IES960623A2 - A weaving process - Google Patents

Abstract

A process for weaving relatively weak yarns comprises leading selected warp threads from spools (10) on a support rack (11) in a desired manner for winding the threads on a warp reeling drum (14). A set of warp sections are wound up side by side on the drum (14) to a desired width. The warp sections are transferred to a spool (40) which is loaded on a loom (42). The warp threads are fed to a weaving station (43) on the loom (42) and a weft thread is delivered between opposite sides of the warp threads for weaving a cloth. A desired longitudinal tension is maintained on the warp thread at the weaving station by winding the cloth on a tensioning roller downstream of the weaving station (43). This tensioning roller has an outer surface of resilient material to gently but firmly grip the cloth without damaging the cloth. Downstream of the loom the cloth is checked at an inspection station (80). <Fig.1>

Description

A weaving process A process for weaving relatively weak yams comprises leading selected warp threads from spools (10) on a support rack (11) in a desired manner for winding the threads on a warp reeling drum (14). A set of warp sections are wound up side by side on the drum (14) to a desired width. The warp sections are transferred to a spool (40) which is loaded on a loom (42). The warp threads are fed to a weaving station (43) on the loom (42) and a weft thread is delivered between opposite sides of the warp threads for weaving a cloth. A desired longitudinal tension is maintained on the warp thread at the weaving station by winding the cloth on a tensioning roller downstream of the weaving station (43). This tensioning roller has an outer surface of resilient material to gently but firmly grip the cloth without damaging the cloth. Downstream of the loom the cloth is checked at an inspection station (80).

TRUE COPY AS LODGED APPLiCAT’ A Weaving Process This invention relates to a weaving process The invention particularly relates to a process for weaving relatively weak yarns to produce high quality cloths. The weaving of such delicate yarns generally causes difficulties as the yarn breaks easily and this can lead to relatively high wastage and numerous interruptions to the weaving process for producing a length of cloth from the yarn. This increases the cost of producing the cloth. Further, cloth woven from such yarns is relatively easily damaged when handling and this presents problems in automated weaving looms leading to, for example, scuffing of the cloth.

The present invention is directed towards overcoming these problems .

According to the invention, there is provided a weaving process comprising the steps :- leading a group of selected warp threads from a plurality of spools rotatably mounted on a support rack, feeding the group of warp threads in a desired manner to a warp reeling drum, applying a predesired tension to each warp thread as it is being fed from a spool to the warp reeling drum, rotating the warp reeling drum for winding the group of warp threads about the drum, winding a desired length of warp thread on the drum, cutting the warp Γ960623 - 2 threads leaving a warp section of a predesired length on the drum, winding a plurality of juxtaposed warp sections of the predesired length onto the warp reeling drum forming a set of wound warp sections on the warp reeling drum, each warp section comprising the selected combination of a number of warp threads, the combined width of the set of the wound warp sections on the warp reeling drum corresponding to a preselected desired cloth width, transferring the set of wound warp sections from the warp reeling drum onto a spool, mounting the spool on a loom, feeding the warp threads from the set of wound warp sections in a controlled manner to a weaving station on the loom, feeding a weft thread between opposite sides of the warp threads for weaving a cloth, tensioning the cloth downstream of the weaving station, for maintaining a preset desired longitudinal tension on the warp threads at the weaving station by winding the cloth around a tensioning roller downstream of the weaving station, the tensioning roller having an outer circumferential surface formed of a resilient material having a plurality of projections thereon for gently but firmly gripping the cloth and longitudinally tensioning the cloth as it is delivered from the weaving station, and winding the cloth on a reel downstream of the weaving station.

In a further embodiment, the process includes transversely tensioning the cloth immediately downstream of the weaving station by engaging opposite sides of the cloth with elongate spreading rollers for urging opposite sides of the cloth outwardly applying a transverse tension to the cloth, each spreading roller engaging the cloth by means of a number of pin wheels and an associated roller element rotatably mounted co-axially on a support, each pin wheel having an outer cloth-engaging surface with a number of outwardly projecting pins thereon and the roller element being mounted inboard of the pin wheels and having an outer circumferential surface formed of a resilient material with a helical ridge formed in the outer surface for urging the cloth outwardly upon rotation of the roller element.

In a further embodiment, the process includes the step of controlling the weight of rapiers used for feeding the weft through the warp in response to the strength of the warp.

In one embodiment of the invention, the process includes the step of supporting a trailing end of the cloth at the weaving station with a support bar during threading of the weft between opposite sides of the warp threads, the support bar having an upper cloth-engaging surface formed by a soft pile, the support bar moving between a raised cloth engaging position when threading the weft and a lowered disengaged position away from the cloth for advancing the cloth at the weaving station.

In another embodiment, the process includes the step of applying a predesired tension to each warp thread by leading the warp thread from the spool around a post, the thread being delivered between a pair of plates mounted on the post, the plates being biassed together for applying the predesired tension to the warp threads.

In another embodiment, the process includes the step of applying a wax to the warp threads as the warp threads are being delivered from the warp reeling drum to the spool, leading the warp threads around portion of a rotatable waxing roller which passes through a wax bath for coating a surface of the waxing roller with wax for application to the warp threads .

In another aspect, the invention provides a process comprising the steps :leading a group of selected warp threads from a plurality of spools rotatably mounted on a support rack, feeding the group of warp threads in a desired manner to a warp reeling drum, applying a predesired tension to each warp thread as it is being fed from a spool to the warp reeling drum, rotating the warp reeling drum for winding the group of warp threads about the drum, winding a desired length of warp thread on the drum, cutting the warp threads leaving a warp section of a predesired length on the drum, winding a plurality of juxtaposed warp sections of the predesired length onto the warp reeling drum, forming a set of wound warp sections on the warp L 960823 reeling drum, each warp section comprising the selected combination of a number of warp threads, the combined width of the set of wound warp sections corresponding to a preselected desired cloth width, transferring the set of wound warp sections from the warp reeling drum onto a spool, mounting the spool on a loom, feeding the warp threads from the set of wound warp sections in a controlled manner to a weaving station on the loom, feeding a weft thread between opposite sides of the warp threads for weaving a cloth, tensioning the cloth downstream of the weaving station, winding the cloth on a reel downstream of the weaving station, delivering the reel of cloth to a cloth inspection station, pulling the cloth from the reel, illuminating the cloth, inspecting the cloth by stretching the cloth vertically at the inspecting station and illuminating the vertical cloth portion for checking the cloth for defects, marking the location of any defects on the cloth, delivering any defective cloth to a repair station for mending any defects in the cloth, and delivering the cloth for further processing. 900023 In another embodiment, the process includes folding the cloth at the inspection station after checking the cloth for defects by leading the cloth back and forth across a table by feeding the cloth through a guide which is pivotally mounted above the table, swinging the guide between opposite sides of the table for folding the cloth on the table.

In a further embodiment, the process includes transversely tensioning the cloth immediately downstream of the weaving station by engaging opposite sides of the cloth with spreading rollers for urging opposite sides of the cloth outwardly applying a transverse tension to the cloth. Preferably, each spreading roller is operable for engaging the cloth by means of a number of pin wheels and an associated roller element rotatably mounted co-axially on a support, each pin wheel having an outer cloth-engaging surface with a number of outwardly projecting pins thereon, and the roller element being mounted inboard of the pin wheels and having an outer circumferential surface formed of a resilient material with a helical ridge formed in the outer surface for urging the cloth outwardly upon rotation of the roller element.

In another embodiment, the process includes winding the cloth around a tensioning roller downstream of the weaving station, for maintaining a preset desired longitudinal tension on the warp threads, the tensioning roller having an outer circumferential surface formed of a resilient material having a plurality of projections thereon for gently but firmly gripping the cloth and longitudinally tensioning the cloth as it is delivered from the weaving station.

In a further embodiment, the process includes the step of controlling the weight of rapiers used for feeding the 980823 weft through the warp in response to the strength of the warp.

In a further embodiment, the process includes the step of supporting a trailing end of the cloth at the weaving station with a support bar during threading of the weft between opposite sides of the warp threads, the support bar having an upper cloth-engaging surface formed by a soft pile, the support bar moving between a raised clothengaging position when threading the weft and a lowered disengaged position away from the cloth for advancing the cloth at the weaving station.

In another embodiment, the process includes the step of applying a predesired tension to each warp thread by leading the warp thread from the spool around a post, the thread being delivered between a pair of plates mounted on the post, the plates being biassed together to tension the warped threads .

In another embodiment, the process includes the steps of applying a wax to the warp threads as the warp threads are being delivered from the warp reeling drum to the spool, leading the warp threads around portion of a rotatable waxing roller which passes through a wax bath for coating a surface of the waxing roller with wax for application to the warp threads .

The invention will be more clearly understood by the following description of some embodiments thereof, given by way of example only, with reference to the accompanying drawings, in which:Fig. 1 is a schematic plan view illustrating a weaving process according to the invention? •60625 Fig. 2 is a perspective view of a warp thread tensioning device used in the process; Fig. 3 is a detail exploded partially sectioned elevational view of the warp thread tensioning device; Fig. 4 is a detail elevational view showing portion of the warp thread tensioning device; Fig. 5 is a diagrammatic illustration of portion of a loom used in the process; Fig. 6 is a detail elevational view of a spreading roller used on the loom; Fig. 7 is a diagrammatic illustration of a weaving station portion of the loom; Fig. 8 is an elevational view of a rapier used in the loom; Fig. 9 is an elevational view of the rapier, shown in an open position; Fig. 10 is a perspective view of a cloth inspecting station used in the process; Fig. 11 is a side elevational view of the cloth inspecting station; and Fig. 12 is a detail view showing a cloth folding portion of the cloth inspecting station.

Referring to the drawings, a weaving process and apparatus according to the invention will be described. 90O62J A plurality of spools 10 of warp thread are rotatably mounted on a support rack 11. Selected warp threads are fed from a number of the spools 10 through a guide 12 to a warp reeling drum 14. The warp reeling drum 14 is rotatably mounted on a support frame 15. A warp feeder 16 is slidably mounted on a track 17 at a front of the frame 15.

A predesired tension is applied to each warp thread 20 as it is being fed from a spool 10 to the warp reeling drum 14. Figs. 2 to 4 show a suitable tensioning device 21 for applying the desired tension to the warp thread 20. The tensioning device 21 has a base plate 22 with an upstanding warp thread guide 23 with a through hole 24 for reception and through passage of the warp thread 20 delivered from a spool 10. The warp thread 20 is led around and between a pair of upstanding posts 26. Each post 26 has a ceramic sleeve 27 around which the warp thread 20 passes. Upper ends 28 of the posts 26 are interconnected by a dipped crossbar 29.

At each post 26, the warp thread 20 passes between a pair of plates, namely, an upper plate 30 and a lower plate 31. The lower plate 31 rests on a cushion 32 which is seated on the base plate 22. One or more washers 34 may be mounted on the upper plate 30 to apply a desired tension to the warp thread 20 as it passes between the plates 30, 31 and around the post 26.

As can be seen in Fig. 2, spare washers 32 can be stored conveniently on the crossbar 29. It will be appreciated that the construction of the tensioning device 21 allows a selected tension to be applied to the warp thread 20 and an operator can readily easily check the tension being applied at any tension device 21 by looking at the washers 980623 mounted on each upper plate 30. Conveniently, also the washers 34 cannot be lost as they are mounted around the posts 26 which are interconnected. The washers may be of different weights which are colour coded for easy recognition.

A plurality of juxtaposed warp sections of a preselected length are wound onto the warp reeling drum 14. Conveniently, the required length of warp section is achieved by controlling the drive for the warp reeling drum 14 to rotate the warp reeling drum 14 until the required preselected length is wound on the drum 14 and then stop the drum 14. The end of the warp section is then cut and secured on the drum 14. Then the feeder 16 can be moved on the slide 17 to align another warp section for winding on the drum 14. In this way, a number of warp sections of a preselect length are wound side-by-side onto the drum 14 until the combined width of the wound warp sections correspond to a desired width of cloth that is to be produced.

When the required width of warp sections has been built up on the drum 14, the warp sections are transferred onto a spool 40 which is rotatably mounted on the support frame 15 and is connected to a drive (not shown) for taking up the warp sections from the drum 14 and winding them on the spool 40.

It will be noted that in some cases, it may be desirable to apply a wax to the warp threads as the warp threads are being delivered from the warp reeling drum 14 to the spool. In this case, the warp threads are led around a rotatable waxing roller (not shown) mounted intermediate the drum 14 and spool 40. A lower portion of the waxing roller passes through a wax bath containing liquid wax for coating a surface of the waxing roller as the lower 99092J portion of the roller passes through the wax bath, the wax being transferred onto the warp threads as they pass over an upper portion of the wax roller.

The spool 40 is then mounted on a loom 42. The warp threads are led from the spool 40 and fed in a controlled manner to a weaving station 43 on the loom 42. Guides 44, through which the warp threads 20 pass, feed the warp threads 20 in a desired configuration to the weaving station 43. The warp threads 20 are fed in two rows 45, 46 to the weaving station 43. At the weaving station 43, a pair of rapiers 47 pass between the rows 45, 46 to feed a weft thread between the rows 45, 46. Then the rows 45, 46 are moved past each other reversing their positions to grip the weft thread between the warp threads 20 thus weaving a cloth 48.

It is important to keep the cloth 48 and the warp threads 20 taut during weaving and to this end the cloth 48 is wound around a tensioning roller 49 downstream of the weaving station 43 prior to winding the cloth 48 on a reel 50 downstream of the weaving station 43.

An outer surface 51 of the tensioning roller 49 is roughened for gripping the cloth 48 and longitudinally tensioning the cloth 48 as it is delivered from the weaving station 43. For handling the delicate cloth, in order to provide the necessary grip while at the same time not scuffing the surface of the cloth 48, the surface 51 of the tensioning roller 49 is covered with a sleeve of a rubber or plastics material with a plurality of projections thereon for gripping the cloth. This ensures advantageously that delicate cloth is not damaged as it is fed away from the weaving station 43 while at the same time firmly engaging the cloth. 960623 Opposite sides of the cloth 4 8 are also urged apart by spreading rollers 55 immediately downstream of the weaving station 43. The spreading rollers 55 apply a desired transverse tension to the cloth 48. Fig. 6 shows a preferred spreading roller 55 which comprises a mounting bar 56 on which are mounted a plurality of rotatable pin wheels 57 each of which has a plurality of spaced-apart pins 58 on an outer cloth-engaging surface thereof. It will be noted that the wheels 57 are tapered and upon rotation tend to urge the cloth 48 laterally outwardly. Inboard of the wheels 57 is an inner roller element 60 having an outer surface of resilient material, such as rubber or plastics material, in which a helical ridge 61 is formed such that rotation of the inner roller 60 as the cloth 48 passes beneath the roller 60 urges the cloth 48 outwardly. It will be noted that the arrangement of each spreading roller 55 is such that the cloth 48 is gripped in a firm but delicate manner to laterally tension the cloth 48 without damaging the cloth 48.

Downstream of the spreading rollers 55 and immediately upstream of the tensioning roller 49, the cloth 48 passes around an auxiliary spreading roller 65 which has a helical ridge 66 extending outwardly toward each end of the roller 65 from a centre of the roller to stretch the cloth 48 on the roller 65, applying a lateral tension to the cloth.

Referring to Figs. 7 to 9, the rapiers 47 are shown. Each rapier 47 has a body 66. An arm 67 is mounted by a pivot pin 68 on the body. A front end 69 of the arm 67 and a front end 70 of the body 66 form a pair of jaws which can be opened (as shown in Fig. 9) for picking up a weft thread and closed (as shown in Fig. 8) to clamp the weft thread between the arm 67 and body 66. A spring 72 mounted at a rear end of the body 66 engages the arm 67 to Wfl? y - 13 bias the arm 67 into the closed position shown in Fig. 8. In use, one of the rapiers 47 grips a weft thread 74 (Fig. 7) and pulls the weft thread between the rows 45, 46 of warp threads. At the same time, the other rapier 47 travels inwardly and the rapiers 47 overlap at a centre of the weaving station. As they approach the centre of the weaving station, the arms 67 of each rapier 47 engage cams 76 which pivot the arms 67 against spring bias to open the jaws and transfer the weft thread to the second rapier which then pulls the weft thread 74 fully across the rows of warp threads. It will be noted that by adjusting the weight of the rapiers 47, optimum weft thread handling can be achieved for different qualities and types of weft thread.

Downstream of the loom 42, the cloth 48 is delivered to a cloth inspection station 80. At the inspection station 80, the reel 50 of cloth 48 is rotatably mounted between support stands 81. Alternatively, the reel of cloth 48 may be mounted directly on a pair of rotatable rollers 82. The cloth 48 is pulled from the reel 50 and passed around guides on a support frame 84. At one end of the support frame 84, the cloth is stretched vertically between an upper roller 86 and a lower roller 87. The upper roller 86 is connected to a counter 88 for measuring the length of the cloth material passed around the upper roller 86. A lamp 89 illuminates the surface of the cloth 48 as it passes between the upper roller 86 and lower roller 87. An operative can view the cloth and mark the location of any defects on the cloth as the cloth passes between the rollers 86, 87.

A lighting box 90 is mounted on the frame 84 inboard of the cloth and contains a lamp for back-lighting the cloth if desired to further assist in detecting faults. Access to view a rear of the cloth is possible by means of a 98002s bridge 92 under which the cloth passes before passing around an overhead drive roller 93. The drive roller 93 is connected to a drive motor 94, the speed of which can be adjusted by means of a speed control 96 so that the operative viewing the cloth can adjust the speed at which it passes the viewing station as desired. After inspection, the cloth is folded on a table 97. To fold the cloth, the cloth 48 passes between a pair of spacedapart guide bars 98 on a swinging arm 99 which is moved back and forth in the direction of arrow A (Fig. 12) by means of a crank mechanism 100.

The cloth is then delivered through a mending station 110 at which defects, if any, in the cloth are mended prior to delivering the cloth for finishing such as washing, drying, pressing and the like.

The invention is not limited to the embodiments hereinbefore described which may be varied in both construction and detail.

Claims (5)

1. A weaving process comprising the steps :leading a group of selected warp threads from a plurality of spools rotatably mounted on a support rack, feeding the group of warp threads in a desired manner to a warp reeling drum, applying a predesired tension to each warp thread as it is being fed from a spool to the warp reeling drum, rotating the warp reeling drum for winding the group of warp threads about the drum, winding a desired length of warp thread on the drum, cutting the warp threads leaving a warp section of a predesired length on the drum, winding a plurality of juxtaposed warp sections of the predesired length onto the warp reeling drum forming a set of wound warp sections on the warp reeling drum, each warp section comprising the selected combination of a number of warp threads, the combined width of the set of the wound warp sections on the warp reeling drum corresponding to a preselected desired cloth width, transferring the set of wound warp sections from the warp reeling drum onto a spool, mounting the spool on a loom, 990623 - 16 feeding the warp threads from the set of wound warp sections in a controlled manner to a weaving station on the loom, feeding a weft thread between opposite sides of the warp threads for weaving a cloth, tensioning the cloth downstream of the weaving station, for maintaining a preset desired longitudinal tension on the warp threads at the weaving station by winding the cloth around a tensioning roller downstream of the weaving station, the tensioning roller having an outer circumferential surface formed of a resilient material having a plurality of projections thereon for gently but firmly gripping the cloth and longitudinally tensioning the cloth as it is delivered from the weaving station, and winding the cloth on a reel downstream of the weaving station.

2. A process as claimed in claim 1 in which the process includes transversely tensioning the cloth immediately downstream of the weaving station by engaging opposite sides of the cloth with elongate spreading rollers for urging opposite sides of the cloth outwardly applying a transverse tension to the cloth, each spreading roller engaging the cloth by means of a number of pin wheels and an associated roller element rotatably mounted co-axially on a support, each pin wheel having an outer clothengaging surface with a number of outwardly projecting pins thereon and the roller element being mounted inboard of the pin wheels and having an outer circumferential surface formed of a resilient •6062x - 17 material with a helical ridge formed in the outer surface for urging the cloth outwardly upon rotation of the roller element, and preferably the process includes the step of supporting a trailing end of the cloth at the weaving station with a support bar during threading of the weft between opposite sides of the warp threads, the support bar having an upper cloth-engaging surface formed by a soft pile, the support bar moving between a raised cloth engaging position when threading the weft and a lowered disengaged position away from the cloth for advancing the cloth at the weaving station.

3. A process as claimed in any preceding claim in which the process includes the steps of delivering the reel of cloth to a cloth inspection station, pulling the cloth from the reel at the inspection station, illuminating the cloth, inspecting the cloth by stretching the cloth vertically at the inspecting station and illuminating the vertical cloth portion for checking the cloth for defects, and marking the location of any defects on the cloth, delivering any defective cloth to a repair station for mending any defects in the cloth, and preferably the process includes the step of applying the predesired tension to each warp thread by leading the warp thread from the spool around a post, the thread being delivered between a pair of plates mounted on the post, the plates being biassed together for applying the predesired tension to the warp threads.

4. A weaving process substantially as hereinbefore described with reference to the accompanying drawings. 006623 ,1 - 18

5. Cloth whenever produced according to the process as claimed in any preceding claim.