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Dr. VM. Patil et al.,IJSID, 2012, 2 (1), 77-89

International Journal of Science Innovations and Discoveries, Volume 2, Issue 1, January-February 212

77

TECHNO-ECONOMICS & ADVANCES OF SHUTTLE-LESS WEAVING TECHNOLOGY

DrVM!"#$%1!D'""*"#2

1Principal Bhosanla College of Engg & Research, Akola, Maharastra, India; 2Assistant Prof. College of Engg &ech., Akola,

Maharastra, India

ISSN+229-.7IJSID

International Journal of Science Innovations and Discoveries n International "eer#evie$ Journal for Science

/"r Ar#$% A3"$%"4% 5%$ #r56 $$$.i%sidonline.info

Received: 06.12.2011

Accepted: 13.02.2012

&'orres"ondin( !ut)or

*ame+ Dr.V.M.Patil

Place+ Aloka, Maharastra, India

-mail+patil.vilasredi!!"ail.co"

*ame+ Pro!.P.D.#hana$at

Place+ Aloka, Maharastra, India

-mail+

%hana$atpdredi!!"ail.co"

A'ST/ACT

his paper is disc!ssed a"o!t de#elop$ents in sh!ttle%less $achines ith hope

that, as a sta!nch ad#ocator of $oderni'ation, aareness of de#elop$ents o!ld lead to

critical anal(sis of $achiner( options, hich in t!rn o!ld help in selection, andi$ple$entation of right technolog(. A$ong sh!ttle%less $achines considera"le

de#elop$ents are o"ser#ed in ) "asic picking principles, Pro*ectile, Rapier and Air*et,

hile the ne $!ltiphase ea#ing de#eloped "( +-ER Co. and )/%fa"ric $an!fact!ring

$ethods are orth disc!ssing. A selecti#e, noteorth( feat!re co#ering #ario!s

$achiner( $an!fact!rers and those that a professional sho!ld kno for "etter

!nderstanding of the $achines o!ld "e disc!ssed.

ey $ords+ Pro*ectile, Rapier, Air*et, )/%fa"ric and $!lti%directional fa"rics.

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78

INT/ODUCTION

0e de#elop$ents in ea#ing ha#e taken place in s!ch a direction, hich ens!res red!ced ti$e, energ( and cost

in#ol#ed. ea#( $echanical parts are no "eing replaced ith electronic or $icroprocessor controlled alternati#es. In the last

to decades spectac!lar progress has "een $ade in the field of ea#ing technolog( and the $ost significant "eing the

replace$ent of con#ectional loo$s "( sh!ttle%less loo$s for increasing prod!cti#it( and !alit( of the end prod!ct.

+h!ttle%less ea#ing is $aking an i$pact on the te3tile ind!str(. he change o#er fro$ fl( sh!ttle to sh!ttle%less

in#ol#es "oth ne technolog( and shift fro$ la"o!r intensi#e to capital intensi#e, $ode of prod!ction. Moreo#er, for e3port

$arket, the !alit( re!ire$ents are "eco$ing $ore and $ore stringent ith the res!lt that the e3port of the Indian $ills is

falling. Market de$and is also for long lengths of fa!lt free cloth, hich is onl( possi"le ith sh!ttle%less ea#ing $achines.

Increased la"o!r cost itho!t an( corresponding increase in prod!cti#it( is res!lting in red!ced profit to $ill oners. +o

toda(, e are in need of sh!ttle%less $achines hich are ea#ing fro$ the lightest to the hea#iest of fa"rics and di#ersified

prod!cts !sing $aterials like sp!n, *!te, oolen, orsted, $etal ire, glass fire, $ono and $!ltifila$ent etc. ith good !alit(.

4e ala(s said that

W /6$r: G55: ;6"%$#< F"4r$=> "!t W"# I M" '< G55: ;6"%$#< F"4r$?>

S!ECIFICATIONS OF ;UALITY FA'/IC+

4idth and length of the piece sho!ld "e ithin accepta"le li$its.

5a"ric constr!ction s!ch as EPI, PPI, 4arp co!nt, 4eft co!nt, "lend percent sho!ld "e ithin li$its.

5a"rics sho!ld "e free fro$ conta$ination of color flaks, pol(prop(lene, hair and *!te or ithin specified li$its per

166 linear $eters.

ensile strength of the fa"ric sho!ld "e as specified.

Ma*or defects s!ch as floats, contin!o!s $issing end, rong dran%end, do!"le end and do!"le pick, #isi"le to the e(esho!ld "e a"sent.

LIMITATION OF SHUTTLE LOOM

/espite the relati#el( high speed and efficiencies in loo$ ith con#entional picking, prod!cti#it( of these $achines ill

contin!e to "e li$ited as long as their f!nda$ental constr!ctions in#ol#ed the !se of sh!ttle prop!lsion. 7incent has shon

that the poer re!ired for picking is proportional to the c!"e of the loo$ speed. If the loo$ speed is increased fro$ 266 to

)66 picks per $in!te, the poer re!ire$ent o!ld increase "( a factor of 8)92:) i.e. ). ti$es appro3i$atel(. his res!lts in

folloing disad#antages

1.

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79

). Consistenc( and relia"le perfor$ance.

. Ass!red deli#er( ti$e.

=. 5le3i"ilit( of the $achine.

>.

+cope for $an!fact!ring creati#e prod!cts.

?. Better%engineered fa"rics, ider fa"rics etc.

!r5:6#$3$#66 2666%)666

Dr6@ #

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80

T"4%-2 V"r$#< 5B F"4r$ W53 5 S$B$ L55@

oda( the $arket partic!larl( de$ands ide #ariet( as $!ch as possi"le at the loest possi"le cost. hese $achines

pro#ide the feat!re s!ch as

F!/#S '0MM0* I* ! M!'I*S+ -

+e#eral essential feat!res fo!nd co$$on ith all sh!ttle%less $achines are listed "elo

igher speed

4ider idth.

Electronic take%!p and let%off.

+hedding s(ste$s% ca$ , do""( and *ac!ard 8$echanical and electronic:.

Electronic $onitoring of eft (arn flight.

Electronic arp stop $otion.

A!to$atic pick finding.

D!ick st(le change.

Microprocessor controls ith digital displa(.

-o noise and #i"ration.

ension free eft s!ppl( "( eft acc!$!lators.

L55@ T

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81

Microprocessor control l!"rication s(ste$.

DV0PM*S I* P#0J'I M!'I*S

C-R +E-ECI0 %

1 G 1, 2, and > colo!rs+ can "e !sed in eft direction.

he s(ste$ is freel( progra$$a"le and operated "( ser#o controller.

0o li$itations on feeder position shifting.

1: E-ECR0IC 4E5 BRAHER %

his de#ice keeps a !nifor$ tension on eft.

he "raking force and the "raking d!ration are progra$$a"le.

Progra$ can "e gi#en for each pick.

he de#ice is dri#en "( stepper $otor.

2: Pre%acceleration to eft (arn is gi#en "( co$pressed air, hich relie#es e3tra tension

a. in eft hile inserting.

): H) +(nthetic pro*ectile can "e !sed for ea#ing of delicate (arns.

: he no. of heald shafts opera"le "( ca$ $otion is e3tended to 1.

=: +peed has "een increased !pto 166 $p$ 8?6 rp$:. /!e to i$pro#e$ent in $an(

". related $echanis$s.

>:

-E/ displa( at signal pole for $achine speed, pro*ectile arri#al ti$e, angle of $achine stop, etc. hich helps in $onitoring

of process.

?: A!to$atic eft "rake repair $otion ena"les shifting of feed package to a reser#ed one in the e#ent of eft "reak "eteen

package and acc!$!lator, no stopping of $achine hich increases the $achine efficienc(.

DEVLO!MENTS IN AI/ET WEAVING+ -

he Air*et ea#ing $achine contin!es to do$inate as the $achines of #er( high speeds. oda(, practicall( 8an Indian

condition: at 1266 rp$ the $achine orks or ider $achine can attain a 4IR of 2=66 $p$. he s(ste$ had the disad#antage

of higher energ( cons!$ption d!e to the !sage of co$pressed air in picking hich acco!nts for >6 of total energ(

cons!$ption.

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82

he $achine $akers clai$ a red!ction in energ( "( a"o!t 16 8+!l'er, +o$et : in their latest $odels. he

de#elop$ents in picking related s(ste$s ha#e helped in e3panding the hori'on of eft $aterial and co!nt. he (arn colo!r

selection !pto > or "e(ond hich de$and is #er( rare. hat $eans, the $a*or li$itations of the s(ste$ are "eing attended

and scope for applica"ilit( has "een increasing.

LATEST DEVELO!MENTS+ -

M5:$B$"#$5 $ WB# Ir#$5 S

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83

T"r: T6% /:+ -

A tapered shape has also "een applied to the t!nnel selection of reed "lade.

A:3"#"+ -

It helps in pre#enting air dispersion.

he eft insertion is $ore sta"le and re!ires less air.

E%#r5$ 'r"$ S66 to 66 rp$: itho!t scarif(ing their special stat!s of fle3i"ilit(. he( ha#e "een $aking

inroads to hea#( fa"rics 8@66 gs$: and also shedding off the knon dra"ack of higher eft aste.

S!ECIALDV0PM*S+

he design i$pro#e$ent in Rapier gripper per$its handling ide range of (arns itho!t an( need for changes.

he $achine oes its speed, fle3i"ilit( and lo energ( cons!$ption to a co$"ination of high technolog( and

econo$ic design. +t(le changes can "e e3ec!ted E3ceptionall( rapidl(K. ha#ing independent $otor dri#es, this (ielded feer

$o#ing parts, feer gears, feer oil seals and no ti$ing "elts i.e. there are feer ele$ents to infl!ence fa"ric !alit(, less need

for resetting and red!ce $aintenance. here are no toothed "elts, hich are prone to ear, and "reakage.

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84

SUMO MOTO/

+a#ing on energ( cons!$ption of $ore than 16 in co$parison ith con#entional cl!tch and "rake config!ration.

Machine speed setting is done acc!ratel( and co$pletel(, electronicall( #ia the ke("oard of $icroprocessor. his red!ces

the setting ti$e to 'ero.

+peed setting is eas( to cop( to other $achine either ith electronic set card or ith prod!ction co$p!ter ith "i%

directional co$$!nication.

A!to$atic pick finding "eco$es faster, hich significantl( red!ces the don ti$es for repairing filling and arp

"reakages.

he $achine can ala(s ork at opti$!$ ea#ing speed in f!nction of !alit( of the (arn, the n!$"er of fra$es, and

fa"ric constr!ction.

!FL (!r5r"@@"4% F$%%$ L"@%%")+ -

It controls the filling "rake ens!res a c!rrent (arn tensions at an( ti$e d!ring insertion c(cle. he P5- can "e

installed for each channel "eteen the pre%inder and entr( of fi3ed $ain no''le. It has "een designed to slo don the

filling at the end of insertion. he P5- th!s significantl( red!ces the peak tension of the pick at the end of the insertion and

decrease the tendenc( of pick to "o!nce "ack in the shed. As a res!lt of hich the filling tip is stretched correctl(.

FEATU/ES+ -

-oer peak tension in filling (arn.

Red!ced tendenc( of filling to "o!nce "ack.

Inserted pick can "e stretched $ore easil(.

Ad*!st$ents are done "( $eans of $achine ke("oard and displa(.

he settings can "e adopted for each filling (arn.

'ENEFITS+ -

5eer filling "reaks.

5eer $achine stops.

Better fa"ric !alit(.

igher prod!cti#it( of $achine and staff.

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85

4eaker filling (arn can "e !sed.

Correct setting of filling aste length and conse!entl( less aste.

;SC (;6$ S#

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86

FEATU/ES+ -

S: F5r@"#$5+ -

he arp (arns pass o#er rotating ea#ing rotor and shed for$ing ele$ents select and lift arp (arn for shed

for$ation.

he c!r#e shape of the ele$ents, rotation of rotor and $o#e$ent of arp positioner help in selection and for$ation

of shed "( controlling the $otion of arp positioner. he ea#e selection is $ade possi"le.

WB# $r#$5+ -

he channel in the shed for$ing ele$ents g!ide in insertion of eft. he eft is inserted "( no''les are si$ilar to

Air*et ea#ing. Additional no''les "eteen shed for$ing ele$ents f!rther s!pport the eft. 5o!r efts are inserted at a ti$e.

he eft $eas!ring, cla$ping, c!tting, sensing and controlling are si$ilar to air *et $achines.

'"#-U+ -

he co$"s located "ehind shed for$ing ele$ent perfor$ the f!nction of con#entional reed. he loer shed, hich

rises after insertion of eft, lift the eft o!t of channel o#er the entire ea#ing idth. he "eat%!p co$" then catches the eft

and "eats !p.

he $od!lar design concept adopted has helped to change arp "ea$ ithin 26 $in. the arp "ea$s !pto 1>66$$

dia$eter can "e !sed. he incl!sion of "atching $otion for cloth inding has red!ced change inter#als. Man( $achines are in

operations since 1@@?% @ and this $ight "e the $achine for $ass prod!ction in f!t!re.

.D-FA'/IC MANUFACTU/ING METHODS

he technical te3tile prod!ct can "e !sed in three different a(s

1.

It can "e a co$ponent part of another prod!ct and directl( contri"!te to the strength, perfor$ance and other propertiesof that prod!ct, e.g., tire cord fa"ric in tires.

2. It can "e !sed as a tool in a process to $an!fact!re another prod!ct, e.g., filtration te3tiles in food prod!ction, paper

$achine clothing in paper $an!fact!ring.

). It can "e !sed alone to perfor$ one or se#eral specific f!nctions, e.g., coated fa"rics to co#er stadi!$s.

he characteristics of )/ spacer fa"rics are $!ltifaceted. It is an e3tre$el( light $aterial. An e3pected ad#antage of

spacer fa"rics is the freedo$ to orientate selected fi"er t(pes and a$o!nts to acco$$odate the design loads of the final

str!ct!ral co$ponent. he $ain goal of thesis e3ists in the de#elop$ent of the ea#ing $achine and str!ct!re ele$ents of )/%

spacer fa"ric for lighteight co$posites. herefore, this thesis spots the light on to i$portant points hich had "een

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87

de#elop$ent of the let%off and take%!p $ethod on the ea#ing $achine and also de#elop$ent of spacer fa"rics str!ct!res. he

i$portance of o#en spacer fa"ric e3ists in !sing it as co$posites in the lighteight constr!ctions.

In )/%fa"ric str!ct!res, the thickness or %direction di$ension is considera"le relati#e to G and di$ensions. 5i"ers

or (arns are intertined, interlaced or inter$eshed in the G 8longit!dinal:, 8cross:, and 8#ertical: directions. 5or )/%

str!ct!res, there $a( "e an endless n!$"er of possi"ilities for (arn spacing in a )%/ space.

F$+ -ria3ial ea#ing

)%/ fa"rics are o#en on special loo$s ith $!ltiple arp and9or eft la(ers. 5ig. shos #ario!s )/%4o#en

str!ct!res. In polar ea#e str!ct!re, fi"ers or (arns are placed e!all( in circ!$ferential, radial and a3ial directions. he fi"er

#ol!$e fraction is aro!nd =6. Polar ea#es are s!ita"le to $ake c(lindrical alls, c(linders, cones and con#ergent%di#ergent

sections. o for$ s!ch a shape, prepreg (arns are inserted into a $andrel in the radial direction.

=%/irection constr!ction Polar ea#e rthogonal ea#e

F$+che$atics of #ario!s )/%o#en fa"ric str!ct!res for co$posites

E3cept for the co$ponents that are f!nda$entall( Cartesian in nat!re, orthogonal ea#es are !s!all( less s!ita"le for

net shape $an!fact!ring than the polar ea#es. nit cell si'e can "e s$aller than polar ea#es hich res!lts in s!perior

$echanical properties. +ince no (arn interlacing takes place in polar and orthogonal str!ct!res, the( are also referred to as

NNnono#en )%/OO str!ct!res in the co$posites ind!str(. oe#er, it is $ore proper to la"el these str!ct!res as o#en

str!ct!res ith 'ero le#el of cri$p.

In angle interlock t(pe of str!ct!res, arp 8or eft: (arns are !sed to "ind se#eral la(ers of eft 8or arp: (arns

together as shon in 5ig.. In place of arp or eft (arns, anadditional third (arn $a( also "e !sed as "inder. +t!ffer (arns,

hich are straight, can "e !sed to increase fi"er #ol!$e fraction and in%plane strength. If the "inder (arns interlace #erticall(

"eteen fa"ric la(ers, the str!ct!re is called orthogonal ea#e.

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88

F$+ - Angle interlock fa"ric; 8A: ith and 8B: itho!t added st!ffer (arns

F$+ -+che$atic of Hings )%/ $achine

Angle interlock or $!lti%la(er fa"rics for flat panel reinforce$ent can "e o#en on traditional loo$s, $ostl( on

sh!ttle loo$s. he arp (arns are !s!all( taken directl( fro$ a creel. his allos $i3ing of different (arns in the arp

direction. ther $ore co$ple3 )/%5a"rics s!ch as polar and orthogonal ea#es re!ire speciali'ed ea#ing $achines. +e#eral

ea#ing $achines ere de#eloped to ea#e co$ple3 )/%str!ct!res as ill!strated in 5ig. M!ltila(er ea#ing into a three%

di$ensional prefor$ consists of interlocking arp (arns in $an( la(ers. 4hereas in con#entional ea#ing all of the arp

(arns are oriented essentiall( in one plane, in the str!ct!re.

CONCLUSION

Man( ti$es in the past it as arg!e that Pro*ectile and Rapier s(ste$s ha#e attained $a3i$!$ speed li$it. oe#er,

these $achines contin!e to enhance the speed li$it and are not far "ehind Air%*et $achines. Most of the de#elop$ents are in

the area of attaining "etter fa"ric !alit(, gentl( treat$ent to arp and eft and red!ce "reakages. Another interesting trend

in the t(pe of sel#edge for$ation and aste red!ction, eft aste has "een red!ce to 'ero e#en in Rapier and Air%*et

$achines.

oe#er, the econo$( of this t(pe of loo$ lies ith its increased eft insertion rate per !nit floor space and red!ced

energ( cons!$ption d!ring selection process. It shos great pro$ise for f!rther scale !p of the inno#ati#e ea#ing $achine

for co$$ercial trials. he f!rther trend in de#elop$ents o!ld, pro"a"l(, "e in si$ilar lines. oe#er, one cannot r!le o!t

so$e s!rprising, thrilling inno#ations like +!l'er M)66 t(pe $!ltiphase ea#ing $achines.

oe#er, ne indispensa"le )/%fa"ric $an!fact!ring $ethods, hich ha#e "een pri$aril( de#ised to organi'e and

asse$"le essentiall( three orthogonal sets of (arn in the fa"ric%length, %idth and thickness directions, has not "een a $atter

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89

of e3a$ination fro$ the point of te3tile technolog(. he !se of sandich str!ct!res is groing also #er( rapidl( aro!nd the

orld. Its $!ch ad#antage, the de#elop$ent of ne $aterials and the need for high perfor$ance, lo eight str!ct!res

ins!re the sandich constr!ction ill contin!e to "e de$and.

'I'LIOG/A!HY

1. e3tile 4orld, 0o#e$"er 266).

2. Asian e3tile Jo!rnal, J!l( 266)

). 5RJ echnolog( of 5!t!re, Ma( 266)

. http99.freshpatents.co$9searchres!lts.phpQc3partner

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. http99.pde3cil.org9nes96016629ad#ances.ht$

@. http99.freshpatents.co$9%dt266@112>ptan266@62?)2.php

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