Weaving preparation at its best Perfect start with Weaving Preparation Systems. Symposium, April 2016
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1 Weaving preparation at its best Perfect start with Weaving Preparation Systems Symposium, April 2016
2 Agenda Weaving preparation at its best Short introduction to the Stäubli Group Perfect start with Weaving Preparation Systems Drawing-in machines Leasing machines Warp tying machines 2
3 Stäubli Group Technological solutions for a vast range of industries textile machinery, industrial connectors and robotics A family owned industrial company which originated in 1892 in Switzerland Turnover surpassing one billion Swiss francs with employees Present across 5 continents with units in 25 countries, agents in 50 countries 3
4 Stäubli Group Three strong and globally active divisions Textile Connectors Robotics Frame weaving Jacquard weaving Weaving preparation Carpet weaving Electronic controllers and drives Fluid connectors Electrical connectors Tool changers Quick mold change systems 4-axis SCARA robots and 6-axis robots Low, medium and heavy payload robots Controllers & software 4
5 Agenda Weaving preparation at its best Short introduction to the Stäubli Group Perfect weaving starts with a good warp Drawing-in machines Leasing machines Warp tying machines 5
6 Weaving a good fabric Quality in : quality out! Warp Preparation Weaving Preparation Weaving mill Yarn Fabric 6
7 Economics Automation is an investment. not a cost! Helicopter view over entire enterprise Weaving mill department Auto. drawingin Maintenance Human resources Weaving Reduction of unproductive working time Unproductive working time is influenced by 1. Legal holidays 2. Organisation 3. Maintenance & repair 4. Setting-up time 5. Beam-, style changes 6. Running conditions (# end breaks) Sales Purchase Start thinking about automatic drawing-in from the word go! Increase of overall efficiency Additional production Reduction of second quality Additional profit 7
8 Economics Automatic drawing-in and its benefits 120% 100% 80% 60% 40% 20% Manual Automatic 0% Organisation Maintenance & repair Setting-up time Style changes Additional fabric Overall efficiency Automatic 1.2 operators per shift Less fluff and flow. Clean harness Start-up with WARPLINK UNI-PORT, harness & warp beam Less stops. Perfect warp beam DELTA SAFIR Manual operators 8
9 Effective Warp Preparation from manual to automatic drawing-in Provide just-in-time availability of the right warp(s) in the right quantity to weaving operations Guarantee the right number of ends in the right sequence, colour and parallelism on every drawn warp beam Reduce throughput times Safeguard optimal cost of operation Render reasonable and affordable investment cost with a good return of investment for weavers Expectations to an effective warp preparation 9
10 Challenges in cloth manufacturing Warp Preparation More styles to be prepared in less time Finer, more delicate yarns to be drawn in Denser warps and/or more critical patterns to be prepared No-availability of labour Weaving Operation Shorter runs / warps (quick style changes) Shorter throughput times, higher efficiency requirements Better loom-state fabric quality Cloth buyers/market Short delivery time Pressure on margins Short piece length 10
11 Drawing in process Drawing in in 1 stroke: Input: Complete warp sheet Drop wire Heald Reed Output: UNI-PORT (complete warp beam with harness) Ready to weave Drop wires Healds Drawing in hook Reed No limits in harness UNI-PORT 11
12 Applications DELTA 110 Women s and men s wear Shirting fabrics Upholstery Stationary drawing in machine Movable drawing in truck 140 ends/minute 20 heald frames 2.3 m, 4.0 m Most economic solution DELTA
13 Applications SAFIR S40 Denim fabrics Bed and table linen Protective clothing Brand new working principle Movable drawing in machine Stationary drawing in station 165 ends/minute 12 heald frames 2.3 m SAFIR S40 13
14 SAFIR S40 DRM for Denim Benefits WORKING PRINCIPLE TODAY 100% warp tying (beam changes) FUTURE 80% warp tying (beam changes) 20% automatic drawing in (style changes) BENEFIT SAFIR S40 Increase of quality due to clean weaving machines. Quick style changes Increasing fabric output due to optimized efficiency of weaving mill Short delivery time Quick response to market changes e.g. multi-layer Denim 14
15 Process optimizing Harness carrying system UNI-PORT Laying in harness to weaving machine with UNI-PORT 24 hours stock of drawn-in warp beams with UNI-PORT 15
16 Warp sheet preparation INPUT Direct warper Without 1:1 lease Up to 8 layers OUTPUT 1:1 lease Ready for drawing in 16
17 Warp Tying TOPMATIC Specialist for medium to very fine yarn count MAGMA Specialist for coarse yarn 2 types of knots Yarn count Ne 3.0, Nm 5 Ne 760, den 7 Ne 0.3 Nm 0.50 Nm 50 17
18 Application Carpet weaving Quick Beam Change TOPMATIC TPM 301 Upper warp beam Lower warp beam Detachable frame head 18
19 Thank you for your attention 19
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