[WARPING]DEFINITION: Transferring many yarns from a creel of single end packages forming a parallel sheet of yarns wound on to a beam or a section beam.

OBJECTIVES: To prepare warp either for a loom or knitting machine. Placing equal length of yarns parallel to each other on a beam or

drum. Collecting the required number of yarns. Transferring yarns from small packages such as cones or cheese to

warp beam. Introducing a pattern/ design (sequence of colored yarns).

TYPES OF WARPING: 1. High speed warping or direct warping 2. Sectional warping 3. Ball warping

Suraj cotton mills limited (weaving unit)use high speed warping so we discus only this type of warping in detail.

HIGH SPEED WARPING: Yarn transfer directly onto a wrapper beam.

Useful for long runs of fabric. More productive as compared to other warping. A flange beam is used, since all yarns are wounded at same time, the

flanges provide sufficient yarn stability on the beam.

Warping machine sections: Warping machine have two major parts

Creel Headstock

CREELFrameworks on which yarn packages are placed while the warping take place.

Types of creelsTwo basic types

Fixed type Moveable type

Some other types are Automatic creel Unrolling creel

Because in high speed warping V –shaped creel is used also in suraj cotton mills limited so we will discuss this type of creel.

Parallel types of creel are used for sectional warping and direct warping.

V-shaped creel has a number of types given below. We will discus only one type that is used in high speed warping.

V-SHAPED CREEL: V-creel with reversible frame. V-creel with traveling packages.

HEADSTOCK Headstock houses the driving mechanism and machine control. It is the heart of warping machine. Parts of headstock and creel will discuss briefly on next pages.

SPECIFICATIONS OF WARPING MECHINES IN Bhanero textile.Machines # 1Name Ben –DirectMake 2005 Made Benninger GermanyMaximum Speed 1200m/minRunning Speed 600-900m/minType of drive +veNo of wings 2Creel w.r.t shape V- shapeCreel w.r.t construction chain typeNo of columns per wing 60 No of spindles per column 9Creel capacity 1080Stop motion sensor capacitiveBeam width 2400mmWorking width 2400mmFlange dia 980mmBarrel dia 300mmCreel angle 35degree

Machines # 2Name Ben –DirectMake 2005 Made Benninger GermanyMaximum Speed 1200m/minRunning Speed 600-900m/minType of drive +veNo of wings 2Creel w.r.t shape V- shapeCreel w.r.t construction chain typeNo of columns per wing 60 No of spindles per column 9Creel capacity 1080Stop motion sensor capacitiveBeam width 2400mmWorking width 2400mmFlange dia 980mmBarrel dia 300mmCreel angle 35degree

CREEL ANGLE CALCULATION:

An Angle b/w two wing of creel is known as creel angle. To find creel angle first we find wing angle i.e. half of the creel angle.

Distance b/w two back column D = 1101.5cm Distance b/w two front column d = 190cmA and B is length of wing = 1502.1Now D – d = a 1101.5 – 190 = 911.5cm A/2 = 911.5/2 = 455.75cm From diagram Sin `c, = a/2/A = 455.75/1502.1 = 0.30341And `C, = 17.66degreeThis is wing angle; creel is double of this angle. So creel angle = 2c = 2*17.66 = 35degree

WARP BEAM CAPACITY The maximum length of warp sheet that we can warp on warp beam

is called warp beam capacity. It is measured in term of length in meters.

Length (meter) = 1.33*D* (A2 – B2)*L*C/EWhere D = density of warp beam (g/cm3) A = flange dia (mm) B = barrel dia (mm) L = space b/w two flanges (mm) C = count of yarn E = total ends per beam Density of warp beam depends upon

Speed of warp beam Creel tension Pressure b/w drum & beam

Space from 0.5cm is left from each side as warp sheet may damage.

Density for different qualities use 20Ne 0.35g/cm3

60Ne 0.45g/cm3

40Ne 0.50g/cm3 SET CALCULATIONSCreel capacity = 1080 (1060 were in use)Machine = BenningerCount = 40Cone weight = 4.167 lbs.

Quality = 60 × 60 × 110 110" 180 × 106Total ends = 13530No. of beams = Total ends Creel capacity = 13530 / 1060 = 12.764 = 13Ends per beams = 13530 / 13 = 1040.76 = 1041 / 6, 966 / 8Cone length = Cone weight × 768 × count = 4.167 × 1041 × 40 = 173543 mWe will take 1% cone remainder, Length taken = 173543 mWe take set length by dividing length taken to the total number of beams;Set length = cone length / beam = 173543 m / 13 =13349m

We have two creels,No. of bags = total ends × no. of creels No of beams × cones / bag = 13530× 2 13 × 24 = 86.73 bags = 86 bags 1 cone

PARTS OF CREEL V-shaped reversible creel is used in high speed warping. Condition when outer portion is working the inner spindles can fill

by packages. Chain type V-shaped creel is used when it need to high speed and

more production. Chain moves by an electric motor and columns move with the help

of chain. We find maximum creel capacity by following formula.

Creel capacity = 2*no of columns * no of spindles/column = 2*60*9 = 1080

CREELV-shaped creel used in high speed warping and has following major parts.

Vertical rods (cone stands or columns) Spindles Yarn guide Tension rods Thread brake Opto stop Cutter Drive arrangement

Pneumatic and hydraulic pressure arrangement

MAINTENCE SCHEDULE The maintenance schedule for warping is following on the basics of period;

1. Machine cleaning one time in one shift.2. Oil change of hydrolic system after 6 month 2 tymes in a year.3. Oil check in every shift.4. Rod sensor cleaning in a one month5. Creel cleaning and Head stock one time in a shift.6. Bearing and beem break checking in every shift.7. Mechanical and power techniciion in every time.

The existing maintenance schedule is followed strictly. These schedules are quite satisfactory as they fulfill machine’s maintenance demands. Daily cleaning and check list is checked and recorded. TO CALCULATE (lb./break) Formula

Lb./b = E*L*1.0936/840*Count*no. Of breaks Where E = ends to be warp L = length to be warp Lb/break determine the quality of yarn (weight method).Table for yarn Breakages on Warping Machinesr.# Name of yarn

break Identification Source of

fault1 Paper cone cut Cut on paper cone winding2 Weak yarn Yarn is break spinning3 Loose yarn Cone is not so dense winding4 Lepta yarn bundle of yarn joint winding5 Cone short Not enough length winding6 Double yarn or taar Two yarn joint winding7 Cut cone Cut on cone transport8 pp. plastic Plastic thing are spin

with yarnspinning