Warping Process machinery & Maintenance

The Objective of warping process is to convert the yarn packages into a warper’s beam having
desired width and containing requisite number of ends.

The yarns are wound onto the warper’s beam in the form of a sheet composed of parallel bands
of yarns each coming out from a package placed on the creel.

Figure 1: Main section of Direct warping machine

The main components of warping machine are-

1) Creel
2) Head stock
3) Control devices
 Main parts of Creel of a Warping machine

( Common for direct, indirect or ball warping )

1)Cone holder : Hold the cone or arrange the cone in the creel
2) Yarn guide : To guide the yarn.
3) Tension rod: To maintain the yarn tension by upper& lower disc tensioner.
4) Ceramic guide disc: To guide the yarn from creel to warping machine.
5) Auto stop sensor: To sense the breakage yarn.
6) Creel panel board: Display where the yarn break.
 Main parts of Head stock of a Warping machine

(Common for direct, indirect or ball warping )

1) Guide Reed: Uniformly spread the yarn over the warp width.
2) Adjustable V-Reed: Guides the yarn to follow the fixed path.
3) Speed Controller: control the speed, crawl speed or full speed.
4) Pressure Roller: Exert required pressure to the warp yarn.
5) Measuring Device: Measures the length of the yarn.
6) Beam Bracket: Holds the warp beam.
7) Emergency Stop Device : For emergency stop.
8) Automatic Knock Off: Stop machine at achieving required length of beam or in case of yarn
breaks.
9) Electrical Panel Board: To give the automatic controlled function.
 Main Parts of Controlling devices

(Common for direct, indirect or ball warping )

-Similar to winding, warp yarns are threaded through tension devices, stop motions, leasing rods
and the reed. The stop motion electrically links each warp end to the warped braking system;
when a warp end breaks, the warp stops. A light indicates the location of the broken end. The
warping process is generally irreversible, unwinding of the beam would cause yarn
entanglement. The stop motion device which can be mechanical or electronic for quick response
is usually located near the creel. Fans are used to prevent lint accumulation when warping staple
yarns.

Yarn Tensioners / Yarn stop motions

Yarn tensioners ensure a constant yarn tension over the entire length and width of the warp, just
from the first to the last meter. High performance Yarn tensioners offer a gentle yarn treatment
and can withstand high loads of fast-running yarns,parlty also of aggressive yarns. Textiles
intended for special applications require highest efficiency and best quality already when
producing the warps. Also a good yarn tensioners ensure constant and high tensile forces, even
when processing high-strength technical materials.Yarn Breakages are eliminated in a most
reliable and easy way by the self-activation of the yarn stop motion and by signaling of the yarn
place breakage.
Types of Yarn tensioners on the basis of Application –

Wrapping yarn tensioner (Model U3V) :

Easy handling , Sturdy construction, low-priced ,Due to its easy handling and cost-efficient
construction, the wrapping yarn tensioner U3V is ideally suited for all denim applications. The
U3V yarn tensioner generates the required yarn tensile force based on the combination of
wrapping and disc weight

1) Manually adjustable yarn tension via the wrapping angle

2) Ballon protection for preventing the jumping-over of the balloon onto the
yarn tensioner

Application Denim
Yarn tension 3 up to 35 cN
Yarn Count 20 up to 400 dtex
Speed 5 up to 500 m/min
ACCUTENSE rotational hysteresis yarn tensioner :

Specially designed for fine glass filaments ; Perfectly steady and smooth yarn tension controllable via
power supply unit,Yarn tension ranges between 2 cN and 35 cN , Creel length compensation adjustable
by segments ,Designed for high speeds.

1) Yarn Guide wheel

2) Opto electronic yarn break detector

Application For fine glass fibers

Special wheel made from
Wheel aluminium and chromium-
plated
Yarn tension range 2-35cN
Yarn Count From 2 tex to 10 tex
Speed Up to 1000m/min
Pre-tensioner Disc pre-tensioner
Eyelets Mad from titanium dioxide