortest setting times are key factors.
Recent upgrades in the L5500 technology have increased the machine's efficiency and performance. For standard weaving, the maximum speed now is 1,200 revolutions per minute, and the maximum weaving width is 4,000 millimeters (mm). This is equal to a production capacity in excess of 2,500-meters-per-minute weft insertion rate.
Drawing-in: An Important Cost Factor
Switzerland-based Stäubli AG reports that automatic drawing-in machines for the weaving harness have long helped weaving mills around the world stay competitive. Automatically drawn-in warps are characterized by zero defect and high quality, and they are available as required for production in a fraction of the time compared with manual drawing-in.
According to Stäubli, the upgraded Safir automatic drawing-in machine offers new opportunities regarding flexibility, thanks to the refinement of proven system components from the Delta line combined with established state-of-the-art technologies, particularly the Opal leasing machine. Since its introduction at ITMA 2007 in Munich, Germany, and after several upgrades, the machine can be configured to draw in one or two warp beams, each having up to eight thread layers. A camera system checks the yarn to be drawn in during each cycle and ensures against drawing-in of double threads or threads of the wrong color.
Stäubli reports there also is flexibility with regard to the weaving harnesses that can be used, as virtually all heddles used in shaft weaving can be handled freely. Heddle distribution can be programmed on up to 28 frames. It also is possible to use two different types of drop wires for the same weaving harness - an application that is especially interesting for terry weaving with upper beams and varying drop wire weights for the ground threads and pile threads. With virtually unrestricted application potential, Stäubli says Safir sets new standards in automatic drawing-in. The machine also features user-friendly ergonomics and convenient operation using a color touchscreen.
Warp-tying is another cost factor in the weaving mill. Stäubli reports its Magma warp-tying machine is especially suitable for tying coarse yarns. A patent-pending system that works without yarn-specific settings enables separation of threads to be tied at the lease, which considerably simplifies operation and changing from one application to the next. A built-in camera system monitors the separation of the threads, thus eliminating doubled threads. Magma also can be set easily to tie double knots, and therefore can tie even very slick yarns reliably, according to the company.
Stäubli's upgraded Safir automatic drawing-in machine can be configured to draw in one or two warp beams, each having up to eight thread layers.
The Magma warp-tying machine for coarse yarns complements Stäubli's Topmatic tying machine line. The machines feature a new, patented separating system that reliably separates threads from the lease completely without using thread-specific separating elements and without making special adjustments. Optical sensors check every separated yarn pair before tying, thus preventing a false double yarn from being tied. The fault can be corrected simply. Depending on yarn material, single or double knots can be tied, as selected by a simple push of a button. Optimization of the tying rate is accomplished using the adjustment wheel.
Magma can tie a range of yarns including wool, cotton, linen and other staple yarns, as well as mono- and multifilaments, polypropylene ribbons, and many other yarn types. The yarn count for staple fibers ranges from Ne 0.3 to 50 for warps with 1:1 lease. The machine comes equipped with an optical double-yarn sensor, and single or double knots can be selected easily. The length of knot ends is variable, with a minimum of 5 mm. The tying frame can be used on all Stäubli type TPF3 tying frames, and easy maintenance is guaranteed, with only regular lubrication needed.
January/February/March 2010
In times of increasing energy costs, it is of utmost interest for fabric producers to use weaving machines that offer reduced energy consumption.
Adaptive Relay Valve Drive
Picanol NV, Belgium, provided the following information about its Adaptive Relay Valve Drive, which is featured on its OMNIplus 800 air-jet weaving machine:
Adaptive Relay Valve Drive (ARVD) automatically adapts the closing timing of the relay nozzle valves to the behavior of the filling yarn. Instead of applying one setting for all the different picks, ARVD applies the best relay valve timing for each individual pick, thus reducing the overall air consumption.
At each insertion cycle, the winding timings from the prewinder are compared with a reference value by the machine's microprocessor. Since the filling insertion speed varies from one pick to another, it is not necessary for the relay nozzles to blow for the same amount of time at each pick. Consequently, the machine adapts the closing timings for the relay nozzle valves automatically. For a fast pick, the relay nozzle valves do not stay open very long. ... For a slow pick, they stay open longer. ... This is done from the second relay nozzle valve onwards.
Picanol notes that decreased air consumption reduces energy costs, and reduced blowing on the filling yarn reduces the number of broken picks. Also, Pick Repair Automation has a higher success rate because the type of filling stops changes.
The Adaptive Relay Valve Drive (ARVD) for Picanol's OMNIplus 800 air-jet weaving machine lowers air consumption and thus reduces energy costs.
Air-Jet Weaving
Italy-based Itema Weaving has recently upgraded its Sulzer Textil™ L5500 air-jet weaving machine, suited primarily for applications such as quality apparel and home textile fabrics made with natural or man-made fibers or blends.
Key benefits of this machine are said to be the fabric quality and low running costs. According to Itema Weaving, the L5500's strength is its competitiveness in terms of its capacity to conveniently weave fabrics that comply with superior quality standards, while also maintaining a high degree of efficiency even at top performance levels. The company adds that "conveniently" also means producing with reduced off-quality rates and reduced air consumption per meter of fabric, which improves profits. The L5500's RTC (Real Time Controller) function enables the machine to adapt to various weaving conditions, thereby obtaining significant air-consumption savings.
Targeted customers are weavers interested in superior production to enable entrance into new, highly profitable markets. The L5500 can be adapted to different production requirements. Easy operation, widest range of application and shortest setting times are key factors.
Recent upgrades in the L5500 technology have increased the machine's efficiency and performance. For standard weaving, the maximum speed now is 1,200 revolutions per minute, and the maximum weaving width is 4,000 millimeters (mm). This is equal to a production capacity in excess of 2,500-meters-per-minute weft insertion rate.
Itema Weaving's Sulzer Textil™ L5500 air-jet machine features several recent upgrades.
Drawing-in: An Important Cost Factor
Switzerland-based Stäubli AG reports that automatic drawing-in machines for the weaving harness have long helped weaving mills around the world stay competitive. Automatically drawn-in warps are characterized by zero defect and high quality, and they are available as required for production in a fraction of the time compared with manual drawing-in.
According to Stäubli, the upgraded Safir automatic drawing-in machine offers new opportunities regarding flexibility, thanks to the refinement of proven system components from the Delta line combined with established state-of-the-art technologies, particularly the Opal leasing machine. Since its introduction at ITMA 2007 in Munich, Germany, and after several upgrades, the machine can be configured to draw in one or two warp beams, each having up to eight thread layers. A camera system checks the yarn to be drawn in during each cycle and ensures against drawing-in of double threads or threads of the wrong color.
Stäubli reports there also is flexibility with regard to the weaving harnesses that can be used, as virtually all heddles used in shaft weaving can be handled freely. Heddle distribution can be programmed on up to 28 frames. It also is possible to use two different types of drop wires for the same weaving harness - an application that is especially interesting for terry weaving with upper beams and varying drop wire weights for the ground threads and pile threads. With virtually unrestricted application potential, Stäubli says Safir sets new standards in automatic drawing-in. The machine also features user-friendly ergonomics and convenient operation using a color touchscreen.
Warp-tying is another cost factor in the weaving mill. Stäubli reports its Magma warp-tying machine is especially suitable for tying coarse yarns. A patent-pending system that works without yarn-specific settings enables separation of threads to be tied at the lease, which considerably simplifies operation and changing from one application to the next. A built-in camera system monitors the separation of the threads, thus eliminating doubled threads. Magma also can be set easily to tie double knots, and therefore can tie even very slick yarns reliably, according to the company.
Stäubli's upgraded Safir automatic drawing-in machine can be configured to draw in one or two warp beams, each having up to eight thread layers.
The Magma warp-tying machine for coarse yarns complements Stäubli's Topmatic tying machine line. The machines feature a new, patented separating system that reliably separates threads from the lease completely without using thread-specific separating elements and without making special adjustments. Optical sensors check every separated yarn pair before tying, thus preventing a false double yarn from being tied. The fault can be corrected simply. Depending on yarn material, single or double knots can be tied, as selected by a simple push of a button. Optimization of the tying rate is accomplished using the adjustment wheel.
Magma can tie a range of yarns including wool, cotton, linen and other staple yarns, as well as mono- and multifilaments, polypropylene ribbons, and many other yarn types. The yarn count for staple fibers ranges from Ne 0.3 to 50 for warps with 1:1 lease. The machine comes equipped with an optical double-yarn sensor, and single or double knots can be selected easily. The length of knot ends is variable, with a minimum of 5 mm. The tying frame can be used on all Stäubli type TPF3 tying frames, and easy maintenance is guaranteed, with only regular lubrication needed.
January/February/March 2010
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最新发展：织造技术
《亚洲纺织世界》为您介绍能够提高织造厂生产效率的最新技术。
执行主编：Jürg Rupp
面料制造商正面料前所未有的压力。全球的织造商都在与劳动力、原材料、生产时间等成本上涨做斗争，并致力于减少能源消耗以保持竞争力。因此，机械供应商也面临着提供与时俱进的机器挑战。
在能源成本不断上涨的时代，对面料制造商来说，利益攸关的是使用能够减少能源消耗的织造机器。
自适应辅喷阀驱动系统
比利时必佳乐公司推出了它的自适应辅喷阀驱动系统，用于它的OMNIplus 800喷气织机。
自适应辅喷阀驱动系统（ARVD）能根据纬线的运动自动适应辅喷阀的闭合时间。ARVD不是只用一种设置应对不同的投梭，而是针对每个独立的纬纱应用最佳的辅喷阀时间，由此降低了整体的空气消耗。
在每个嵌入周期里，通过机器自身的微处理器将预络纱机的络纱时间与一个参考值进行比较。由于纬纱嵌入速度根据纬数的不同而变化，所以辅喷阀无需在每次投梭时都花同样多的鼓风时间。对于慢速的投梭，它
们保持开放的时间更长。这是通过在前的第二个辅喷阀来完成。
必佳乐表示，减少空气消耗意味着减少能源成本，而减少纬纱的鼓风能够减少断纬的数量。同时，由于投梭的类型不再变化，自动纬纱修复的成功几率更高。
用于毕佳乐OMNIplus 800喷气织机的自适应辅喷阀驱动系统（ARVD）减少了空气消耗，由此减低了能源成本。
喷气织机
意大利意达织造公司最近升级了它的Sulzer Textil™ L5500喷气织机，主要适用的领域包括使用天然或人造纤维或混纺纤维生产优质服装和家用纺织品。
这种机器的主要优点在于面料的质量和低廉的运行成本。据意达织造公司称，L5500的强度是它的竞争优势，就它的产能来说，可以方便的织造出符合最高质量标准的面料，而 且还能在保证最佳表现的同时保持高效运行。该公司补充到，"方便地"也意味着降低了生产不达标产品的概率，以及减少了生产每平米面料所消耗的空气，这可以提高利润。L5500的RTC（实时控制器）功 能让它可以适应不同的织造条件，由此极大的节省空气消耗。
目标客户是对优质生产感兴趣的织造商，这可以让他们进入新的、利润高的市场。L5500可以适应不同的生产要求。操作简单，有最大的幅宽和最短的设置时间，这都是它的关键指标。
L5500技术上的最新升级提高了该机器的效率和性能。对于标准织造来说，目前的最大速度是每分钟1200转，最大的织造幅宽是4000毫米。这相当于一个产能超过每分钟2500米的引纬速度。
意达织造公司的Sulzer Textil™ L5500喷气织机最近进行了几项升级。
穿经：一个重要的成本因素
据瑞士史陶比尔公司介绍，用于织造综的自动穿经机长期以来帮助全球的织造厂保持了竞争力。自动穿经的经纱的特点是零缺陷和质量上乘，与手动穿经相比，当要求在一小部分时间内生产，它们也是可行的。
据史陶比尔公司称，升级后的Safir自动穿经机在灵活性上带来更多机会，这要感谢Delta产品线上的验证系统部件的改进，以及成熟的先进技术，特别是Opal分经机。自 从在德国慕尼黑举办的ITMA 2007国际纺机展上推出以后，它经历了几次升级，这种机器可以通过配置牵引一根或两根经轴，每根最多可以有8个经纱层。有一个摄像系统检查纱线在每个循环中是否都经过穿经，并 确保防止双股线或颜色错误的线被穿经。
据史陶比尔公司介绍，就可用的织造综而言也有灵活性，事实上在轴织中使用的所有综片都能自由的操控。综片分布能够通过编程达到28架。它 还有可能在同一个织造综里使用两种不同的停经片--这种应用对于有上层经轴和针对地线和绒线停经片重量不断变化的毛圈织造很有趣。事实上它的应用潜力是无穷的，史陶比尔称Safir为自动穿经设立了新的标准。该 机器的特点还包括符合人体工程学的用户友好彩色触摸屏和方便的操作。
经纱接头是织造厂的另一个成本因素。据史陶比尔介绍，它的Magma经纱接头机特别适合接粗纱。这种正在申请专利的系统无需纱线特别设置就能运行，可以实现线的分离并在分经处接头，这 极大的简化了操作，以及从一种应用向另一种转变的过程。它还带有内置的摄像系统，可以监控线的分离，由此来消除双股线。据该公司称，Magma还能容易的设置为接双头接，因此能够可靠地接非常光滑的纱线。
史陶比尔公司升级版的Safir自动穿经机可以通过配置牵引一根或两根经轴，每根最多可以有8个经纱层。
针对粗纱的Magma经纱接头机补充了史陶比尔的Topmatic接头机产品线。该机器的特点是带有新的、获得专利的分离系统，能够可靠的从分经处分离纱线，完全不使用纱线特殊分离部件，也 无需做特殊的调整。光学传感器在接头之前检测每股分开的纱线束，防止错误的双股线被接头。而这一失误能够轻易的更正。根据纱线材料的不同，只需简单的按一个按钮就可以选择接单头接或双头接。使 用调整方向盘可以完成接头速度的优化。
Magma能够接不同类型的纱线，包括羊毛、棉、亚麻和其它的短纤纱线，以及单丝和复丝、聚丙烯带和其它很多种类的纱线。对于短纤的纱支数范围从0.3到50Ne，经纱1:1分经。该 机器配有一个光学双股纱传感器，可以简易的选择单头接或双头接。接头端的长度可以不同，最大可达到5毫米。接头框可以用于所有的史陶比尔TPF3接头机上，保证维护简单，只需定期上油润滑。