Weaving the way towards energy conservation

The recent debt crisis in the two major markets, Europe and the US, appears to have put the entire textile and apparel industry in an uncertain position. On top of that, massive pressures have mounted with the spiraling raw materials prices and labor costs. Under such circumstances, weavers in particular are struggling to survive. The most daunting challenge faced by textile weavers, according to Swiss weaving machinery maker Stäubli, is to respond quickly to the rapidly changing market demand, where there is already overcapacity in fabric production, and the prices are low. To help them improve their competitiveness, weaving machinery suppliers have worked to develop new technologies. But what is the leading direction for the development of weaving machinery? The latest developments in weaving machines lie in energy conservation, high productivity, high performance, flexibility, consistent fabric quality and versatility in terms of applications, said Dr Hua Tao, Instructor of Institute of Textiles and Clothing of Hong Kong Polytechnic University, at the recent Review Seminar on ITMA 2011 in Hong Kong. His views were echoed. "Energy saving and sustainability will continue to be important in weaving machinery's development. However, the machines must be easy to operate and maintain low price, durability and flexibility to produce not just one particular product but a range of products," noted Reinhard Furrer, Marketing & Sales of Stäubli Sargans Ag. Latest technological advancements In the realm of weaving machinery, a number of suppliers are finding their ways to improve their weaving technologies in terms of enhancing productivity, flexibility, fabric quality and so on. Stäubli, for instance, has developed shedding machinery for high productivity and some for extremely high flexibility. Besides, the company notes that it is offering products to rationalize and automate weaving preparation processes such as warp tying, drawing-in, and warp leasing. 5m-width carpet weaving machines For Belgium-based Van de Wiele, a significant development is the engineering of carpet weaving machines of 5m in width. Weaving area rugs on a 5m-machine gives more sellable sizes of carpet, says the company. On a 4m-machine, numerous small carpets and runners are woven. These carpets are quite expensive and sold under cost price. On a 5m-machine, weavers can better fit commercial sizes in width. Also for wall-to-wall carpet and artificial grass, the width of 5m or 15ft gives many advantages. According to Van de Wiele, another big advantage is energy saving. With energy consumption unchanged, the production on a 5m-machine is up to 20% more, so the saving of energy is up to 20%. The company continue to explain that the 5m-machine is equipped with an energy bus, distributing and recuperating the energy between the motors in the machine. As a result, this can contribute to extra energy saving of up to 15%. ITEMA Weaving's Maestro weft detector on its Silver 501 rapier machineBonas ZJS2-28 New weft monitoring approach Italian weaving machinery supplier, ITEMA Weaving, has introduced the Maestro Weft Monitoring System on its new Silver 501 Rapier Machine. According to the company, Maestro uses a special weft detector that transmits signals from each eyelet to the micro-processor of the loom. Innovative software from the loom's micro-processor allows real time analysis of the signal and thus efficient handling of all weft breakage conditions. As introduced, the weft detector has been designed to produce a numerical value for each of the 8 or 12 eyelets of the detector. If no weft is inserted for a given position, the signal value will be extremely low (the signal noise level); if a weft yarn is moving in the eyelet, the numerical value can go up as high as 4000, thus offering a very good signal/noise ratio. ITEMA Weaving explains that for each pick insertion, the 8 or 12 numerical values are continuously transmitted to the loom's micro-processor, multiple times for each pick. In fact, the numerical values are transmitted for each degree of the weaving cycle. The data communication between weft detector and the loom's electronics is handled by a very fast and secure means of data communication. With ITEMA Weaving's new electronic NCP (common electronic platform for its loom types), the required computation power is guaranteed even at extremely high rapier weaving speeds, says the company. SyncroDrive and Open Reed Weave Technology German weaving machinery maker Lindauer Dornier has also made remarkable strides in weaving technology. It has developed SyncroDrive drive system. It explains that the shedding motion runs up with a controlled start with gentle material handling; the shedding motion and weaving machine then synchronize at a reference point. The large data volume that must then be transferred in real-time can only be ensured without interruption with the new FT electronics. At the same time, the company has reduced voltage peaks during run-up by 1/3 as against classic direct drives. This saves the weaver considerable electricity costs. It stresses that this system allows an electronic close of shed adjustment even when the machine is running and is therefore unique. Its SyncroDrive brings a drastic reduction in load peaks and, therefore, 6 to 10% higher performance and longer service life. Besides, its Open Reed Weave Technology makes it possible to combine embroidery and weaving in one process. In practical use, this embroidery weaving system is usable for clothing and drapery. An extended technology has been developed as multiaxial technology for partial reinforcement for technical textiles. All these innovations are available for Dornier's air-jet and rapier weaving machines. Some weaving machinery suppliers and their products To help weavers bolster their productivity and product quality, weaving machinery makers have development cutting edge technologies. Presented below are some of their latest innovations. Bonas ZJS2-28 Bonas ZJ and LJ series Bonas Jacquard weaving ZJ and LJ series boast harmonic mechanism driving low friction selectors and benefit from low torque, low mass and low inertia. Both models use only a minimum number of mechanical connections - one shaft connects both sides of lifting arms, but because of light torque, without excess torsion. With its LJ range, designed with bigger capacity hooks sizes in mind, the company uses dual cam box for concise shed control and dwell shed capabilities. Its machines require low maintenance due to its patented solenoid - "attracting hook- to latch" selectors, with only one moving part is exempt of any maintenance or lubrication - a major advantage when accessible Jacquard sizes frequently within use are 6144 hooks or above. Bonas selector, with its inherent 100% electronic principles, gives 100% diagnostic, fault control. Besides, factors such as temperature, air flow and design integrity are closely monitored, managed and cared for. The adjustable split heck also improves quality and efficiency. Comez MCJ/EL 700/384 weaving needle loom Comez MCJ/EL 700/384 jacquard weaving needle loom Comez's innovative high-performance electronic Jacquard needle loom, for the production of exclusive high quality narrow fabrics, both rigid and elastic: laces, ribbons, articles for corsetry, ribbons for technical applications, all of which can be personalised with special inscriptions or intricate patterns. Comez MCJ/EL 700/384 offers the renewal of mechanical parts and elimination of the dobby unit, the application of innovative electronics, with new hardware and software, and a lean and robust structure that is easy to use and simplifies maintenance operations. The needle loom also offers smooth operation with noise reduced to a minimum and complete absence of vibrations, as well as high productivity and reliability. It is available in different models and can be equipped with 4 to 8 heads and with ribbon guide roller width of up to 90 mm. The dobby unit has been eliminated on this new needle loom. All yarns used (pattern, elastic and/or binding threads) are controlled by a new electronic jacquard head with 384 hooks that is specially designed to simultaneously manage both rigid and elastic threads, resulting in a leaner, more compact structure that is easy to thread. Dornier AWS 8/J G air-jet weaving machine Dornier's AWS 8/J G air-jet weaving machine With 190cm nominal width at 900rpm, Dornier's AWS 8/J G air-jet weaving machine is designed for high quality Jacquard fabrics. Its new, pioneering and patented drive concept SyncroDrive is one of the significant components. An electric control circuit to the separate drive of the Jacquard machine replaces the cardan connection between weaving and Jacquard machines. Separate starts for the Jacquard and weaving machines then merging at a rendezvous point allows a soft start which halves the peak current and ensures high speed stability without peak forces. This reduces wear on all components in the shedding area such as the harness and thus reduces machine standstills and warp end breaks. This drastic reduction in mechanical loads means weaving machines with this drive concept run 6 - 10% faster. Sultex A9500 air jet weaving machine ITEMA Weaving's Sultex A9500 air-jet weaving machine Swiss ITEMA Weaving has introduced its new Sultex A9500 air-jet weaving machine. With its high performance and simplified design, the A9500 produces excellent fabric quality; its minimal air consumption is unrivaled. The machine is equipped with a special shed geometry designed to promote a long dwell while drastically reducing air consumption. The long weft insertion time and the high efficient nozzles insure the optimum acceleration curve for any type of yarn. The new electronic platform, through its large, full color touch screen display offers new functionalities and opens the doors to an efficient dialogue with the ITEMA Service Network. The Sultex A9500 air jet weaving machine is best suited for medium to heavy Denim, colored weaving and sheeting applications. Also, its Vamatex Silver 501 rapier weaving machine is equipped with the new electronic platform and is based on a totally revised mechanical design to ensure superior weaving performances and absolute stability in a continuous operation of difficult styles such as Denim or heavy fabrics. The electronically controlled NH2 53 narrow fabric loom Jakob Müller NH2 53 narrow fabric loom Jakob Müller's new electronically controlled narrow fabric loom NH2 53 is an electronically controlled loom for the weaving of medium-weight, elastic and non-elastic narrow fabrics. Electronically controlled shedding takes place via linear motors mounted directly on the shafts. These replace pattern chains and drums and both permit unlimited repeat lengths and pattern changes in minimum time. The weft and auxiliary thread transport, as well as the narrow fabric take-off and main drive are also all electronically controlled and smoothly adjustable. As compared to conventional needle looms, the NH2 53 is fitted with considerably fewer mechanical parts, which results in both less wear and a cut in energy consumption of around 35 per cent, i.e. maximum 1 kW. Picanol's OMNIplus Summum-4-P-340 for cotton sheeting Picanol's OMNIplus Summum air-jet weaving machines Belgium-based weaving machinery manufacturer Picanol has developed the new generation of air-jet weaving machines - OMNIplus Summum. The company notes the OMNIplus Summum will gradually replace the OMP800 over the course of next year and will be the new platform for further developments in the airjet segment. The main highlights of this machine are the new insertion system and the Picanol BlueBox system, the new electronic platform for Picanol machines. Picanol BlueBox is the new electronic platform for Picanol weaving machines. It features superior microprocessor performance and memory capacity, a design constructed to meet the hardest working conditions, with state-of-the-art components and detection technology, remote check-up possibility, a modular build-up and offering the user many monitoring tools. This new platform is superior to any existing system on the market. The new insertion system, with fully electronic pressure regulators, a separate and integrated air tank for each weaving channel and a unique triple air tank set-up for the relay nozzles, offers many advantages in terms of user-friendliness and flexibility. The integrated BlueBox concept, which translates all the available data into optimal settings for maximum performance at lowest possible air consumption, allows all this without making compromises when it comes to performance, flexibility and energy. Stäubli SX V electronic jacquard machine Stäubli SX series jacquard machines Among Stäubli's electronic Jacquard machines, SX is its most modern type. Productivity of the SX surpasses that of other models, the machine is more compact, and it offers higher performance - meaning high loads and high speed. Its nearly vibration-free drive mechanism is extremely reliable and energy efficient. The machine consumes fewer wearing parts and requires a minimum of maintenance. The SX is available in two sizes, with 1408 or 2688 hooks. It is adaptable to rapier, air jet, and projectile weft-insertion systems. It has recently introduced its new type SX V Jacquard machine for the production of velvet fabrics. It is equipped with 2688 hooks driven by the M6.2 three-position module. The SX V can be adapted to any type of new or existing velvet weaving machine. Besides, its UNIVAL 100 Jacquard machine with single-end control is superbly suited to the production of technical fabrics. New, smaller configurations with fewer actuators have been developed particularly for this application. The two new models can be equipped with up to 512 or 1024 actuators, complementing the previous range with configurations between 2048 and 15360 actuators. Of particular interest to technical weavers, the new configurations facilitate production of narrower fabrics, from simple fabrics to sophisticated textiles such as multi-layers. All UNIVAL 100 models are easy to program using the JC6U colour touch-screen controller, allowing the setting and archiving of shed parameters such as shed angle adjustment, opening profile, and crossing phase difference. Van de Wiele's Rug & Carpet Innovator RCI Van de Wiele Rug & Carpet Innovator RCI Van de Wiele's Innovator generation of carpet weaving machines gives a boost to the carpet industry. The heart of the new developments is the Rug & Carpet Innovator in two and three rapier execution, respectively RCI02 and RCI03. The Innovator generation is characterised by an increased productivity, especially in 5m width, and a better stability. The RCI can be equipped with Smart Frames -SF- by which each ground heddle frame is driven by a separate servo-motor. Smart frames allow easy changing of different ground weave structures. The use of servomotors allows timing differences, different dwells and asymmetric motions to weave carpets with a clean back and less incorporated yarns. The new Smart Cutting Motion (SCM) with servo drive guarantees a perfect cutting. The cutting frequency as wells as the sharpening of the knife are programmable. The sefledge yarns of the Smart Edges -SE- are driven by small servomotors, placed under the cumberboard for a good accessibility and adjustment in width. The Rug & Carpet Innovator RCI03, the three rapier execution, gives 50% more production in 2/3 V Source:Journal for Asia on Textile & Apparel by Staff Reporters