ASSIGNMENT NO: 01

COMPARISON MECHANICAL DOBBIES &

ELECTRONIC DOBBY MECHANISM

NAME : K.D.U.NAVODYA

MODULE : TT3270

COURSE : BSc. ENGINEERING

DATE OF SUB: 03/07/2018

What is the Dobby shedding system?

It is required to separates the warp threads into two layers or divisions to form a tunnel known as
shed when the number of heald shafts or the number of picks in the repeat of pattern or both are
beyond the capacity of tappet shedding. This is being able to accommodate up to 32 shafts, a much
greater weave repeat and complicated design is possible.

The dobby consists of three principal mechanisms.

 Drive mechanism – An auxiliary shaft is permanently driven from the weaving machine. It
operates two steel bars (knives), having a regular reciprocating motion or it operates coupling
rings on a rotary dobby.
 Selection mechanism – It is operated by dobby card (or by some form of pattern chain). It reads
or checks the design information punched on a dobby card, and transmits the necessary
movement from the drive mechanism to the lifting mechanism.
 Lifting mechanism – Operates the head shaft motion

Dobby mechanisms are classified as negative, positive and rotary dobbies; they can be mechanical or
electronic. In negative dobby shedding the heald frames are lifted by the dobby and lowered by a spring
reversing motion. In positive dobby shedding, the dobby both raises and lowers the heald shafts. Today,
the trend is away from negative dobby to electronically controlled positive dobby mechanisms, which
can operate at very high speeds.

Mechanical dobby Electronic dobby

Chain and pegs are used to selection
Computer controlled shaft selection
mechanism
The construction of shaft sequences is done Construction is done on computer screen
by building a mechanical dobby chain. with weave software’s.
More easy and understandable way to
A little bit tougher way to design fabric.
design fabric.
Unable to visualize the repeated designs in Can visualize the repeated weave design on
fabric in mind. the screen.
Loading and switching of weave patterns can
Loading and switching of weave drafts
be done in seconds without getting up from
takes longer time.
the loom.
Tedious work in designing and producing Remove tedious work in designing and
fabric. producing the fabric.
Mechanical dobby

 In mechanical dobbies, the programme for the selection of heald frames is stored in mechanical
elements such as pattern chains or punched cards and it is time consuming process.

 In the long run, plastic cards may get damaged and lead to wrong selection.

 Through the mechanical selection device is precisely built it may not be reliable for the high
speed shuttle less looms.

 The reading of the stored information is carried out mechanically using needles.

 These mechanisms are relatively slow and the programme carriers are bulky.

 The amount of information stored (weft repeat) is limited.

To overcome these disadvantages of mechanical dobbies, the electronic dobbies have been introduced.

Electronic dobby

Designing aspects in E-dobby

 CAD software is developed to automate the process of peg plan generation from a given
weave design.
 One inputs and edits a design at the screen and immediately executes it on the loom.
 To overcome the problems in the mechanical dobbies, a design is proposed and implemented
to convert the existing mechanical dobbies into micro controller based electronic dobby.
 These signals are conveyed to the electro mechanical device, for lifting the particular shafts.
 The computer can also analyze each desired weave to get a drafting plan and lifting plan in a
matter of second. The computer can create a data file covering the lifting plan for the
microprocessor controller unit.
 Using the software, a textile designer can generate a panorama of derived weaves, starting
with an elementary weave, on the computer monitor.
 The electronic dobby will give almost unlimited harness combinations using a computer and
software from Fiberworks PCW, Patternland, Weavemaker and etc.
Importance of Electronic Dobby Mechanism

 Suitable for very high sped production.

 The slow spring loaded mechanical sensing pins have been replaced by reliable fast electro
magnets and sensors and there by improved the shed formation speed.

 Fabric construction is easily changed with a simple operation (Pattern setting).

 Combined with multi-color and at-will motion, versatility is further increased.

 For the electronic dobby loom, the filling selection (filling pattern) is also controlled by the
electronic dobby motion.

 Changes in weft insertion have a greater impact on speed. Due to this speed has changed from
few dozens to thousands per minute.

 Electronic versions no longer require support equipment such as punches. Designs can be made
from anywhere using a laptop or computer so it has become more advantageous for
manufacturers to produce small yardages for reasonable price.

Advantages & Disadvantages of Electronic Dobby Mechanism

Advantages Disadvantages

 No limitation on the speed of loom.  More complicated mechanism.

 Maintenance costs are reduced.  Initial capital requirement is high.

 Greater versatility.  Production cost is high.

Electronic negative dobby (Lever dobby)

 A negative cam dobby with electronic devices and a special programme to select the heald frame
so the driving as well as lifting parts of this dobby is mechanical but the selection is electronic.

 The baulk lever is activated to move by pushing bars which are driven by complementary cams A.
This part of complementary cam operated pushing bars is shown separately. This part is the
driving mechanism of the dobby.

 The pushing bars (J) are used to push the baulk lever F, however returning motion is caused by
spring attached to the heald frames (not shown). Therefore it is a negative dobby. There is also a
positive version of this dobby.

 The retaining hook C selects the hinged hooks I of the baulk lever by an electromagnet B that is
either charged or not depending upon the selection programme.

 With minimum pivots, smooth working movements and high accuracy in selection this concept
enables this machine to run at high speed without vibration.

 The programme for selection can be uploaded to EPROMs available in the electronic dobby. The
dobby is either networked to the programming computer or programme carries such as floppy
discs, USBs, portable programming drives or CDs can be used.

Electronic positive dobby (Rotary principle)

  The dobby consists essentially of two units, a cam unit and an electromagnet selection control
unit.

 The revolving parts of the cam unit are all mounted on the cam shaft which is driven by the main
shaft of the loom.

 In opposite side adjacent to the coupler ring is a crank mechanism, which encloses a cam with
bearing and mounted loosely on the cam shaft. The catch fulcrum at the outside of the cam unit
connects it with the coupler ring by its projection always being engaged with one of the carrier
grooves by means of a spring. The cam in the crank mechanism projects and a cam disc is loosely
mounted on the projection. The cam disc activates the lifting jack, depending on the position
occupied by the cam inside the cam disc.

 There are thus three discs arranged in three layers side by side on the cam shaft. Among these
three plates only the coupler ring gets the direct drive from the camshaft while the rotation of
the other two discs depends upon the carrier grooves.

 If the catch is engaged with a grove, the cam unit and the cam disc will rotate along with the
coupler ring. The 1800 rotation of the cam causes a lifting or lowering of the heald frames.

 The electromagnetic selection unit consists of two selectors which are activated by the selector
lever fulcrum at the middle. The position of the selector lever is altered by the attraction of
electromagnet. A combined oscillatory movement is given to both the selector lever and the
electromagnet by the matched cams.

 When the selector lever moves down along with the electromagnet if it is in a charged state and
it pushes the selector. Alternatively, it pushes the selector if it is not charged. As a result, the
catch is released from the coupler ring or engages with it depending on which selector is pushed
by the selector lever.

 All those elements are involved in the lifting or lowering of one heald frame.

High performance rotary dobby of the series 2600

1-Magnet bar

2-Selector

3-Control lever

4-Rachet

5-Driver

6-Cam unit

7-Connecting rod

8-Jack
The high performance rotary dobbies of series 2600 with electronic controls operate according to the
rotary principle.

According to the pattern, the control elements transmit electrical signals to magnet bar. This moves
corresponding selector which depending on its state on the magnet bar presses on one of the two
control levers. If ratchet is underneath the control leer which is pressed down, the ratchet is released.

When the ratchet is engaged with the driver, it then couples cam unit. By this process the motion of the
cam shaft is also transferred to the cam unit. By way of connecting rod and jack the harness frame is
then moved.

If the harness frame is to be moved to one of its end positions, the control lever which has not been
pressed down pushes ratchet by spring force out of the driver, so that the harness frame remains either
in upper or lower shed.

 Electronically controlled 2600 rotary dobbies are suitable for producing patterned fabrics of all
kinds.

 They can be used on different types of weaving machines, positioned low or high.

 Optimized adaptations are available for both weft insertion systems.

 2600 type dobbies are driven directly by the loom by a direct coupling on the dobby shaft or a
timing belt.

Advantages

 Modular construction to enhance accessibility

 Extremely resilient, consistent and reliable

 Outstanding performance

 Shed opening simple to adjust

 Low maintenance

 Oil bath lubrication or circulation type lubrication electronically monitored

 Electronic control by independent control unit, integral control unit or weaving machine
electronics

REFERENCES

https://www.scribd.com/doc/62223628/E-DOBBY

https://www.slideshare.net/aybalaozcan/dobby-mechanisms

http://nptel.ac.in/courses/116102005/34