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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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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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). 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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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!$!lators.
L55@ T
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Microprocessor control l!"rication s(ste$.
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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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 $aintenance. here are no toothed "elts, hich are prone to ear, and "reakage.
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SUMO MOTO/
+a#ing on energ( cons!$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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4eaker filling (arn can "e !sed.
Correct setting of filling aste length and conse!entl( less aste.
;SC (;6$ S#
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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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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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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 $atter
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of e3a$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)
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