Beat-Up

Beating-up:

It is the third primary motion in weaving. It is a process of pushing the newly inserted weft yarn
to the woven fabric at a point known as the “fell of the cloth” with the help of a reed fixed in the
sley. The sley is given a sudden and quick movement towards the fell of the cloth by the cranks
in the crankshaft.

Purposes of beating-up:
The main purposes of beating up are:
1. To push the newly inserted weft yarn to the “fell of the cloth”.
2. To produce compact fabric.

1.1. Classification,
Classification of beating-up:
Beating-up may be classified in many ways. Some of those are mentioned below:
1. According to the no. of beat-up:
(a) Single beat-up
(b) Double beat-up
2. According to the movement of the cloth fell:
(a) Fixed fell
(b) Moving fell
3. According to the movement of reed:
(a) False or variable beat-up
(b) Real beat-up
4. According to beat-up mechanism:
(a) Conventional beat-up (Crank & crank arm)
(b) Modern beat-up (Cam beat-up)
(c) Link beat-up
5. According beat-up development:
(a) Traditional/ Normal beat-up
(b) Special beat-up: False beat-up

1.2. principles of crank and crank arm,

Single beat-up mechanism:

In a single beat-up mechanism, one beat-up is done per rotation of the crankshaft. Single beat-up
is used to produce most fabrics that are not so compact.
Construction:

The lower end of the Sley sword is pivoted to the rocking shaft. The sley race is connected to the
sley sword.

A connecting rod or crank arm is connected to the back of the sley race by a pin called a sword
pin and its other end fastens around the bend in the crankshaft, which is known as cranks. Reed
is joined by Sley Race with the help of Reed Cover.

Working principle

● For the beating up process, the sley sword must reciprocate. The sley sword is connected
to a rocking shaft for this purpose.

● When the crank of the crankshaft rotates and comes in the forward position, then it
pushes the crank arm forward. Thus crank arm gives to & fro movement.

● As the crank arm is connected to the sley race and the reed is situated above the reed
race, the reed also moves forward as the crank arm moves forward. The reed pushes the
weft in the fell of the cloth.
● In this mechanism, one beat-up is done for every picking.
https://youtu.be/vtyPkxBeugs?si=StZOsnTKqObMnqBB
 1.3. double beat-up mechanisms:

Double beat-up mechanism

If after inserting a pick, two beat-ups occur successively by one revolution of the crankshaft it is
called double beat-up.
To produce very compact fabric (e.g. - canvas/triple/tent), double beat-up is used.

1. Rocking shaft 2. Sley sword 3. Sword pin 4. Reed 5. Crank shaft 6. Crank 7. Crank arm 8
& 9. Additional connecting arm 10. Knuckle joint
Beat-up occurs at 1 and 3 position.
Construction:
❖ The lower end of the Sley sword is pivoted to the rocking shaft. The sley race is
connected to the sley sword.
❖ Crank arm is connected with two additional connecting arms by means of a knuckle joint.

Working principle:
● In one drawing the arms E & F are straight, but when the crank moves to the top
center it is pushed up and E & F are bent.
● When the crank moves downwards, the knuckle joint is also moved downwards and
there comes a stage when the arm becomes straight & a beat-up is done by the
system.
● When the crank again moves up, the knuckle joint also moves up, and again the
arms become straight and cause the beat-up.
● Hence the two beat-ups are done for a pick.

https://youtu.be/Wva-sXtQQuk?si=XsX8MJ9SPPTKk8MA

Cam beat-up mechanism or how the weft yarn is released from the projectile guide during
beat-up:

fig: Cam beat up mechanism.

Mechanism:
 ⮚ When the projectile runs through the guide in unison with the weft, yarn lays into the
guide. The two antifriction rollers follow the two cams, which means antifriction roller-1
follows the outer profile of cam-1 and antifriction roller-2 so on. The nose of the cam-2
pressed the antifriction roller-2 in the left side direction. So the sley moves right side and
as a result, the weft yarn releases from the guide by the slot of the guide and at a time
reed beats up the newly inserted weft to the fell of the cloth.
⮚ It should be noted that two cams are used to limit the movement of the sley. Here smooth
beat-up is obtained by the rotary motion of the cam and there is no eccentric motion.

1.4. Sley eccentricity ratio and its effects.

Sley Eccentricity ratio:

The ratio of the radius of the crank circle and the length of the crank arm is called the Sley
eccentricity ratio.
Sley eccentricity ratio, e= r/L
Where, r= Radius of crank circle
L= Length of crank arm.

Advantages of higher sley eccentricity ratio:

1. As SER increases the sley remains longer nearer to its most backward position and more
time for the passage of the shuttle.
2. As SER increases the velocity of the sley around beat up also increases. It tends to
increase the effectiveness of the shuttle.

Disadvantages of higher SER:

1. Causes rapid acceleration and deceleration of the sley around beat up.
2. A more robust loom is required.

Types of reed:
1. Plain reed
 Figure: Plain reed
2. Profile reed: The dents of this reed are bent to make a guide to facilitate the compressed
air passage of the air-jet loom.

Figure: Profile Reed

3. Closed reed: The top and bottom sides of the reed are closed.
4. Open reed: The top side of the reed is open. This special reed is used for lappet weaving.
https://youtu.be/xTqGQm9WtCg?si=aJ8KDt97Zl5zdUsf

Technical terms relevant to reed:

1. Reed space: The space covered by the reed in the loom is called reed space.
2. Reed width: The width covered by the warp sheet within the reed is called reed width.
3. Reed count: The number of dents per unit length of the reed is called reed count.
4. Denting: Threading the warp yarns through the reed dent is called denting.
5. Denting order/plan: The plan regarding the number of warp yarns per dent is called
denting order. The standard denting order is 2. It varies depending on the weave plan and
some technical reasons.
Types of denting order: i. Regular, ii. Irregular, iii. Skip denting

i.

ii.

iii.

Types of reed count system:

There are lots of reed count systems. Among them, mostly practiced reed systems are as follows:
1. Stockport system: Number of dents per 2 inches of the reed.
2. Bradford system: Number of groups of 20 dents per 36 inches of the reed.

Identification of a reed:
What does 3/100 S 60”/5” Blue mean?
Ans. S denotes to Stockport reed count system. 3 refers to the denting order and 100 refers to the
reed count. 60” means reed space and 5” means reed height. Blue means the sticker color on the
top baulk of the reed.

Selection of a suitable reed count to attain the required EPI:

Reed count = Finished EPI-10% shrinkage

Example: Reed count = 120-10% = 108

2 1
Determine the denting order/plan for a 2
twill and 1
(2) Oxford yarn dyed fabric with
proper reasoning

Ans. For 2/2 twill denting order equals to the warp repeat of the weave plain and that is 4.
Reason: To prevent the twill line breaking, all of the warp of one repeat must be threaded
through the same dent.

For Oxford, the denting order will remain the same (2) but the denting plan will be changed.
Figure (ii) will be the denting plan for the Oxford design.
Reason: Interlacement of the first and second warp is the same. They go upward and downward
together during the shedding. That’s why there will be huge friction between them. The same
will happen to the third and fourth warp. Ultimately, the shade of the yarn-dyed fabric will be
damaged and yarn strength will be decreased. To prevent this friction, warp yarn of the same
interlacement cannot be in the same dent.

Mathematical problems:

❖ Calculate the “reed space” required to produce an elastic fabric having 30% shrinkage
(width of finished fabric 50″)

● Required reed space =

= 65 inch
❖ Calculate the required finished EPI if the reed count is 54 and the denting order is 3.

No. of warp yarn within 1 inch = 54*3/2 = 81

If 10% shrinkage occurs after the finishing process
Finished EPI = 81/ (100-10) % = 90

❖ Reed count conversion:

 The required finished EPI is 120. If the denting order is 3 then calculate the suitable reed
count.
Reed count for denting order, 2 = 120-10% = 108
Final reed count x final denting order = Initial reed count x initial denting order
Final reed count x 3 = 108 x 2
Final reed count = 216/3 = 72

Choose a suitable reed count for the following denting orders to attain the required EPI.
i.

ii.

iii.

i. 120-10%=108 as 2 ends per dent

ii. Avg. denting order = 2+4/2 = 3
Reed count = 108*2/3 = 72
iii. Avg. denting order = 2+0+4/3 = 2. So, the reed count is the same as
number (i), 72.
❖

Choose a suitable reed count and denting order to attain the required EPI if the design is
1
2
twill.
Ans. Required denting order = 3 (warp repeat of the weave plan)
Reed count for denting order, 2 = 80-10% = 72
 The required reed count = 72*2/3 = 48

❖ Decide which case will you choose for a wider loom.

i. Crank arm length is 20 inches and crank radius is 8 cm.
ii. Crank arm length is 21 inches and crank radius is 9 cm

Ans. Sley eccentric ratio for case-(i) = 8/20*2.54 = 0.157

Sley eccentric ratio for case-(ii) = 9/21*2.54 = 0.169

Greater the Sley eccentric ratio, wider the loom will be. I will choose case-ii