WARP STOP MOTION

Automation Textile Machinery :

Automatic Warp Stop Motion

The yarn inspector Warpstop Types 3010 (mono), 3011 (major/minor), and 3012 (major/
minor/length selector) are used to detect yarn faults during the warping process. By using the
latest light wave conductor technique, a high operational standard of the surveillance system
is guaranteed. Thanks to the digital sensitivity setting with a stepped calibration possibility
from 0,1%, even the smallest faults are detected. The yarn inspector is comprised of the
control unit Warpstop series 3000, with integrated operator panel, an inspection head bed,
and supporting frame. The version 3012 requires, in addition, an impulse sensor to monitor
the yarn speed. The inspection head works using the latest light wave conductor technology
for the evaluation of the data transfer to the control unit. The optical head guarantees a high
linearity of the light beam and also provides a stable sensitivity level over the full working
width of the unit.
Since no electronic parts are contained inside the inspection head, the unit is not sensitive to
any electromagnetic influences. Should it be necessary to exchange the transmitter or
receiver of the inspection head, no adjustment is needed since all electronic parts are inside
the control unit. An improved guidance of the yarn through the light beam is ensured by
means of the rounded section overrun profile on the inspection head, as well as a reduction
in the soiling of the inspection head caused by slub and yarn residue. The signal received in
the control unit is compared to the pre-set threshold stopping signal. The warping machine
will then be stopped. The control unit is provided with an integrated operator panel with LCD
display and keyboard that can be placed in any position to suit your requirements.
Depending on the model of the unit, the following information is displayed on the LCD
screen: yarn noise level value, size of the last stop signal, preset stopping and counting
thresholds, length information, and total number of faults indicated. All operational
parameters can be entered via an easy-to-use menu control. In addition, it is possible to
provide the control unit with a printer interface.
Safe and fast detection of thread breaks in the warp sheet helps to reduce losses. The newly
developed laser light barrier system laserstop sets a standard in reliability and safety in the
control of warp sheets on elastomeric equipment. This newly developed system uses the
most up-to-date laser technology for the light barriers and an evaluation incorporating the
most modern digital signal processing in the control unit. The special characteristics of the
system are:
• Fast and safe detection of broken threads
• Compact construction of the laser light channels
• Visible, safe red-light laser (laser class 1)
• Vibration insensitive receiver
The Control unit consists of digital signal evaluation and computer supported, automatic
system. The laser light barriers operate with a visible red-light laser (670 nm). These 6 diode
lasers are used because of their long operating life and low mechanical sensitivity
characteristics. The high homogeneity of the light beam guarantees a constant sensitivity
over the full working width. In the receiver, a newly developed measuring system is used,
which gives excellent results in terms of vibration independence and sensitivity. The laser
light barriers are mounted parallel to the yarn sheet. When a broken thread comes out of the
yarn sheet, it will break the laser beam. The resulting impulse will be digitally processed and
the elastomeric machine will be stopped immediately.

Warp Stop Motion

The warp sheet is fed in the weaving process at a low speed and with a large number of the
warp ends. Hence, checking the continuity of the individual warp ends requires an essentially
different approach from that adopted in the weft checking.
The main problems of the warp stop motion design are:
1. The high number of warp ends to be checked; in cotton weaving the average warp set is
20 ends/cm, and in silk and filament weaving it is 40 ends/cm and more.
2. The large free length of the warp ends to be checked; the warp length in the weaving
plane ranges from 1.2 to 1.6 m.
3. The many possible breakage points, scattered at considerable distances, that is, on the
lease rods, in the drop wires of the warp stop motion, in the drop wires of the stop motion, in
the healds, in the reed, and at the beat-up line. Moreover, the warp end may already be
disrupted on the warp beam.

Classifications
The warp stop motions are classified in three categories:
1. The drop wire stop motions
2. The harness stop motions
3. The contactless electro-optical stop motions
With the drop wire and harness stop motions, the stop signal may be transmitted
mechanically or electrically. The contactless stop motions are usually based on an electro-
optical checking principle and an electrical stop signal transmission.

The Warp Stop Motion for Large Width Weaving Machine

On the large width weaving machines, the warp stop motions frame must be adequately rigid
or supported in the middle to avoid deflection of the warp stop motion rods. To make the
breakage location easier, the warp stop motion rods are divided in two zones, each provided
with an individual breakage indication system.
The through rod helps to find the dropped wire more rapidly. The rod is swung out in the two
indicated directions, and while moving freely under the drop wires pinned on the tension
warp ends, it pushes the dropped wire outside the row.

The Harness Stop Motion

If the warp end breaks at the front near the reed, it may get entangled with the other way
ends. If it is not slackened at the rear of the weaving plane, the respective drop wire does not
drop down and the weaving machine is not stopped. In this instance, it is convenient to use
harness warp stop motion.
The mental shaft rods and carrying the healds are connected to one terminal of the electro
circuit. The lower part of the heald shaft frame is provided with plate, which is connected to
the other terminal of the electric circuit. The current is not fed in the circuit unless the heald
shaft is at the lower position; then the spring-loaded contacts come to rest on the contact
plate, which is mounted on the machine frame and insulated from it. Electrically connected
contact are on one side, rods, and on the other plate. During normal operation, the healds
are lifted by the motion of the warp tension when the heald is at the lower position and the
electric circuit is disconnected. When a warp end breaks, the heald drops, and when current
is switched on at the lower heald shaft position, the electric circuit is completed, releasing a
stop signal, and the weaving machine is stopped.

The Electro-Optical Warp Stop Motions

One of the systems is based on the use of pulse counter that, mounted on a cursor, travels
regularly across the warp sheet. If a warp end from the preset number is missing, the
weaving machine is stopped. This type of warp stop motion is still in the phase of
experimentation. It may only be placed where the warp ends are uniformly distributed, that is,
close to the fabric fell or on the back rest roller or, possibly, on the lease rods. It may be
expected that, in the future, the warp sheet will be checked by this method in two places, on
a special singlepass leasing comb at the rear of the weaving machine and close in front of
the beat-up line.

The Hayashi Optic-Electronic Warp Stop Motions

The light beams are emitted in the shed by a lamp fixed at the reed and a lamp mounted on
the machine frame. The two light sources are operated by a magnetic switch within one part
of the machine revolution as long as the shed is fully open. On the opposite side of the warp
sheet, photoelectric transistors are fitted on the reed and the machine frame respectively.
In the warp stop motion, when a warp end breaks, or when spliced warp ends pass, the
luminous flux is disrupted and the weaving machine is stopped. This type of warp stop
motion is suitable for the weaving widths up to 4 m. It is a contactless checking of the shed
cleanliness. The stop motion has outstanding reliability in silk and filament weaving. It
appears that owing to the textile dust and fly connected with the staple yarns of natural fibers
as well as to the water spray connected with the water jet weaving, it will be less reliable in
the above two sectors.

The Warp and Reed Protector Motions

If the shuttle or gripper projectile, flying through the warp, were retarded or otherwise failed to
arrive in the reversing box in time, it would be caught and braked by the closing shed. During
the subsequent movement of the reed toward the beat -up position, the warp ends would
break; the reed, but also the shuttle or gripper projectile and possibly the temples, would be
damaged. The damage caused by it is extremely laborious, time consuming, and costly to
repair. To eliminate the risk, the weaving machines are provided with warp and reed
protector motion, which stops the machines in time. The design of the warp protector motion
must meet strict requirements:
1. The stop motion must be absolutely reliable because any failure in operation would result
in a heavy breakdown of the weaving machine.
2. The stop motion must interlock the machine start as long as the trouble is not removed.
3. While withstanding high stresses, the stop motion must have small dimensions and allow
weight.
The warp protector motions, used at present, can be divided into two groups:
1. The stop motions with mechanical sensors, designed for a mechanical signal transmission
on the weaving machines equipped with a mechanical clutch and brake system, or for an
electrical signal transmission on the weaving machines equipped with an electromagnetic
clutch and brake system
2. The contactless stop motions operating on either a photoelectric, capacitance, or induction
principle

The Contacless Stop Motions

The photoelectric stop motion during the weft carrier, moving in the direction of the screen,
when it attains the exit position, the light beam emitted by lamp and directed toward a
phototransistor. A disadvantage of this system is that the stop motion fails to operate if the
lamp is burned or soiled. According to modified design, the stop motion operates through two
checking positions:
1. The screening of the light beam by the moving weft carrier between lamp and
photoelectric sensor is merely registered by the stop motion and the weaving machine is not
stopped.
2. When the weft carrier attains the exit position, the photoelectric sensor must again be
exposed to the light; otherwise the weaving machine would be stopped. Both checks are
interconnected so that when a short pick occurs or when the lamp filament is burned, the
weaving machine is stopped.
A capacitance warp protector motion operates on the principle of the change of the sensor
capacitance caused by a metallic weft carrier attaining the exit position. A block diagram of
this stop motion is shown in the Figure 10.5, which includes a radio-frequency oscillator, stop
motion sensor, signal amplifier, and signal translator. The double arrow indicates the output
signal. The induction stop motion is arranged similarly.

Weaving ACIMIT
Warp control
The supervision of the warp threads is an essential factor for the fabric quality.
The device used is called warp stop motion; it stops the running of the weaving machine at
each
thread breakage or even when the thread becomes slack, that is when the thread gets a
tension
level considerably below normal level (delicate fabrics).
The warp stop motions generally used today employ electrical or electronic detection
systems.

Electric warp stop motion

The operating system is the following (Fig. 110): each warp thread is passed into the bottom
slit of
a metallic drop wire 2, which this way is supported by the thread under tension. Through the
top
slit of the drop wire passes the contact rail 3 composed of an U-shaped outside coating in
stainless
steel, of a strip of insulating material and of a flat conductive inside blade in nickel-plated
copper,
provided on the upper part with a toothing.
The contact rail 3 is part of a low voltage electric circuit, of which the drop wire 2 acts as
circuit
breaker.
Fig. 110 −Electric warp stop motion:
1 −Warp thread
2 −Metallic drop wire
3 −Contact rail

Under normal conditions the drop wire is

supported by the thread and no current
passes through the circuit. However when
the thread breaks or loosens too much, the
drop wire falls and its asymmetric form in the inside of t he upper part gets it to come into
contact at the same time with the outside U
shaped drop wire and with the inside drop wire. Thus the circuit is closed and a passage of
current
is generated which is detected by a processing station of the machine and causes the stop in
the
desired position (with closed shed, to facilitate the intervention of the operator on the broken
thread). In the version of Fig. 111, the search for the broken thread is carried out by lateral
levers
which cause the sliding of the toothed bars in order to pinpoint with their movement the fallen
drop wire.

Electronic warp stop motion

This is the latest solution proposed
by the manufacturers of weaving
machines.
The electronic warp stop motion in
Fig. 112 signals, by means of a
digital indicator, the contact rail and
the position of the drop wire which
originated the contact. In the
example of Fig. 112, the drop wire is
placed on the fifth contact rail at a
distance of 275 cm; the measuring
ribbon with its scale guides the
operator directly to the breakage
zone.
This solution permits not only the
quick finding of the broken thread by
the weaver, but allows also an
automatic analysis of the warp stops
through a data detection system.

To facilitate the detection of the

broken ends, some manufacturers
offer the possibility of installing
electronic warp stop motions with luminous signaling diodes on both sides of each control
rail.
The model in Fig. 113 signals by the lighting of a red light-emitting diode placed at the end of
each contact rail the bar and its half on which the drop wire has fallen.

Fabric defects and problems of machine regulation

Warp stop motion

The selection of the type of drop wire, of the weight and density of each contact rail must be
made
with great care on basis of the yarn count and composition, following the indication of the
manufacturers. The responsiveness of the warp stop motion can be increased by reducing
the drop
height of the drop wires towards the contact rail, in case of threads which are prone to get
entangled or which show very difference counts or twists. This responsiveness can be
reduced in
case of loose threads or false stops.