CERTIFICATE OF APPROVAL

THIS IS TO CERTIFY THAT THE PROJECT WORK ENTITLED AUTOMATION IN TEXTILES IS BONAFIDE RECORD OF PROJECT WORK DONE BY, ANSARI ABUZAR (2010009) & GHASIT ZUBAIR (2009010)

IN PARTIAL FULFILLMENT FOR DIPLOMA IN TEXTILE TECHNOLOGY.

GUIDED BY Prof. A.S. Deshmukh

H.O.D. Mr.H.V. Ramteke

Date: 17-05-2013 Place: Mumbai

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SUBMISSION

WE THE STUDENT OF THIRD YEAR OF THE COURSE OF DIPLOMA IN MAN-MADE TEXTILE

TECHNOLOGY HEREBY SUBMIT THAT WE HAVE COMPLETED THE PROJECT WORK AS DESCRIBED IN THIS REPORT BY OUR OWN SKILLS AND STUDIED IT FROM TIME TO TIME DURING THIS PERIOD AS PER THE INSTRUCTION OF OUR GUIDE Prof. A.S. Deshmukh AND WE HAVE NOT COPIED THE REPORT, OR ITS ANY APPRECIABLE PART FROM ANY OTHER LITERATURE IN CONSIDERATION OF THE ACADEMIC ETHICS.WE HAVE MADE THIS PROJECT WITH

DEDICATION AND LOT OF HARD WORK.

DATE: -17-05-2013 ANSARI ABUZAR GHASIT ZUBAIR

SIGNATURE OF STUDENT Signature Signature

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ACKNOWLEDGEMENT
We wish to take this opportunity in expressing my sincere thanks to the people, we are obliged to, for their encouragement and inspiration that they had shown thought this project.

We express our deep sense of gratitude to our revered guide MR. A.S. Deshmukh. His guidance throughout the preparation of this had led us to complete this project successfully.

We also to the very of thanks to entire staff of SASMIRA specially all the librarian, who have deterred us from helping in Collecting the information and data require for our project and we finally thank our parents and friends for giving their Co-operation.

Finally, once again we want to express our deed hearted thank for to my most Respected guide MR.A.S. Deshmukhfor giving moral support throughout this project.

And also We want give thanks to all for seeing us throughout this project.

our well wishers

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Behind every success there is a source of inspiration, in our case Mr. A.S. Deshmukh whose inspiration and constant

incouragement late us to complete this project report to the satisfaction. Inspite of very short schedule of academic work, he spread to his valueable time to us, and acted as friend and guide and not as mere conventoinal guide, therefore take oppurtinity to thank prof. A.S. Deshmukh whole heartedely.

Secondary we would like to regards all the SASMIRA staff specially librarian who giving us the idea about project and also providing us the material for the same. Last but no least we would like to thanks our all the friends for giving us constant incouragement and co-operate us from time to time.

[DMTT]

ANSARI ABUZAR

GHASIT ZUBAIR

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INDEX

TOPIC
1. Introduction

Page No.
6-10

2. modern yarn preparation a. winding b. warping

11-18

3. Automation in warp sizing

19-28

4. Shuttle less wave machine a. sulzer weaving machine b. air jet loom c. water jet loom

29-41

5. Application of computer in textile

42-44

6. Conclusion

45

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Chapter 1

INTRODUCTION
The textile manufacturing process from fibers to yarn and yarns to fabrics involves many processes the fiber when undergoes treatment of opening, carding, drawing, roving and spinning is converted into yarn which then undergoes yarn preparatory treatment that is winding warping then the warp yarn goes for sizing treatment to be ready for being woven into fabric. Automation has been nearly applied to all the machinery involved in the manufacturing from the fabric. The amount of automation being done depends upon the possibilities the need and the available means, while the priorities of these factors already varied. The degree of automation machine to machine and from one processor to another. Automation as always been carried for certain purpose. It may be to reduce the labour, to increase the production, to increase the quality of product and many other reasons are involved. The following description will consider the automation done in various fields of textile.

Materials Handling
One of the most fertile field for mechanisation is heavy of material. One day of manually handling large packages such as bale of cotton are

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gone.Moterised or electric jeeps and jeeps load and unload. Stack, and distribute faster and more economically, then can be done by hand. Throughout the plants hoise conveyers and mechanics dollys.Transport material between operations more easily and more cheaply than can do man power.

Opening And Fitting:

Improved opening and cleaning have resulted in saving areas other than labor specifically when modern equipment are used, a low grade raw stock is capable of yielding an in product equal in quality to that obtain with older machineries and more expensive raw materials.

At the end of blow room, automatic lap changers make things very easier, but also increase the efficiency and quality, especially in conjunction with weaving and storage. These replaced manual cleaning machines like trutzschler yield qualities, which previously attainable only after laborious manual blending in a hand struck.

Carding

The improved methods of opening and cleaning have festered and encouraged the development of better carding techniques. However the major development in carding namely vacuumed stripping has resulted independently of these changes.

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Normally each card required one to three stripping in a shift of eight hours, depending upon the stop being processed. The advantage of vacuumed processing stripping is the work of two labors. To be done by the six or eight man with brash. Not only it faster and cheaper to strip by vacuumed, but working condition are improve and more uniform production is possible.

With heavier laps have come conveyors to replace human tracking and hanging on cards with power laps to lay card tenders assignment can be increase ten to thirty percent.

Drawing
The operation of drawing, disregarding the larger supply package and finished package is notable for improved speed with reduced variations. Todays modern draw frames are six to eight time faster at the rate five hundred meter per minute approximately. More micro dust is extracted in drawing operation. Auto doffing and can change is introduce auto draft levelling is applied on draw frames.

Roving
Now days single process roving is offered whereas the older man remembers the short draft slobbers, intermediate and speeders.

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The processing improvement in converting raw cotton to finish the fabric is not independent unit developments. It operation is depends on its quality and operating characteristics. Not only at preceding steps in preparation but also in how the material are to be handled insufficient operation thus the waste improvement in opening blending carding and drawing laid the ground work for reducing roving processes and tremendous strides in the utilisation of high and super draft in spinning made it practical. No sacrifices in quality have resulted and the saving has been tremendous. Automation has been carried out in limited extend due to greet strides of operation before and after rovings, direct slivers to yarn processing is beginning to eliminate the roving frame.

Spinning
Spinning has always been small package and low production, high operation cost upon the success of which rested much of the manufacturers ability to produce quality goods for market. Any substantial contribution to these operations under the way of not sacrifices in quality has been needed for years.

Spooling and Warping

Automatic spoolers and high speed wrappers exemplify the strides taken by the manufacturers in utilizing the mechanical application to reduce labour cost and improve handling.

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This process at a little to product value. Wears spot and yarn defects are corrected to a limit extent, but basically the operation nearly transfer the yarn from bobbin to beam through the intermediate package.

Winding, spooling and related operations have become automated. Automatic winding and warping have certainly festered. Many of the improvement in spinning packages.

Weaving

Generally speaking, the conversion of fibers into finished product involves three steps, preparation conversion to yarn and weaving. Weaving itself involves two step of preparation the warp and feeling followed by the weaving process. That combined the warp and feelings to make the finished fabrics.

Weaving is perhaps of the first of the any textile operation to have experience. Automation in recent years the three steps in weaving process filling preparation; warp preparation and weaving of fabrics have experienced tremendous automation.

The uni-fill loom winder has combined the filling operation with weaving the uni-fill loom attachment combines many operations, hence

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eliminating labours, transportation and material cost in addition to improving both quality and quantity of the finished products.

CHAPTER-2

MODERN YARN PREPARATION

WINDING:

AUTOMATIC M/C:

The first successful automatic winder was the Barber Colman spooler which still effectively processing substantial proportion of the yarn wound in the world today. Some 50 years after its commercial intro. It is sometime described as semi automatic winder as the broken end on the

unwinding ring tube is not relied but ejected for refeeding. Barber Colman Spooler belongs to large group winder.

The term group winder has evolved as a result of the development of winding m/cs with progressively smaller no of winding position per automatic knotter. Several m/cs are now available with an automatic knotter and a bobbin
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change mechanism at every winding position. So the BC Spooler with up to 306 positions to one travelling knotter clearly warrants inclusions with a large category.

Developments in small group winding m/cs have continued on well defined line throughout the last 20years. Three features appeared to have received most attention in design, the configuration and the no of wind position to be serviced by one knotter, the degree of automation or the transfer of skill from separator to m/c and equipment flexibility. 3 main configurations have emerged there are rectilinear and stationery wind position and travelling knotter and 10-12 wind position/knotter of which the schlafhorst autoconer is typical circular with travelling spindle positions and stationery knotter and similar wind position to knotter ratio, of which the schweiter call is typical and one knotter per spindle rectilinear of which the savio RAS, the morata no 7-11mach coner and the leesona uniconer are typical.

AUTOCONER:

Automatic wind m/c has been adopted mainly for 3,reasons: 1. Reliability 2. Economic viability 3. Excellent uneinding properties of quality package.

Quality and economy are the standard feature assumes package quality due to:

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 Electronic monitoring of the running yarn Sensitive tension device Electronically tested yarn joints Precise build up of package

High production & low Wind cost due to:

(i)Electronically controlled splicing or knotting (ii)Automatic package doffer (iii)Favorable material flow due to inline construction

Amendable and easily supervised working area simple maintenance & operation.

Due to the facility of having various types of supply creel for processing and bobbin spinning flange bobbins full package or the package remains versality of the autoconer is unsurprised.

Autoconer package quality package

Electronic tested yarn joints either spliced or knots Even package density

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 Excellent unwind properties due to adjustable displacement of yarn layers and antique patterning Constant package diameter Constant yarn length Measured transfer tail

Flexibility:-

The textile mill can specify for its autoconer either an automatic splicer, fishermens knotter or weavers knotter, depend on yarn and nature of process. As the autoconer splicer is suitable for all yarns it is now standard feature of m/c.

THE AUTOCONER PACKAGE DOFFER:

ASSURED HIGH PRODUCTION:

The automatic package doffer ensures constant high production. As full package do not have to wait for manual doffing. Bobbin creeling is the most frequent task of the operative, waiting package lead directly to production lossess. The automatic doffer relieves the operative of this task moreover it contributes to the achievement of a more human working environment. Correctly wound on starting layers are essential for achieving a complete run off the yarn from the

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package in subsequent processing. Provision of a transfer tail with adjustable length by the package doffer cost neither time nor money. Producing a transfer tail manually requires 6 min of time. And a package runs time of 50 minutes. The increase in production is about 6% when the packages are doffed automatically.

KNOT PROBLEMS:

The thickness of the fishermans knot is 3-4 times and that of the weavers knot 2-3 times, more than the yarn itself. The bulkiness of knot and tails are the friction point during withdrawal of yarn over the end of the package yarn layers may be dragged along.

To

overcome all the difficulties , spliced join has been carried out ,

the advantage of spliced joint are adequate strength and diameter is nearly equal to yarn with practically not thickening.

SPLICING METHODS

Two different splicing systems which operate with air and refinement have succeeded in automatic winding up to now. The fibers in the yarn are intermingled by air and coupled together in such a way that great many yarns value of 80-100% of the basic yarn strengths are achieved.

On the automatic splicer the ends to be joined are presented to the splicing chamber by the guide elements after closing the cover of splicing chamber and
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positioning the feeder for sufficient over lap , the actual splicing procedure start with the actuation of the cutters. Almost synchronously with the cutting of the end, the compressed air impulse is released by a magnetic value. This electronically controlled compressed air blats initiates three operations sequence. in

WARPING

The objective of all wrapping system, beam , sectional , tricot , etc are to be present continuous length of yarn to the succeeding process with all the ends continuously present with the integrity and elasticity of the yarn as wound fully preserved, this is a deceptively simple concept , the creel package changed dimensionally as the process continues , the beam increase in diameter and provision must be made for constant yarn speed either by contact drum or variable spindle speed .

It is also necessary to adjust the packing density of the beam for different applications .the warping machine has evolved as a highly sophisticated machine . The creel design the down time associated with creel changes and

there are several stages in automation between a simple and single creel and so called automatic creel which reduces creel change time . to absolute minimum and permits over all beam wrapping efficiencies of over 50 %

THE WRAPPING CREEL

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The creel is no longer merely a convince method of holding the yarn packages in position for wrapping but it an integral part of the machine, no single type of creel is capable of giving high beam efficiencies of all yarn material and linear densities, set lengths and final applications, there are for general purpose types of creel In common, use truck, continuous, magazine, chain and automatic with specialist creel for tricot, and sizing machine service continues chain creel.

This principle was first successfully applied by the Barber Colman Co. Over fifty year ago, but many designs, such as Beiger GCA creel, has adopted this basic design feature. The two wings of an acute angled creel are each served by endless chin which moves the column of yarn package holders and tension units round and endless track, transfer in the expanded packages from the position outside the creel wings to the creeling position inside the creel and the creel packages into the running position. Creel changes can be completed using such a system in less than 15 minutes, and significant reduction of this creel change time are unlikely without considerable mechanical complexity which the relatively small potential savings are unlikely to justify. Fig 1 Shows the Beninger creel GCA with the package frame mounted on an endless chain in each wing of the creel. A Creel is being transferred from the creeling position to the running position. The pegs shown as empty will normally carry cone residue from the running position. Into the creeling position where they are replaced by full packages for the next creel. Fig.2shows the GCF creel with Beninger ZDA beamer.

AUTOMATIC CREEL:

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The Schlafhorst automatic creel Z25 is one of the most highly developed creels currently available. It is essentially a truck creel with automatic chain loading and with two features to reduce creel change time. The first is yarn threading. The creeler threads. The yarn from the package simultaneously.

Through tension device and break detector and collects all the ends from one tension column and twists them together before locating them in a holder on the threading truck. As the truck is pushed forward it automatically threads and separates the ends according to creel tiers and column.

The knotting carriage work is conjunction with creel Z25 has the shortest creel change time of any available system. The carriage stands at the rear of the creel during beaming, and is released when running yarn packages are almost expended. As the carriage moves along the creel every end is cut between package and tension devises the live end being secure in the clamp. When the knotter carriage reaches the front of the creel, the operative operates the chain conveyor and remove the creel truck from the creel. The creel trucks are designed with special pegs with clamp at their extremities so that when each cone is is loaded the ends is located in the clamp. The knotter carriage has the separate knotter head for each tier on each side of the creel. When the full creels trucks are correctly assembled by the conveyor chain, the knotter carriage ties one column each side simultaneously. This takes 5 seconds, with seconds traverse time to the next column thus 576 and creel with 48 column per side of 6 tiers will take 5-6 minutes to complete the knotting all the ends.

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Chapter No. 3 AUTOMATION IN WARP SIZING

OBJECTS OF SIZING

To improvewearability of the warp and to overcome inherenet deficiencies of the yarn to with stand the stresses and strains of weaving. This can be attained by improving primarily the abrasion resistance of the yarn. This is turn is achieved with the formation of a film around the yarn along with some penetration of sizing ingredients.

To improve abrasion resistance of the yarn.

To reduce hairiness of yarn.

To reduce generation of static charge for polyster blend yarn To improve breaking strength of cellulosic yarn.

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Winding the warp on to the warp beam

Minimum size take-up, saving in size material, heat energy and perfect beam winding are the worth-mentioning features of new sizing machine.

In the aria of sizing, among the leading manufactures, sucker malterhacoba Germany showed their high-performance sizing machine, for staple fibre and filament yarns separately. The remarkable features of machines are the beam creed (types Am, An) and the beam let-off device (type Ap) the beam-creel can even accommodate shuttleless beam.

Single let-off of warps beam can be provide to use beams of varying diameters. Numbers of ends yarn clots. The individuals let-off control is regulated by the process computer. The size box (types SE and SD) ensures precise size application by even pressure of one or two sequeezing devices, which are independent of machine speed. The warp sheet can be dried undivided or divided into several sheets. The wiessner heat recovery system.Captures up to 30% of the energy in the waste air by means of glass tube heat exchangers. Thus 15% - 20% of operational cost can be saved. The sized yarn winding on beam is electronically regulated. The sized yarn winding on beam is electronically regulated. The lubrication device is used for the application of way and oil to the sized yarn. The dust-extracter is advantage for keeping the sized yarn clean.

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Gamataxsnc of Itlay showed a sizing machine which as and automatic control on speed/ tension, sqeezing, humidity and temperature, so that the values, ones set, are maintained during-production cycles with remarkable guarantee of precision and reliability sizing and squeezing boxes are separate to suit different requirements.

Tsudakoma of Japan exhibited spun sizing machine (HS-2011) which has many optional devices to suit her users requirements. The machinery two-size boxes and the touch-free vertical yarn sheet pullout system. The letter system reduces full and yarn breakage. It pneumatic band brake, which ensures optimum yarn tension control for irregular diameters of back-beams. The sequence of he sizing process and the objectives of automation. Figure shows the functions of warp sizing. There are basically five processing areas involced in the production of a sized warp namely. Size preparation including storage and supply to the machine, in which chemical or natural products are made up into aquarius liquor and prepared for the sizing machine. Running-off the yarn from the section beams. Sizing of the warp yarns ile application of the size liquor to the yarn Drying of the yarn. Winding the warp onto the warp beam.

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In sizing preparation, problems of size quality & process control are the primary reasons why certain functions in the process are assigned to control systems. In unwinding from in the sections beams the aim is to improve warp quality by reducing end break frequency and also the increase, sizing machine output by high unwinding speeds. In the wet zone,, the prime considerations in automation are uniform optimum size application and economy of size usage. In dryer design, greatest importance is attached to maximum throughout, energy sawing, heat recovery and economy development in beaming machines on the others hand involve improvement of warp beam quality combined with a significance reduction in the operatives work land. Manual duties can be carried out automatically by suitable mechanism as explained below: With some degree of standardisation in size agents, feed stock supply can be automated by silicons and metering devices. The operative then only has to preselect addition of size in according with a prescribed recipe and set the matering system. One important function in size preparation is meeting the quality specification, as incorrectly made up size liquor can create problems in weaving. The risk can be overcome by using boiling up system incorporating process control. The boiling up process then follows a programmed sequence combined with continuos measurement of velocity temperature and time. As soon as the present values are reached and the size thus attains the intended quality, the formation is realeased for transfer into the reservoir.

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The size is stored in reservoirs which should be situated in the vicinity of the sizing machine and away from size kettle. The transfer system allows monitoring of the reservoir contents from the size kitchen by remote display and automatic filling immediately as need arise. The operative can thus monitor requirements and replenishment of the sizing machine centrally from the size ketches. Transfer of size from the reservoir to the size box can be automatically controlled in accordance with size usage in conjunction with a measuring and matering system without the need for operative involvement. A combination of all four of the above solutions ensures constant size quality, resolves loading and transfer problems and provides maximum convenience to the operative. The operative is only left with monitoring duties which take up relatively little time.

SIZE INGREDIENTS:

A warp yarn should be strong, elastic, extensible and smooth. The ingredients used in sizing are usually starches and gums and fatty or oily substances. The two type of ingredients tend to have apposing effects on the yarn and a compromise has to be made to yield the lowest end-breakage rate. Other ingredients are commonly added to the size, including anticeptics, antimidew agents, etc.

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Typical ingredients for water based liquors are shown in table-1 ingredients for water based sizes.

Adhesive Potato starch Starch from cereals (corn, wheat, rice etc.) Carboxy methyl cellulose (CMC) Polyvinglealconol (PVA) Polyvingle chloride

Lubricants Mineral waxes Vegetable waxes animal fats

Additives Salicyclicacidf Zinc phenol chloride

Mineral oils

Emlusifiers

Vegetable oil

It is possible that non-aqueous liquors will be used increasingly in the future, but there is as yet little experience in this area.

Consequently, only a queous solutions are considered in the text. [typical recipes are given in table-2]

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The adhesive usually in granule form is mixed with water and heated to form a paste which ultimately becomes a viscous fluid. Starch is a complex carbohydrate which combines with water, this causes the materials to swell & change character. The viscosity of the boiled starch is controlled to a great extent by the amounts to which the surface of the granule is dissolved. This in turn is affected by the recipe, the degree of mechanical mixing, the temperature and time of boiling.

[typical viscosity curves are shown in fig-3]

It will be seen that under certain conditions prolonged boiling will cause a decline in the viscosity. Similar effects can be obtained by over-vigorous mechanical working. In both cases, this is caused by breakage of the fairly weak hydrogen bonds formed during the gelatinizing phase.

Although viscosity is important, there are other factors to be considered in relations to feeding, if for instance, the size particles are affected by heat alone (e.g.melting of the waxes), the material might clump together and not feed properly. Similarly, in a wet feed system, trouble might be caused by premature gelatiniziation of the material before it reaches the place where it is boiled.

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Lubricants, soaps, and waxes, are commonly used, the letter acting as softeners. Without such softeners, the yarns would not be sufficiently extensive further more, the size would crack and particles would drop away from the yarn; this in turn; would create local stress concentrations and encourage end breaks.

The most important factors in choosing size ingredients are:

a) The recipe should be that which givesfewest and end-breaks in weaving. b) The recipe should be that which givesthe least amount of exfoliations (dusting off) c) The recipe should be that which permit easy size removal in a later operation. d) The recipe should be that which gives good fabric characteristics, e) The recipe should be comfortable with the machinery. f) The recipe should not cause any heald hazard. g) It should not cause any degree of textile material. h) Cost of sizing plus cost of weaving and finishing should be minimum.

FACTOR WHICH AFFECT PROPERTIES OF SIZED YARN

1. The percentage of lubricant to adhesive material.
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2. The amount of size put on yarn. 3. Technique of sizing, such as yarn speed temperature of dying, tension etc. The ingredient and techniques must be chosen to full-fill the requirement metntioned earlier.

Warp Sizing Machine:

1. Cylinder drying. a) Two cylinder type b) Multi-cylinder type 2. Hot air drying 3. Combined system.

Machines may be further classified according to method of yarn supply as indicated in figure. A sizing machine contain a number of components sections. The beam creel is a frame which carries some 8 to10 warper beam which may be arranged in various ways. The arrangement shown in figure can give equal tension in all sheet but it requires most space of three alternatives the arrangement shown in figure reduce the space required but it is at the expenses of tension uniformity. The third alternative is a compromise. Negative let-off is normally used

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because of its simplicity but occasionally the beams are directly driven and control to

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Chapter 4

SHUTTLE LESS WEAVING MACHINE

A)

AS SULZAR WEAVING MACHINE

INTRODUCTION

The idea of gripper type weaving American inventor Mr. Salisberry in 1901. Latest swizer machine are consider best all modern weaving machines due to their excellent technical and commercial performance. They can produce various type of weaves using a very wide range of natural and synthetic yarn.

General Description

Shorter run more varied production and need for increase productivity have late to situation in weaving where by setting up a weaving loom. And a particular executing style changes quickly and efficiently have become of paramount importance. Sulzer projectile weaving see the need to approach the problematic nature of style changes has been essentially one of logistic and judicious calculations. In order to organize man power expenditure , machine down time, material flow and order processing for optimum economic efficiency.

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The quick style change ability of sulzer projectile weaving machine is helping cut down time needed for style changes and at the same time is helping increase productivity time. Additionaly it create potential to protect extra order and generate increased profit ability.

In this m/c the weft yarn introduced into shed by means of projectile the high performance low number of thread break short time required for warp and weft changes mimimum setting work low wear and high reliability are the reason for up the particular good relationship between the cloth output and labor input on sulzer projectile weaving machine.

All the above advantages which positively influences the performance ratio of the machine. Thus this several function have made sulzer projectile weaving more and more profitable over the automatic and conventional looms.

PREPARATION FOR SHUTTLE LESS WEAVING MACHINE

Shuttle less loom require a high standard or yarn preparations. This requirement is vital if highly expensive shuttleless looms are to be run at a higher efficiency and with a reason allocation.

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WARP PREPARATION

Warp preparation of standard comparable with those acceptable for automatic looms are used there will be less warp breakage per pound of yarn than when same yarn is woven in automatic looms preparation changes have been found for improvement associated with the change of weaving principle.

The remarks apply to carded yarns, medium count combed yarns are found to present less difficulty than yarn is count range 12s to 20s whichis emerging as most economic field of application for this type of weaving machine.

The object of all warping systems beam, sectional or other specialist type, is to present a continuous length of yarn to succeeding process with all the ends continuously present and with integrity and elasticity of yarn as would fully be preserved.

WEFT PREPARATION

Weft insertion rate is high and unwinding is intermittent on projectile weaving machine. So it is essential to have anti patterning device to prevent the slough off the fabric.

On the projectile weaving machine the weft is unwounded from on stationary packages creeled on the machine frame. Thsu no weft reserve is carried along the shed as in shuttle and multiphase weaving. Due to this large size yarn

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packages, considerably large then the main advantages of projectile weft insertion system because it considerably reduces the amount of labor connected with the weft supply to the weaving machine.

PRINCIPLE OF SULZER PROJECTILE WEAVING MACHINE

In common with all high performance shuttle less weaving machine the Sulzer differs from a conventional automatic loom in two respects, viz. the method of weft insertion into shed and method of moving reed including projectile track other motions including shedding. Take-up and let-off are simply variants of known mechanism. This chapter contributes to information on working principles of Sulzer weaving.

The basic mechanical principles of Sulzer projectile weaving machine are to be considered as follows:

1. Shedding 2. Beat-up mechanism 3. Take-up and let-off mechanism 4. Weaving with than one color in weft 5. Selvedge formation.

Apart from this principles other mechanical principles are also include in this.

SHEDDING:
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in Sulzer projectile weaving machine, the shed can be produced by means of tappet, dobby and jacquard. These units are precision built to meet high speed requirements of weaving machines. The depth of shed produced. On produced on Sulzer loom is about 2-5 inches or 6.35cm where as this depth of shed in much larger in conventional and automatic bobbin changing looms, hence warp threads are subjected to less straing in Sulzer weaving machine. But warp breakages are high owing too much greater than speed of loom.

PICKING SYSTEM:
In Sulzer projectile weaving machine. Picking is done with torsion bar, several gripper projectiles are employed for the sulzer shuttleless weaving machine. They are return to the picking side by conveyer fitted below the warp ends. The gripper carries the pick of weft through the shed using shear strain energy, which is stored in the torsion bar. Shear strain energy it derived by twisting torsion bar to a predetermined extent and triggering off to provide the means of propulsion. This principle has several considerable advantages. As the energy available for picking depends only on the angular displacement of free end for a particular design of torsion bar the strength of picks is completely independent of the speed of the machine. Secondary the energy can be used to attain very high velocity, as the mass being projected is very small.velocities approximately twice as great as those commonly used for shuttles i.e. 80 feet/sec. as the gripper si returned to the picking side by a slow moving conveyer operating between the receiving box and the picking unit and fitted below the shed, it can be lifted accurately into the picking position so that shed picking always commences from a previous pick. This means that a constant picking force is
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consistently applied to the gripper to the gripper. The gripper projection energy is about 1/3 to of that normal experienced in conventional shuttles.

TORSION BAR PICKING MECHANISM

The picking arrangement in the sulzer shuttle less weaving machine may as seen in fig. the drawing illustrates the torsion bar picking system of this loom.

The torsion bar (A) has its splined end (B) rigidly constrained in and adjusting the twisting angle and hence the gripper projection velocity. The other end of the torsion bar is splined into the picking arm (C), which carries the picking shoe (D) at its upper extremity. The gripper (E) is shown in the shuttle lifter with the gripper spring opener (F). the conveyer is not seen in the fig. but it is placed under the warp shed at the back centre picking position.

The bevel wheel drive (G) rotates the picking cam shaft (H) which carries the picking tappet (T). the pivoted lever (S) is rigidly connected to the torsion bar and through a short linkage to the toggle plate (R). theaction of the cam is for the small bowl (P) to bear against the toggle (Q), rotating anticlockwise about the centre (O). thus withdrawing the picking shoe to its nearest position.

In this position the three centre of toggle arrangement are in line and the torsion bar is twisted to its maximum. The nose of the picking cam then bears against the bowl carried between the toggle plates and moves the central pivot, of the toggle arrangement off the line of centres. Thus permits the whole of shear strain energy to be transmitted instantaneously to the gripper. The gripper leaves
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the shoe after about inches of travel at 78 feet/sec2 at a point about 0.6 from the gripper rest position. The residual energy in the picking system is absorption by the hydraulic system about 62.5% energy is dissipated in the picking unit break. The body (m) are also shown in the figure. The gripper guided (k) are also shown. After the gripper has come to rest under the shuttle brake it is returned 1.6 inch to 1.8 inch in a fixed position in relation to the receiving side selvedge prior to being ejected into the receiver the dropped on to the conveyer. The picking track is locked between the picking and receiving units at the back centre and the pick is delivered across the stationary sley race. The forces acting on the gripper, other then gravity are picking force and yarn tension both acting along its major axis. The guide blades are lubricated with oil, picked up from the gripper. As a result, the

B) AIR-JET LOOM
THE ELIMINATION OF the ubiquitous shuttle has for many years exercised the minds of many who have come in contact with the weaving process. The first recorded attempt at substitution of the shuttle by a jet of compressed air appears to have been made by J.C. Brooks, a native of accrington, Lanchashire, who emigrated to the U.S.A and was granted a patent in 1914. Fifteen years later, in 1929, E.H. Ballou took out a patent for a method of air jet weft insertion which differed from that of Brooks in providing, among other details. A suction which differed from that of Brooks in providing, among other details, a suction nozzle in addition to the blowing nozzle. Finally Mr. Max paabo, an Estonian by birth, who went to sweeden as a refuge sometime around the end of the war, developed the air jet loom known as MAXBO
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ESSENTIAL REQUIREMENTS:
An essential feature of air-jet picking is the provision of a device which will serve, prior to or during weft insertion to measure off a length of weft sufficient for the width of cloth being woven. With gripper shuttle and repier. System such a device is unnecessary, the carrier on the former type of loom, being checked at the end of its flight, while on rapier looms, the rapier with weft attached, is moved positively a predetermined distance. With the air jet system, however, the air, as it passes though the nozzle entrains the weft and drags it through the warp shed. If unrestrained, the weft would be prepelled at a speed dependent on the drag-force acting upon it due to the friction between the jet and the weft. This force acting upon it due to the friction between the jet and the weft. This force is in turn, a function of nature and velocity of the air jet of the characteristics and dimensions of the weft. In addition, the changing dimension of the weft package tend to cause disturbance of the conditions behind the nozzle. Not only therefore is an efficient meter necessary to counteract these varying factors, but without such a device uniformity of weft thread length from pick could not be guaranteed. It is also important that, the requisite length having been measured. The weft should be released without restraint, so that on emerging from the nozzle, the maximum velocity dependent on the drag-force developed can be rapidly achieved.

The character of the issuing jet of air is of it will be evident that an everpresent problem of pneumatic picking is air-stream control and that some method of confining the stream is necessary. But, no matter how effective such a control system may be, there are so many factors contributing to undulation of the weft

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that some form of straightening device is necessary, particularly at the receiving and.

The following items may therefore be considered as essential requirements for successful air-jet weft insertion: i. ii. iii. iv. v. A pre-measuring device A short quick air blast A nozzle preferably not attached to the sley Air-stream control and A suction device at the receiving end.

THE MAXBO LOOM:

The MAXBO air-jet loom does not differ in principle from a conventional loom except for the method of weft insertion. Elimination of the shuttle has resulted in several modifications in the traditional design of the loom. Thus, it is no longer necessary to arrange for the closed shed-line to be in an approximately horizontal position, the warp-stop motion can be modified, shedding dwell can be dispensed with and other changes made in the general design. That advantage has been taken of these possibilities in the design of the maxboloom will be evident from fig. which shows schematically the passage of the warp. The loom consists of a simple cast iron framing with a fixed flange warp beam located at the back and occupying about 24 sq.ft. of floor space. The warp sheet passes vertically upward

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to the intermediate roller and over a tension roller which is approximately 5ft. above floor level. The yarn is then passed over the back and front guide rollers, with the warp stop motion situated between the two. From the front roller the warp descends at an angle of 150 to the vertical (increased in later to almost 450) is drawn through the healds. The heald frame ends being mounted in slides, which make and angle of 150 with horizontal. The reed immediately below the healds has its metal baulks in the top and bottom reed cases fastened to the sley by set screen.

SCHEDDING:

Positive shedding can give approximately simple haromonic motion to the healds shaft without dwell at speed of 310 ppm. The time for sheet crossing is to facility of nozzle in the event of weft break.

The picking machenism consist of 1. weft measuring device 2. blowing nozzle

PICKING SEQUENCE

The weft is drawn from stationary supply package mounted at floor level at the LHS of the loom. Then passes underneath a nylon tension wheel over the
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surface of measuring drum and into the drum through a guide eye situated at the centre of drum the projecting pin on the surface of measuring drum is withdrawn by a cam action at the same time.

(C) WATER JET LOOM

The first loom to make a use of water jet for insertion of weft was developed by Czechoslovak engineer vladimisvaty. When the loom was first shown in western Europe at the Brussels. Textile mechinary exhibition 1955 largely regarded as a cureocity. The participants in an international symposium of shuttle less weaving where able to visit in installation of more than 150 water jet loom. It becomes clear that a development as taken place which could not be ignored.

Technically this is an extremely interesting weaving machine which deserve close and careful study. The purpose of these chapter is to study basic physical principle underline hydraulic weft tension.

GENERAL DESCRIPTION
Apart from methods of its weft insertion the water jet loom does not differ in principle from a conventional loom and a brief out line only of its main mechanism will therefore the suffice the warp beam is of conventional size but is mounted considerably higher than on conventional loom is can be seen in figure. It is possible to rotate warp beam forward and backward by means of handwheel

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situated at front of loom. The warp passes over a single loaded roller. Which takes place of back roller in a conventional loom.in additional advantages of these slopping warp line is saving of floor space.

1) SHEDDING

Shedding is carried out by negative dobby. Can sure crane motion which in most of the looms are for B shaft. The selvedge is formed by a conventional type of leno motion. The heal shaft moves at right angle to the warp line. The picking operation is carried in fully open sheet.

2)PRINCIPLE OF WEFT INSERTION

The weft supply in the form of cone of bobbin is situated at the LHS of loom. The four main stagesof weft insertionis shown in figure.

THE WEFT SUPPLY SYSTEM

It is illustrated in figure has four main portion. 1) to apply tension on the weft before it is wound on to measuring device. 2) To measure required weft reserve on each pick. 3) To apply tension to the weft during picking. 4) To pull the protruding end of weft back into the nozzle after the operation of cutter.

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OPERATION OF WEFT SUPPLY SYSTEM

The sequence of operation by which the weft supply system functions can be explained with reference to the figure.

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CHAPTER 5

APPLICATION OF COMPUTER TEXTILES

LOOM MONITORING

The heart of mill is weaving shade where much of the advance process control development has taken place by linking a computer to a loom for monitoring purpose computer maintained direct and continuous contact to via sensing device which a loom the computer automatically polls each loom sensor one every minute and legs of on to a magnetic disc records the on off condition. The warp stops, weft stops and any other stop by mechanical reasons.

COLOUR MATCHING

For a mill man computer color matching is most important and profitable area in textile industry.

Computer matching of color for virtually any type of substrate and all kinds of fabric is a fast maturing science. The computer is reducing color matching time from days and weeks to hours and

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minutes. But there is an also impressive pay out in more accurate matchs better color quality, dye stuff cost saving and saving in dye in inventory investment. The principle involved in the color control system can be out line in three stages. 1. Determination of di characteristics 2. Recipe formulation of computer 3. Recipe correction if necessary

COMPUTER IN TEXTILE DESIGNER

The increase variety of available fibers and textile manufacturing method make it imperative for new methods of textiles designs to be developed, both in order to achieve optimum solution to design problem and because the traditional ground rules no longer apply in new situation. Computer Added Design is the key to the new situation. Furthermore it offers a chance of bringing a designing much close to the production process which is important both in itself and as a means of reducing significantly the tile leg between appreciation of need for a new design and its appearance in the shops.

The designer can display the design on a grid with different ratio of horizontal and vertical lines. They can also vary the number of warp
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yarn per inch to see the design good look if woven with different degree of coarseness. They can even repeat the design with different spacing between center or specify different lines of symmetry and thus develop a full design from a small segment.

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CHAPTER 6

CONCLUSION
The modest step towards automation here altered the production sequence in spinning mills it is also evident however that keeping up with its technical evaluation and achievement. Automate isnt easy specially when the cost are consider automation has only just started it will continue to gain ground both in purely technical process and also specially in splitting the possibilities opened by microprocessor.

The desirably of perusing the technical change has been recurrent them in the textile industry for many decades. The guiding force and we find seeing reliance on technology as a means of copying todays problem and creating tomorrows opportunities.

Impelled by general progress technical advance and economic expansion. Machine engineering has quickened its face of development and wideled its scope. Undoubtedly the shuttle less weaving machine now has the greatest important in overall pictures with nearly all leading weaving producers engaged in development new or existing shuttleless design.

Thanks to economic flexibility and ability to follow fashion sulzer machine holds a dominating position in weaving.

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REFERENCE
1. Indian textile general 1996.

2. Weaving conversion of yarn to fabric.

3. International textile bulletin

4. Bitramono graph series on winding

5. Process control in winding

6. Autoconer system 283

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