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Techno-Economics of Shuttleless Looms

Lohit Bakore Final yearTextile Technology SVITS, Indore

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Introduction

The Shuttleless looms came in to existence as a result of the

growing production demands. The shuttleless Looms apart from

their high Speed weaving abilities are also ahead of their shuttle

counterparts in various other aspects.

This is the reason which makes them more suitable as present

day weaving machines.

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Advantages of Shuttleless looms over Predecessors

Higher operating speed resulting in higher production.

Less picking energy is required.

More colours in weft direction.

Higher design capabilities.

Wider width fabrics can be woven.

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The Technology of Shuttleless Looms

These looms are different in the picking , beat up, let-off and

take-up mechanism.

Also these looms are equipped with the QSC systems , ESLY

Motions, electronic controls and microprocessor devices which

make them an entirely different and more productive machine.

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The Filling Insertion TechniqueInstead of a heavy shuttle these looms use comparatively lighter weft carriers. The advantages are:

• Higher weft insertion rates and loom speeds• Lesser vibrations and higher stability• More production• Lesser power requirements

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The Beat Up Mechanism

These machines use a matched cam Beat Up Mechanism. The

sley is driven by a set of complementary cams with cam followers

on both sides of the machine. The reed holder is made of light

alloy with great stiffness. The sley with its reed holder is perfectly

balanced by means of counter weights and provides a powerful

beat-up over the whole weaving width, without any vibration.

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The Let off and Take Up Mechanism

• These machine use electronic let off and take up mechanisms.

• The required pick density is electronically set and makes it possible to weave patterned fabrics with alternating pick densities

• The take-up and let-off are driven by the same type of motor. The electronic link between let-off and take-up is an additional tool for the weaver to manage fabric quality.

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Electronic Selvedge System

In the Electronic Selvedge System full leno false selvedge

motions are electrically driven by individual stepper motors.

They are mounted in front of the healds, so that all the

healds remain available for the fabric pattern.

The selvedge crossing and pattern are programmed on the

microprocessor.

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The Electronic Selvedge Mechanism

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Automatic Full Pick Finding Mechanism

At a filling break the machine stops and only the healds are moved automatically to free the broken pick for removal by the weaver. The automatic pickfinder and the slow motion movements are not driven by a separate motor – the pickfinding is simply done by the Sumo at slow speed.

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The Quick Style Change (QSC) system enables a style change to

be carried out in about 80 minutes*. The style change is done

by replacing the entire rear part of the split frame, with the

warp beam, backrest and support, warp stop motion, harnesses

and reed. All the settings involved in preparing the fabric on

the warp side are done before the style change, outside the

weaving shed.

Quick Style Change

* Picanol loom

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Average Loom Stoppage Time*

Stop factor With QSC system Without QSC system

Waiting time 5 5Loom unloading 10 40

Trolley waiting time 10 40Loom loading 8 25

Reed,hardness locking 6 60

New style setting 15 15Loom restart 5 25

Interference loss 4 12Total 74 203

* For Picanol Loom

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The Loom drive

The oil-cooled Sumo main motor drives most of these weaving

machine directly, without belt or clutch and brake. The

combination of the highly energy-efficient Sumo motor with the

direct drive of the main shaft and shedding motion results in

power savings of more than 10% in comparison with conventional

clutch and brake configurations. The speed of the motor is

controlled electronically, without a frequency converter, thus

reducing power consumption.

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The Sumo Motor

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The following table presents a comparison of production rates of different weaving machines.

Loom Type Available width in cm Speed in rpm Weft insertion

Rate(m /min )

Conventional Powerloom 180 180 300 - 400

Projectile

Sulzer Ruti

P7100 190-540 320 1100-1200

P7200 190-540 430 1500

STB Russia 180-330 300 750

Rigid Rapier

SACM 150 550 1100

Dornier 150-400 460 1000

GUNNE 230 330 1200

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Loom Type Available width in cm Speed in rpm Weft insertion

Rate(m /min )

Flexible Rapier

Somet 165-410 550 1300

Vamatex 160-380 510 1300

Sulzer Ruti 110-280 325 1200

Nuovo Pignone 220-420 440 1000

Water Jet

Metor SPA 230 1000 1600

Nisson 150-210 1000 2000

Tsudakoma 150-210 1000 2000

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Loom Type Available width in cm Speed in rpm Weft insertion

Rate(m /min )Air Jet

Sulzer Ruti upto 300 750 1600

Picanol Omni 190-380 800 1800

Picanol Delta 190 1100 2000

Toyoda 150-330 850 2000

Tsudakoma 150-340 1000 2200

Lakshmi Ruti 190 500 1200

Dornier 430 600 2520

Linear Multiphase

Elitex About 190 1100-1600 2000-3000

Drum type Multiphase

Sulzer M8300 190 3230 6088(Plain)

170 2430 4118(Twill)

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Economics of Shuttleless LoomsPLAIN

AUTOLOOM

NEW RAPIER

AIR JET PROJ. D W PROJ. S W

ITEM(SEMI AUTO)

H.S

REED SPACE CM

190.00 190.00 190 190 190 190

RPM 120.00 180.00 450 700 300 400

AVG PPI 72.00 72.00 72 72 72 72

EFFICIENCY 70.00 80.00 85 85 85 85

PROD/DAY

MTRS/MC34.17 62.18 165.16 256.92 146.81 220.22

PROD/YEAR MTRS/M C

11959.50 21763.00 57806.00 89922.00 51383.50 77077

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Loom PLAINAUTOLOOM

NEW RAPIER

AIR JET PROJ. D W PROJ. S W

TOTAL WVG COST

CONSIDERING NET OF RS.

0.70 PROFIT /-MTR

11.36 11.85 10.19 7.80 7.58 6.55

Details of the fabric being produced 40s Warp 40s Weft, 136 EPI, 72 PPI, 63" Width.

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Conclusion

Conclusion: Net profit is one of the major considerations to keep any organisation running. Analysis of the results shows that shuttleless looms are more economical than shuttle looms.

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References

• Weaving Mechanisms – Dr. M. K. Talukdar, Prof. Srirammalu.• Shuttleless Weaving – Richard A Morrocks• Power loom Development and Exports Council –

www.pdexcil.com

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Thank You