"OPTIMIZATION IN DESIGN OF SECTIONAL WARPING MACHINE" A PROJECT REPORT SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OF THE DEGREE OF BACHELOR OF TECHNOLOGY IN MECHANICAL ENGINEERING PDF

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“OPTIMIZATION IN DESIGN OF SECTIONAL WARPING MACHINE” A PROJECT REPORT SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OF THE DEGREE OF BACHELOR OF TECHNOLOGY IN MECHANICAL ENGINEERING Submitted To Department of Mechanical Engineering IITE, INDUS UNIVERSITY, Ahmedabad Submitted By...

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“OPTIMIZATION IN DESIGN OF SECTIONAL WARPING MACHINE” A PROJECT REPORT

SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OF THE DEGREE OF BACHELOR OF TECHNOLOGY IN MECHANICAL ENGINEERING Submitted To Department of Mechanical Engineering IITE, INDUS UNIVERSITY, Ahmedabad Submitted By Name DARSHAN K. PATEL

Enrollment No. (IU1541110088) Guided By Prof. Marnish Modi Mechanical Department

Indus Institute of Technology and Engineering, Rancharda Indus University, Ahmedabad November 2018 1|P ag e

Department of Mechanical Engineering INDUS INSTITUTE OF TECHNOLOGY & ENGINEERING Indus University, Ahmedabad

Certificate This is to certify that project work entitled “Optimization in design of sectional warping machine” is an original work carried out by “Darshan K. Patel ” in partial fulfillment for the award of degree of Bachelor of Technology in Mechanical Engineering, Indus Institute of Technology & Engineering at Indus University, Ahmedabad during the academic year 2018-2019. The project report has been approved as it satisfies the academic requirements in respect of project work prescribed for the Bachelor of Technology Degree.

Date:

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Declaration I hereby certify that I am the author of this report and that neither any part of this report nor the whole of the report has been submitted for a degree to any other University or Institution. I certify that, to the best of my knowledge, my report does not infringe upon anyone’s copyright nor violate any proprietary rights and that any ideas, techniques, quotations, or any other material from the work of other people included in my report, published or otherwise, are fully acknowledged in accordance with the standard referencing practices. Furthermore, to the extent that I have included copyrighted material that surpasses the bounds of fair dealing within the meaning of the Indian Copyright Act, I certify that I have obtained a written permission from the copyright owner(s) to include such material(s) in my report and have included copies of such copyright clearances to my appendix. I declare that this is a true copy of my report, including any final revisions, as approved by my report review committee.

Date: Place: Sign of Students: Name of Students: Enrollment No:

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Acknowledgement Foremost, I would like to express my sincere gratitude to my guide Prof. Marnish Modi for the continuous support of my Project study and research, for his patience, motivation, enthusiasm, and immense knowledge. His guidance helped me in all the time of research and writing of this report. I could not have imagined having a better advisor and mentor for my Project study. Besides my advisor, I would like to thank to P r o f . M i t e s h M u n g l a , HOD, Mechanical Engineering department, who gives guidance for the Project work and their insistence for meeting deadlines we can do such excellent work. I offer my special gratitude to all the faculty members, Mechanical Engineering Department, Indus University for their help and support. I thank to my friends for providing me such a warm atmosphere to make my study more delightful and memorable. I would like to express endless gratitude to “My Parents” who gave me everything they could to enable me to reach the highest possible education level. I only hope that they know how their love, support and patience encouraged me to fulfill their dream. I would like to thank all people who have helped and inspired me during my Report study.

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Table of Contents Page no.

Title

1

Certificate

2

Declaration

3

Acknowledgement

4

Table of Contents

5

List of Figures

7

List of Tables

8

Abstract

10

Chapter-1 Company Profile

11

1.1 Introduction

11

1.2 Products

12

1.2.1 Sectional Warping Machine

12

1.2.2 Creel

16

1.2.3 Single end sizing machine

17

1.2.4 Beamer

20

Chapter-2 Introduction

21

2.1 Basic Information

21

2.2 Working Principle Of Sectional Warping Machine

21

2.3 Components of a Warping Machine

22

2.4 Importance of Warping

23

2.5 Important Requirement of Warping

23

Chapter-3 Literature Review

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24

Chapter-4 Machine Setup

31

4.1 Main Parts of Sectional Warping Machine

31

4.2 Sequence of Sectional Warping Process

31

Chapter-5 Problem Definition

36

5.1 Defects & Remedies of Warping

36

5.2 Problem Objective

38

5.3 Parameters which Power consumption is high in system

38

5.4 How to reduce time of one full cycle of beamer

38

Chapter-6 Design Calculation & Analysis

39

6.1 Warping Calculations

39

6.2 Analysis Of Sectional Warping Machine

45

6.3 Experimental Work

47

6.3.1 Warping Speed And Warp Yarn Tension 6.3.2 Warp Yarn Material and Cone position on Warping Creel

Conclusion

53

Reference

54

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LIST OF FIGURES

Figure No. Figure Description

Page No.

Figure 1

MODEL RI 109

13

Figure 2

MODEL RI 107S

14

Figure 3

MODEL RI 1002

15

Figure 4

CREEL

16

Figure 5

Single End sizing machine

18

Figure 6

Beamer

20

Figure 7

Beaming Device and Warping Shaft

25

Figure 8

Warp Beam

26

Figure 9

Arrangement of creel

27

Figure 10

Warp knitting beam

28

Figure 11

Torque and speed relation

29

Figure 12

Sketch of a Yarn path through two zone tension device

30

Figure 13

Specification of creel

31

Figure 14

Expandable Reed

32

Figure 15

Drum

33

Figure 16

Arrangement of beamer

34

Figure 17

Process of sectional warping

35

Figure 18

Warping

39

Figure 19

Schematic representation of sectional warping principle

40

Figure 20

Traverse in sectional warping

41

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LIST OF TABLES

Table No No.

Table Description

Page

Table 1

Technical feature of creel

17

Table 2

Specifications and results for the produced samples (YCD 70)

47

Table 3

Specifications and results for the produced samples (YCD 150)

48

Table 4

Specifications and results for the produced samples (YCD 300)

49

Table 5

Specifications and results for the produced samples (Cotton)

50

Table 6

Specifications and results for the produced samples(Spun Polyester)

51

Table 7

Specifications and results for the produced(Poly acrylic)

52

Table 8

Optimum yarn operational settings.

53

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LIST OF SYMBOLS, ABBREVIATIONS & NOMENCLATURE

Symbol

Abbreviations

Name

N S

No. of Bobbins Warping Speed

T

Time Taken For One cycle of Beamer

P

Power Required for one cycle of Beamer

L

Length of Yarn

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ABSTRACT

 The sectional warping machine is used for preparation of multi coloured warps to be woven as striped of checked design fabrics. It is also used for doubled grey or mono-coloured warps that do not require sizing. Unlike the beam or direct warping where a warp beam is produced that is sent to the subsequent sizing processes, in the case of sectional warping, the weaver’s beam is produced and hence does not require sizing. In the case of single yarns that are multi coloured, the yarns are sized and then wound on the sectional warp beam. The yarn is wound in sections, each section having a particular width. Thus the total number of warp ends for the weaver’s beam is divided into suitable number of sections on a warping drum. The sections are then combined to form the weavers beam. Therefore, there are two distinct operations involved, namely, warping and beaming.  After the market Feedback we found that The Main & Common Problem Is The Sectional Warping Machine’s Power Consumption is too High.

 So We have to solve this problem with reduce the time of one full cycle of Beamer

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CHAPTER-1- COMPANY

PROFILE

Rabatex Industries Plot No. 559, Opp Road No. 9, Kathwada GIDC, Ahmedabad 382 430 ( Gujarat ) India

1.1 INTRODUCTION A good beginning imprinted the future. The great future of Rabatex Group was incepted in the year 1962, our first step towards becoming a trendsetter in the textile industry as well as other engineering industry . We gained experience during the initial periods by manufacturing basic sectional warping machines / material handling-storage machinery / customised machinery. Now we offer advanced computerized sectional warping machines, single end sample warping machines, single end sizing machines, speciality warping creels with electronic controls, precision tensioner, material handling – Storage equipment for various industry ,customized tailor made machinery for technical textile. Our range of machinery are suitable for every segment from micro units to large scale modern units. Being a customer satisfaction as price motto, today we have more than 43% repeat order which assures continual growth and dedicated after sale service and support to customers.

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1.2

PRODUCTS

1.2.1Sectional Warping Machines 

Model RI 109



Model RI 107s



Model RI 1002

1.2.2Creel 1.2.3Single End Sizing Machine 1.2.4Beamer

1.2.1 Sectional Warping Machine 

In the Fabrics Warp ends required are more than 2000-10,000 Therefore to prepare this type of warp beam(weavers Beam) we required Sectional Warping Machine.



Sectional warping Preferred over beam warping for multi-colored Warp also.



Here No. of Section having total ends equal to creel capacity e.g. 800 ends of one section will warp for 8 times and hence 6400 ends will be warp on the drum. These total ends will transfer to weavers beam and this beam will go to Loom.



Here the design of the drum is not cylindrical throughout but it is kept conical at the starting end of the drum to avoid collapse of the arm.



It is also used for double/grey or mono-colored warps that do not require sizing.

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Model RI 109           

Laser sensor for yarn built up measurement & automatic setting of feed value Traverse of reed table unit through precise AC Digital servo drive High precision ball screws for reed table and feeler table traverse Reed table and feeler roller table traverse on precise linear guides Feeler roller (kick back type) for compact beam with individual AC digital servo drive Closest yarn deliver to drum distance for avoiding misalignment of section width and cross ends Easily accessible warping desk board Energy efficient powerful disc brake with accumulator fully PLC controlled Safety provision for warping and beaming Inbuilt printer for processed data sheet On line actual length measurement

Fig.1.MODEL RI 109

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 MODEL RI 107S

 Traverse of reed table unit through precise AC digital servo drive

 Reed table driven on precise ball screw  Closest yarn deliver to drum distance for avoiding misalignment of section width and cross ends  Easily accessible warping desk board  Energy efficient powerful disc brake with accumulator fully PLC controlled  Inbuilt printer for processed data sheet  Separate beaming unit

Fig.2.MODEL RI 107S

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 MODEL RI 1002    

Solid Metalic Drum with Fixed Cone Auto Stop Counter Meter Hydraulic Belt Brake and Beam Donning Doffing Emergency Brake on Power Fail

Fig.3.MODEL RI 1002

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1.2.2 CREEL

Feature Highlights    

MS tube fabricated structure Tensioner frame withdrawable manually Thread draw off : inside to outside Stop motion with row wise indication

Optional Accessories  Over head cleaner  Static eliminator on stop motion

Fig.4.Creel

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Technical Feature of Creel

Standard pitch

240 mm (vertical/horizontal)

Standard ends

240/320/400/480/560/640 /720/800/880/960 ends

Standard vertical deck

8 (optional deck :5/6/7/8/10/12)

Cone holder

Spindles fixed type

Pitch on request

200 mm/280 mm/300 mm/350 mm

Tensioner type

Ratchet type/Tiana type

Stop motion

Electro mechanical type/photo cell type

Eyelet

Ceramic eyelet (closer/open type)

Table 1.Technical Feature Of Creel

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1.2.3 Single End Sizing Machine 

The Single End Sizing winder for the warp contributes to the improvement of weaving efficiency and quality.



The Single End sizing winder has combination of three processes which are coating (Sizing), drying and winding continuously on individual spindle, these improves weaving efficiency resulting into quick samples.

Fig.5.Single end sizing machine

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Features Highlights  The ergonomically designed and individual spindle driven Rabatex Single End Sizing

Machine RI 8001 is available in 4, 8, 12, 16 or 20 spindle configurations.  The machine offers easy yarn passage, there is no excess yarn tension and has an easy to

handle yarn brake.

 It is possible to size yarns counts of between 10’s and 120’s Ne & 30 to 210 deniers at

winding speeds of up to 300 metres per minute, depending on the yarn type.  The RI 8001 comes with a grooved drum or yarn traverse system for polyester yarn and

the length measuring system (optional).

 The RI 8001 comes with choice of an electrical or dry steam heater for the heating system

to dry the yarn. The air circulation fan and the temperature controller provide uniform and required temperature for all spindles, to ensure and maintain even drying.

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1.2.4 Beamer Feature Highlights       

Heavy duty fixed beaming structure on both sides. Adjustable beam arm on both side. PLC controlled. Constant line speed control. Constant tension control through hydraulic. Servo valve For salvaging damages beams and for warp knitting.

Fig.6.Beamer

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Chapter -2-Introduction Of Sectional Warping Machine 2.1 Basic Introduction In warping machine used in a warp preparation process for a weaving machine, yarns drawn out from a multiplicity for yarn supply packages fitted to warper creels are taken up around a warper drum. Therefore an extremely large number of the yarn supply package corresponding to the number of warps for the weaving machine are supported by the warper creels on vertical planes at such intervals that the yarns being drawn out do not interfere with each other, for instance, a thousand and several hundreds of packages to the creels has been performed manually by the worker, by one package at a time.

2.2 Working Principle of Sectional Warping Machine

The working principle of a sectional warping machine is as follows: 1. Yarn ends supplied from creel are spaced very closely and thus form a warp sheet. This sheet is wound on a beam. The width of the beam between flanges is equal to the loom warp set width of the section sheet. The no. of section beams is determined by respective no. of ends in the section and the complete warp. 2. Each such sheet of warp ends is called a section. 3. Stability of the yarn build of the first section on the reel is obtained by moving the section sheet laterally at a regular rate fitted at one end of reel. 4. When the first section is completed, then the others of its build on the drum is replica of the original incline sections to the number required for the complete warp are wound on the next section. 5. Fancy warps are prepared by dressing yarn packages in the creel for each section in conformity with warp pattern plan. 6. Section sheets are attached to a beam and withdrawn simultaneously from the reel by rotation of the beam. For winding the warp on to the beam, this unrolling is controlled to provide accurate warp tension in textile weaving. 7. As beaming off proceeds, the warp beam is moved laterally at the same ate but in the direction opposite to that of the section during warping. This confirms that the complete warp sheet runs from the reel to between the beam flanges without the necessity for lateral deviation.

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2.3 Components of a Warping Machine The warping machine is mainly divided into two major components Creel  Headstock

Components of Creel       

yarn clearer stop device indicator tensioners yarn guide package base blower or suction fan

Components of Headstock          

adjustable V-wraith measuring and marking device yarn speed controlling device pneumatic or hydraulic pressure unit break assembly driving drum stop motion building drum beam bracket lease rod

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2.4 Importance of Warping:      

Construction of a beam of warp yarn. Construction of a parallel yarn sheet. Modifying the faults of yarn like thick or thin place. Winding the pre- determined length of yarn. Combination of small packages. Accelerating the next process.

2.5 Important requirements of Warping: 1. The tension of all wound ends must be uniform and possibly constant during all the time of with drawl from the supply package. 2. Warping should not impair the physical and mechanical properties of yarn. 3. The tension should be moderate to allow the yarn complete retain its elastic properties. 4. Predetermined length should be observed. 5. Production rate should be high as possible. 6. The surface of warping package must be cylindrical.

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Chapter 3-Literature Reviews 3.1 Analysis of Developments in Mechanical Design of Textile Warping Machines Prof. Ashwin Thakkar Head, Textile Technology Department, L....