The quality criteria of looms for looms have been increasingly severe in recent years as a result of the growing demand in the market as well as the increased use of shuttleless looms. In the next section, we will discuss ways to enhance the quality of the weaving beam and decrease the amount of time spent managing sizing faults.
1. An Explanation of the Different Types of Weaving Beam Defects
Flaws in weaving beams that are the result of the size process may be loosely classified into the following four groups: artificial defects, mechanical defects, defects that were created by the process that came before, and slurry defects. They are not entirely separate from one another, since they share some characteristics, as well as a connection and an effect with one another. If a particular flaw is not addressed in the appropriate manner, it will almost certainly give rise to further flaws that are both more significant and more severe.
Because of this, it is not feasible to place flaws and the factors that contribute to them into distinct categories when discussing their names and causes. According to the findings of this study, the faults in the weaving beam are responsible for both the quality issues with the weaving beam itself and the physical quality issues with the surface of the fabric. Only a handful of the most frequent ways for preventing and treating flaws are given here since there are so many different kinds of defects.
2 Defect Root Cause Investigation and Preventative Measures
Targeted early prevention and active taking of appropriate steps to eradicate size faults in a timely manner is the key to increasing the inherent quality of the loom, and it is also the assurance of improving both the productivity of the loom and the quality of the product.
2.1 Sizing rate
When determining the overall quality of the woven beam used for size, the sizing rate is a very essential metric to look at. If the size rate is either too high or too low, there will be more warp breakage, which will, in turn, influence both the productivity of the loom and the quality of the finished product. If the size rate is too low, the wear resistance of the warp yarn will be reduced. Additionally, the surface of the yarn will get fuzzified and pilled, and the rate of warp breaking will rise during the weaving process. If the sizing rate is too low, weaving may even be impossible.
2.2 Moisture regain
Moisture recovery is another essential signal that must be considered when determining the overall quality of size beams, and the minimum acceptable pass rate must be at least 85 percent. There is a direct correlation between the magnitude of the moisture recovery, the magnitude of the sizing rate, and the sources of both of these phenomena. In most cases, the same causes that cause the size rate to be too low will also cause the moisture recovery to be too low. On the other hand, the same factors that cause the sizing rate to be too high will also cause the moisture regain to be too high. The temperature that has been set on the drying drum has, of course, a direct bearing on this as well.
2.3 Elongation
During the sizing process, the warp yarn is permitted to bear a certain tension draft in order to meet the production needs. However, the tension draft must be controlled within an appropriate range in order to ensure that the yarn arrangement and winding are uniform and that the production needs are met. If the tension is too low, the production cannot progress in a smooth manner; if the tension and elongation are too high, the yarn will lose its original elasticity and tenacity, which will increase the amount of weaving end breaking that occurs.
2.4 The difference between long yards and short yards
These kinds of flaws are often brought on by both human and mechanical sources. Any loom that does not achieve the length that is needed by the process design is a fault that is considered to be lengthy and under-sized.
There are a lot of different things that might produce sizing issues. Enhancing the quality of the woven beam while simultaneously lowering the number of flaws in the woven beam are the fundamental assurances that will lead to an increase in the productive capacity of the loom as well as the product's overall quality. It is the responsibility of the front warping beam to guarantee that the sheet yarn, tension, and arrangement are all consistent, and that the sizing rate is at least 98 percent. The selection and formulation of the slurry are appropriate, and the sizing qualification rate is not less than 90 percent; the moisture regain rate is suitable, and the qualified rate is not less than 85 percent; and the elongation rate is appropriate, and the qualified rate is not less than 90 percent.
The workers who are on duty are responsible for keeping the gates open and operating them in a strict manner. They also ensure that the equipment is in good operating condition, that the fundamental quality management work is complete, that the system is in place, and that they concentrate on optimizing the process operation, ensuring the quality of the raw yarn, maintaining environmental temperature and humidity control, managing auxiliary equipment, providing quality training to personnel, and so on. As a result of the management effort, the quality of the weaving beam will continue to improve, and the quality of a number of other quality indicators may also see an increase.