NATIONAL UNIVERSITY OF ENGINEERING

FACULTY OF CHEMICAL AND TEXTILE

ENGINEERING
ACADEMIC DEPARTMENT OF TEXTILE ENGINEERING

LABORATORY OF TISSUE-FORMING SYSTEMS II

PIT-32/A
ACADEMIC PERIOD 2019-2
REPORT N° 4
“WORKSHOP 4

TEACHER: Eng. Rigoberto Marin Lira

MADE BY: Fabbian Marcelo Zegarra Montoya

DATE OF COMPLETION OF THE PRACTICE: 11/25/19

REPORT DELIVERY DATE: 12/2/19

LIMA PERU

INDEX
 NATIONAL UNIVERSITY OF ENGINEERING..............................................................1
FACULTY OF CHEMICAL AND TEXTILE ENGINEERING....................................1
INDEX.....................................................................................................................................2
2.1 DRIVE:..............................................................................................................3
2.3 UNWINDING OF THE WARP AND REGULATION OF THE FABRIC:....4
2.4. PULL ELEVATOR DEVICE:..........................................................................5
2.5. PRAM FINDER DEVICE:................................................................................5
2.6. TRIGGER MECHANISM OR TRIGGER BOX OR “SU” BOX....................6
27. RETURN TRANSPORTATION OF THE PROJECTILE:..............................7
28. BATAN DRIVE:...............................................................................................7
2.9. RECEPTION MECHANISM OR RECEPTION BOX OR “FA” BOX...........8
2.10. EDGE AND INTERMEDIATE EDGE MECHANISM:..............................9
1.

1. AIM

• Identify both the brand and model, as well as its main characteristics (weft
insertion system, shed formation system, maximum number of frames, etc.) of
the looms observed in the SULZER TW-11 loom.

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 • The calculation of the working width and the folder will be determined, in
addition to the shrinkage of the weft.

2. VISIT TO THE UNI FLAT WEAVING PILOT PLANT

2.1 DRIVE:

❖ Allows you to verify operation.

❖ It makes it easier for us to observe the timing of tissue formation and in this
way we ensure that it is synchronized.
❖ This movement is carried out by a motor that drives the mechanisms
through trapezoidal belts and flywheels.
❖ The flywheel serves to regulate the timing for changing the cams.

2.2 CONTROL INSTALLATION:

❖ It allows us to quickly verify that the mechanical function of the different

groups of the weaving machine is in optimal working conditions.
❖ This device generates a machine stop in the event of a component failure.
The equipment stop mechanism occurs mechanically or electrically.

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❖ The stop system is located to the left of the flywheel.

2.3 UNWINDING OF THE WARP AND REGULATION OF THE FABRIC:

❖ It is carried out by the thread holder using a system of levers and a disc
clutch.
❖ This mechanism allows us to regulate the tension of the warp threads.
❖ The movement of the thread guide is driven by a worm gear

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 warp regulator Fabric regulator

2.4. PULL ELEVATOR DEVICE:

❖ The main function of the eccentric is to form the puff in a 360° timing.
❖ They contain a lifting device with which all the paintings can be placed at the
same height (non-stall position at the same height)
❖ This device simplifies splicing time for thread breaks.

2.5. PRAM FINDER DEVICE:

❖ Look for the broken passes to remove the plot and start again.
❖ The frames go back to the previous puff and this causes the eccentrics to go
back.
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❖ When the loom is working and the weft breaks, this causes the shed former
to synchronize with the fabric winder.
❖ Allows the shedding mechanism to move.

2.6. TRIGGER MECHANISM OR TRIGGER BOX OR “SU” BOX

❖ This movement begins when the projectile is placed in the firing position, it
hooks the end of the thread and is accelerated by the firing lever of the
torsion bar at the moment of firing.
❖ After the shot, a scissors cuts the thread at the end of the movement and the
remaining end is delivered to the next projectile.
❖ The number of times the projectile is launched is the same as the RPM of
the engine.

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27. RETURN TRANSPORTATION OF THE PROJECTILE:
❖ This movement is carried out through a chain that is located under the shed.
❖ This chain forms a channel over which projectiles are returned from the
receiving mechanism to the firing mechanism.
❖ It is carried out using the drag links of a constant running chain.

28. BATAN DRIVE:

❖ It is located inside the loom, it is difficult to observe.
❖ At the insertion of the frame the fulling mill is stopped so that the firing bolt,
projectile guide and receiving bolt are in one line.

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❖ In comb fulling, the guide teeth are hidden downwards, outside the shed,
and thus leave the weft thread free through an opening directed upwards.

2.9. RECEPTION MECHANISM OR RECEPTION BOX OR “FA” BOX

❖ The projectile leaves the end of the weft thread free and is moved to the
return transport device.
❖ The receiving mechanism can move parallel to the shooting direction and
thus adapts to the respective working width of the weaving machine.
❖ Through the reception mechanism, the projectile is slowed in two steps, until
it comes to a complete stop.
❖ The regulation of these brakes is done mechanically.

2.10. EDGE AND INTERMEDIATE EDGE MECHANISM:

❖ The selvage forming system is located at the beginning of the firing and
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 receiving mechanism.
❖ We find the scissors in the area of the firing mechanism and there will only
be one scissors per fabric.
❖ When weaving several pieces simultaneously, selvedges are formed at the
separation points of the fabric using intermediate selvedge mechanisms.
❖ In the intermediate selvedge mechanism we also find a scissor.
❖ The thread ends, 1.5 cm long, are inserted bilaterally in the next shed and
woven with the weft thread that they are inserted, thus forming a solid
insertion edge.

Intermediate selvedge forming mechanism

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 IMAGE 1: THE SULZER TW-11 LOOM

IMAGE 2: SHOWS THE SULZER TW-11 LOOM THE FOLDER AREA

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3.SULZER TW-11 LOOM

3.1. CHARACTERISTICS OF THE LOOM

❖ Maximum working width: 330 cm

❖ Weft insertion system: projectile
❖ Shed forming system: eccentric
❖ Maximum number of frames: 10 frames

3.2. CALCULATIONS ON THE LOOM

❖ CALCULATION OF THE WIDTH OF THE FOLDER

ITEM ACTIVITY RESULT

CALCULATE THE WORKING WIDTH (AT)

1 Calculate the working width according to the working width 330.4cm
calculation format

SEPARATION BETWEEN FOLDERS (SP)

2 Measure the distance between the twin beams of the SULZER 10.4cm
TW11 loom

CALCULATION OF THE FOLDER WIDTH (AP) 330.4-10.4

3 Calculate the width of the folder using the following. Formula: (AT- Ap=( )
SP)/2 Ap=160cm

Measure the entire width of the folder and compare the

4
differences%
158.2 - 160I x100%
2 =1.14%

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 CALCULATION OF WORKING WIDTH

ITEM ACTIVITY RESULT

MAXIMUM WIDTH OF THE LOOM (AMT)
1 Look for the plate that indicates the width of the loom 130”=330.2cm

COMB WIDTH (AP)

2 Find or calculate the width of comb to be woven 163.7cm

NUMBER OF FABRICS (NT) 130" 2.54cm

Find or calculate the number of fabrics to produce from the -----------x -—
3 163.7cm 1"
following. Way: AMT/AP =2

NUMBER OF INTERMEDIATE EDGE FORMING

MECHANISMS (OI)
4 Calculate the number of intermediate selvedges, which is the 2-1=1
number of fabrics minus 1

At=2x163.7+1x3
5 CALCULATE THE WORKING WIDTH (AT)
At= 330.4 cm
Calculate this value as follows: NTxAP+(NT-1)x3
I330.2 - 330.4I x100%
MEASURE THE ENTIRE WORKING WIDTH AND COMPARE 2 =0.06%
6
THE DIFFERENCES %

❖ CALCULATION OF THE WEFT SHRINK PERCENTAGE

ITEM ACTIVITY RESULT

COMB WIDTH (AP)
1 Find or calculate the width of comb to be woven 163.7cm

FABRIC WIDTH (AT)

2 Measure the width of the fabric you are weaving. 151.8cm

CALCULATE % SHRINK
Perform AP-AT subtraction 11.9cm
Divide the previous value by the AT Multiply by 100 to the -and-,----x100%
3 151.8cm
previous value =7.839%

❖ Production calculation on the loom

ITEM ACTIVITY RESULT

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 MEASURE LOOM RPM (RPM)
1 Use the tachometer and measure the RPM of the loom 300RPM

CALCULATE WEFT DENSITY (Dt)

54 pas_^^ 6 pas
2 Use the thread count and calculate the weft density 2.5cm . cm

CALCULATE THE THEORETICAL PRODUCTION

(MT/HR) 300rev
min cmpas 60min 1m
3
Apply the hourly production formula Way: (RPM/Dt) x (60 =8.33 ^ e hn
21.6 100cm

min/1h) x (1m/100cm)

CALCULATE WEEKLY PRODUCTION (MT/SEM) P( ^ )= 8.33 ^myx24x7x0.8x2 x

wk
Apply the actual production formula (MT/HR) n
4
x24x7x80%xN fabrics P( ^ )=2239.104 ^ x
sem sem

4. VISIT TO THE PERUVIAN COTTON PLANT

The location of this company is on Av. Industrial 730, in the Lima area. Its production is
concentrated in the areas of Weaving and Dry Cleaning. The processes that we were
able to appreciate on our tour were: flat weaving, gumming, fabric quality control and
dyeing (although we only observed the latter from afar). One of the items that we could
notice that had a high production was the gauze for surgical use that had a special
thread in the warp to facilitate the location of this in operations, this was a radiopaque
thread. Now we will comment on the data of each section of the plant.

4.1 Flat Weaving Area:

❖ Direct warping:

-Creek capacity: 500 kg

Footage: 4000 – 20,000 meters
-Efficiency: 50% - 70%
The cause of the low efficiency is the assembly.

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 -Finest title: 31
- You obtain a set of twin folders, in which the thicker folder is used for the
loom.
- You can have twin folders or a single folder (monofolder).
- Produced item: has the following characteristics

-------• 386 x 840k GA 0295 4------1

20A

# Footage Item Type Order Number

Thread

- To arrive at the weight, a title 31 was woven in the warp and 34 in the weft.

❖ Sectional warping:

-Here you obtain a single set of folders and with all the fabric threads.

- Jacquard

- The puff forming system is a STAUBLI brand machine. This operates 600
needles.

- PICANOL – GAMMA: It normally works with 500 RPM depending on the

article, but in this case it operated between 320 RPM or 280 RPM. This was
done in order to take care of the parts and avoid rapid deterioration of the
machine.

❖ PULL FORMATION MECHANISMS:

In the company we were able to notice that we found the three shed formation
systems that are: Eccentric, dobby and Jacquard.
-The Sulzer machine that used the Dobby system produced the surgical gauze,
and it was also possible to verify that the type of clamp used was flexible.

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 Surgical gauze technical sheet

Shed deformation system: Eccentrics

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 Shedding system: Dobby

❖ GUMMED:

- In the gluing we find several folders ready for the process.

- The quality controls of the process are: the use of the Zahn cup,
refractometer and the pick up.
- In this process there is a stretch of 2% to 3%.
- A mixture of CMC, with starch and additives, which is already prepared,
is used as glue.
- A 1 m 3 pot is used for gluing.
- The rubber is ultimately stored in a tank at a higher level and is
distributed by gravity to the gluer.

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 PRODUCTION CONTROL:

- In this area we found an operator checking the fabric against the light to
be able to distinguish any flaws in the weaving process.

5. OBSERVATIONS

• For an air loom, the title of the weft thread to be worked must be taken into
account, since depending on this, the appropriate nozzles and air pressure
must be chosen. During the plant visit we were able to verify the operation of
the air jet insertion looms.

• Rapier looms have a wide range of working counts for the weft, but a different
adjustment must be made for each count.
• For a Sulzer rapier loom, the high cost of its spare parts and its high
degeneration of the components must be taken into account. This is also taken
into account for the JACQUARD system, hence the reduction in its production
speed.
• Ring compressors are used for air weft insertion looms.
• The red color represents a loom with an air insertion system. The blue, for
clamp and the yellow, for projectile.
• In the surgical gauze the warp thread had a bright blue color.
• The plant had its water treatment system for internal disposal of the plant.

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6. CONCLUSIONS

• The actual nominal width of a loom is a few centimeters more than indicated
on the plates.
• The main purpose of the false selvage is to support the weft. Being the
highest quality and most complicated, the tucked edge.
• Looms are color-labeled for quick recognition of their weft insertion type.

• There is a type of visual signal based on colors for each type of cause of loom
stoppage.
• The trigger point of a loom cannot be the same as the stop point.
• A loom with Jacquard shed forming system and insertion system
weft by dart is the most versatile combination for working flat fabric.

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