Machine upgrade and modernization

Ensuring perfect thread tension in the selvedge area.

Floppy Selvedge

When weaving dense fabrics, such as airbag or filter fabric etc., the selvedge areas of the fabric may be looser than the rest of the fabric.

The result is selvedge waviness, also known as floppy selvedge.

With the new Selvedge Thread Let-off LT3 waviness in the selvedge area can be prevented.

Coating Difficulties

The wider the fabrics are produced, the more pronounced the waviness becomes. These fabrics are often coated in a second phase.

The wavy selvedges also have a negative effect when coating. Due to loose selvedges a uniform coating of the fabric is almost impossible.

On ribbon weaving machines, rope brakes with weights are used to set the warp tension, requiring regular adjustments as the warp beam diameter decreases.

The warp let-off ECR is an electronically controlled rope brake that automatically adjusts the rope tension, ensuring constant warp tension across the entire beam and optimizing production efficiency.

By retrofitting existing rope brakes with the ECR control unit, a sophisticated system is created that automatically adjusts the warp tension during the weaving process. The current warp tension is continuously monitored using a load cell, and the braking force is dynamically regulated by adjusting the rope tension with a cylinder. This precise adjustment ensures uniform warp tension, maintaining consistency from the full to the empty bobbin, which is essential for ensuring fabric quality throughout the production process.

The core principle behind the KAST ECR system is the realization that the warp beam does not need to be actively driven in order to maintain the constant tension. The warp beam only requires braking, simplifying the entire process and improving energy efficiency by eliminating the need for continuous mechanical drive.

The warp tension can be easily monitored on intuitive user interface of the ECR control unit in real time. Weavers will appreciate that the constant adjustment of weights and manual adjustment is no longer required and reducing the likelihood of errors.

The KAST ECR has been engineered to enhance fabric quality and productivity. This new automatic warp tension control system for ribbon weaving machines offers additional benefits, such as reducing labor costs by simplifying warp tension adjustments and ensuring reproducibility.

Weaving from creel with warp thread delivery unit.

The warp feed unit controls the warp tension between the creel and the weaving machine.

The feed roller delivers the warp material with the set tension to the weaving machine.

Usually the warp tension between the creel and the feed unit is less than the warp tension between the feed unit and the weaving machine.

The warp tension between the feed unit and the weaving machine is measured with a load cell and controlled by the control unit.

The warp thread tension can be entered directly on the control unit.

There is no doubt that it is important to work with a good quality creel that keeps the tension fairly constant over the entire yarn group.

If the unwinding of the creel is not perfect, even the best warp feed unit cannot compensate for the tension fluctuations across the entire warp.

A “linked motion control” is a warp thread feed system that consists of several warp beams and a PC-based control technology.

With the use of 14 warp beams, the warp running time can be doubled. This massively reduces the number of warp beam changes and increases the efficiency of the narrow fabric weaving machine.

The thread tension is measured with a load cell and replaces the setting of control cams and proximity sensors.

The desired warp thread tension for each warp beam can be entered directly on the control and eliminates the need to set the warp thread tension with springs.

The input is made via a touchscreen display.

The direct measurement of the warp thread tension is used to control the warp beam motors and enables the set and actual thread tension to be displayed on the monitor.

The warp thread feed system is designed for the current technical requirements but is prepared for future applications in ​​Industry 4.0.

Ensuring perfect thread tension in the selvedge area.

Floppy Selvedge

When weaving dense fabrics, such as airbag or filter fabric etc., the selvedge areas of the fabric may be looser than the rest of the fabric.

The result is selvedge waviness, also known as floppy selvedge.

With the new Selvedge Thread Let-off LT3 waviness in the selvedge area can be prevented.

Coating Difficulties

The wider the fabrics are produced, the more pronounced the waviness becomes. These fabrics are often coated in a second phase.

The wavy selvedges also have a negative effect when coating. Due to loose selvedges a uniform coating of the fabric is almost impossible.

On ribbon weaving machines, rope brakes with weights are used to set the warp tension, requiring regular adjustments as the warp beam diameter decreases.

The warp let-off ECR is an electronically controlled rope brake that automatically adjusts the rope tension, ensuring constant warp tension across the entire beam and optimizing production efficiency.

By retrofitting existing rope brakes with the ECR control unit, a sophisticated system is created that automatically adjusts the warp tension during the weaving process. The current warp tension is continuously monitored using a load cell, and the braking force is dynamically regulated by adjusting the rope tension with a cylinder. This precise adjustment ensures uniform warp tension, maintaining consistency from the full to the empty bobbin, which is essential for ensuring fabric quality throughout the production process.

The core principle behind the KAST ECR system is the realization that the warp beam does not need to be actively driven in order to maintain the constant tension. The warp beam only requires braking, simplifying the entire process and improving energy efficiency by eliminating the need for continuous mechanical drive.

The warp tension can be easily monitored on intuitive user interface of the ECR control unit in real time. Weavers will appreciate that the constant adjustment of weights and manual adjustment is no longer required and reducing the likelihood of errors.

The KAST ECR has been engineered to enhance fabric quality and productivity. This new automatic warp tension control system for ribbon weaving machines offers additional benefits, such as reducing labor costs by simplifying warp tension adjustments and ensuring reproducibility.

Weaving from creel with warp thread delivery unit.

The warp feed unit controls the warp tension between the creel and the weaving machine.

The feed roller delivers the warp material with the set tension to the weaving machine.

Usually the warp tension between the creel and the feed unit is less than the warp tension between the feed unit and the weaving machine.

The warp tension between the feed unit and the weaving machine is measured with a load cell and controlled by the control unit.

The warp thread tension can be entered directly on the control unit.

There is no doubt that it is important to work with a good quality creel that keeps the tension fairly constant over the entire yarn group.

If the unwinding of the creel is not perfect, even the best warp feed unit cannot compensate for the tension fluctuations across the entire warp.