Khulna University of Engineering & Technology

Experiment No: 02

Name of the Experiment:

Study on Rapier weaving mechanism.

Remark:

Date of Performance: 06-04-2021 Name: Naimul Hasan

Date of Submission: 05-06-2021 Roll: 1621060

Year: 4th

Term: 2nd
 Department of Textile Engineering, KUET

1.0 INTRODUCTION

Rapier weaving today exists in diversified forms. During the last two decades the developments
in rapier weaving have been carried out in a rapid continuous way. Rapier weaving machine
produces top- quality fabrics from spun yarns such as cotton-wool, camel hair, silk, synthetic
fibers and fancy yarns. Today’s rapier weaving machine has become fast and exceptionally
flexible. It offers a choice of various reed widths, shedding motions, selvedges and filling
insertion colors. This makes it suitable for weaving an extended range of articles: fashion fabrics,
shirting, denim, suiting, industrial or furnishing fabrics, in one to eight or twelve filling colors or
yarns, with a maximum weight of 500 g/m2. Today’s rapier weaving machine is designed with
modern electronics, with total automation of weaving and central microprocessor control system,
also ensuring maximum reliability, amazing user-friendliness, ease-of operation, shorter style
changing time, excellent fabric quality, low energy consumption, and optimized insertion cycle
for unequalled industrial speed

In weaving, different types of looms are used for producing fabric from the weaver’s beam.
Rapier loom is a popular shuttle-less loom for producing different types of designed fabric. In
most of the denim industry, rapier looms are used hugely. Rapier loom carries the filling yarn
through the shade of warp yarns to the other side of the loom by finger like carriers called rapier.

A rapier loom is a shuttle less weaving loom in which the filling yarn is carried through the shed
of warp yarns to the other side of the loom by finger-like carriers called rapiers. A stationary
package of yarn is used to supply the weft yarns in the rapier machine. One end of a rapier, a rod
or steel tape, carries the weft yarn. The other end of the rapier is connected to the control system.
The rapier moves across the width of the fabric, carrying the weft yarn across through the shed to
the opposite side. The rapier is then retracted, leaving the new pick in place.

In some versions of the loom, two rapiers are used, each half the width of the fabric in size. One
rapier carries the yarn to the center of the shed, where the opposing rapier picks up the yarn and
carries it the remainder of the way across the shed. The double rapier is used more frequently
than the single rapier due to its increased pick insertion speed and ability to weave wider widths
of fabric.

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2.0 OBJECTIVES:

From this experiment we will learn about these objectives

 To study about the rapier loom.

 To learn about the features of the rapier loom.
 To identify different parts and functions of the rapier loom.
 To learn about the working principle of rapier loom.
 To identify yarn path diagram of rapier loom.
 To learn about the rigid rapier and flexible rapier.
 To know the advantages of rapier loom.

3.0 FEATURES:

The features of the rapier loom are given below:

1. The picking action in rapier loom is done by rapier.

2. In this loom one rapier or two rapiers is used for picking.

3. Picking can be takes place from one side, or both side across the loom.

4. Rapier performs a reciprocating motion.

5. Rapier machines weave more rapidly than most shuttle machines but more slowly than

most other projectile machines.

6. An important advantage of rapier machines is their flexibility, which permits the laying

of picks of different colors.

7. This type of loom machine is suitable for weft patterning.

8. Rapier loom also weave yarns of any type of fiber and can weave fabrics up to 110 inches

in width without modification.

9. In rapier loom do not need to create air or water pressure so it saves the power.

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 Department of Textile Engineering, KUET

10. Rapier loom machine consumes moderate power.

11. The rapier is too stiff then it will not coil.

12. Rigid and flexible rapier machines operate at speeds ranging from about 200 to 260 ppm

13. This loom uses up to 1300 meters of weft yarn per minute.

14. They have a noise level like that of modern projectile looms.

15. Rapier loom is most productive in the manufacturing of light to medium weight fabrics.

16. Fancy fabric is produced by using rapier loom in weaving sector.

17. They can produce a wide variety of fabrics ranging from muslin to drapery and

upholstery materials.

18. Normally, rapier loom has a simple mechanism.

19. Ultra-modern rapier machines are built with two distinct weaving areas for two separate

fabrics.

20. For two separate fabrics rapier picks up the yarn from the center, between the two fabrics,

and carries it across one weaving area; as it finishes laying that pick.

21. In a modern machine two or three cloths can be woven simultaneously.

4.0 MECHANISM/WORKING PRINCIPLE

The technique of weft transfer is dependent on the principle of operation. Butt is essential in both
the Gabler and the Dewas systems that one rapier head should enter the other cleanly in order to
make the transfer. Any non-sliding transfer contact between the heads is likely to cause burr on
some part of the rapier, and this may then catch the warp or weft during weaving to cause yarn
break.

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 Department of Textile Engineering, KUET

The picking or weft insertion system is based on modified repair principle, two carriers entering
the warp Shed simultaneously from each side of the loom and meeting almost half way through
the shed. These are two basic type of rapier heads:

1. Loop transfer rapier machine-Gabler Principle.

2. Tip transfer repair machine -Dewas Principle.

4.1 Gabler Principle:

Figure 1 illustrates rapier heads that are suitable for use with the Gable technique as found on the
Versa mat loom. The weft is never gripped. It is placed opposite the cut-out A in the right-hand
rapier head, and, as the rapier advances towards the center of the loom, the yarn passes from its
clamped position, round the rapier head, to the supply package in the form of a hairpin. When the
two rapier heads meet at the center of the 100m,the smaller left-hand rapier head enters the yarn-
carrying right-hand head. The thread at A is passed under the spring-loaded cover guide at B,
and, as the left-hand rapier is withdrawn, it repositions the weft at C. The yarn can then slide
through the left-hand rapier head as it is withdrawn so that the hairpin is straightened out.

Figure 1: Gabler Type Weft Insertion (Versamat Loom)

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4.1.1 Gabler System Yarn Path Diagram:

Figure 2 shows the weft yarn path diagram of Gabler system insertion method given below:

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4.2 Dewas Principle:

Figure 2: Weft Yarn Path Diagram (Gabler System)

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In the Dewas system, shown in Figure 3, the yarn is gripped in each rapier head. The gripping
unit usually consists of a fixed point against which a spring-loaded clamp presses to trap the
weft. In the MAV loom illustrated, and in many other looms, the spring-loaded clamp has a cam
profile that meets a fixed point on the loom or sley-mounting. These points open the clamps
when the weft is to be picked up or released outside the selvedge. The right-hand head thus traps
the weft at A and pulls it through the shed until the rapiers meet. The thread is then guided round
point B, and, as the left-hand head withdraws, the thread is trapped at C and pulled across the
loom to complete insertion. In some looms, the spring in the delivery head is opened at the time
of transfer. This is done by the specially shaped profile of the left-hand rapier head, and it
obviates the need to pull the weft out of the spring clamp in the delivery head. Thus, the
possibility of weft breaks at transfer is minimized. Furthermore, there is no chance of the weft's
being pulled out of the receiving spring.

Figure 3: Dewas Type Weft Insertion (MAV Loom)

4.2.1 Dewas System Yarn Path Diagram:

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Figure 4 shows the weft yarn path diagram of Gabler system insertion method given below:

Figure 4: Weft Yarn Path Diagram (Dewas System)

5.0 ADVANTAGES:

Using Rigid Rapier:

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1. They do not require guiding across the warp sheet; the rapier head slides on the warp,
or on the race-board.
2. High mass and rigid construction ensure straight movement of rapier heads.
3. A great diversity for both warp and weft threads in yarn count and character.

Using Flexible Rapier:

1. Less floor space requirement, spatial productivity is higher.

2. Flexible rapier band are wound on wheels or placed in semi-circular channels when
they are withdrawn outside the shed, and the result is working widths up to 5 m.

Combining:

1. The rapier loom doesn’t require dynamic forces or anything like the magnitude as
those involved in the conventional loom.
2. The weft insertion rate in a rapier loom is very much influenced by the method of
weft control. Weft insertion rate is very high rather than any conventional loom.
3. It can occur double pick at a time by double picking insertion system. Here is no need
to cut the weft selvedges and no weft wastage.
4. Weft insertion rate is very high rather than any conventional loom Rigid rapiers has a
useful feature that they can be simultaneously inserted in two sheds one above the
other, for producing double plush and certain carpets.

6.0 DISCUSSION:

A rapier loom is a shuttle less weaving loom in which the filling yarn is carried through the shed
of warp yarns to the other side of the loom. Weft insertion rate in rapier loom is very high rather

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 Department of Textile Engineering, KUET

than any conventional loom. So it is important to study the rapier loom. In this experiment, we
have learned about the rapier loom properly and efficiently. We have also studied about the
different parts and functions that are associated with the rapier loom in accordance with the
different weft insertion method. We have studied about the weft yarn path diagram through the
cone package to the weaving zone. We have also studied the advantages of rapier loom in
comparison to other shuttle less looms. We have also informed about the features of rapier loom
in depth. We have also identified the yarn path diagram of rapier loom in this study. We have
learned about the rigid rapier and flexible rapier. Overall we can say that, we have achieved our
objectives from this study and now have a better understanding about the rapier loom.

7.0 CONCLUSION:

The rapier loom doesn’t require dynamic forces or anything like the magnitude as those involved
in the conventional loom. It is a shuttle less loom. So, weft insertion technique is different to
conventional shuttle loom. Rapier loom is much faster than a conventional loom. As a textile
engineer it is our mandate to learn about the different parts and function that are related with the
mechanism very deeply and properly. And we have learned this thing from this experiment. It
will be very much helpful and beneficial for our practical job sector and working environment.
This experiment will help us to operate a rapier loom in future if necessary.

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