Study of predicting the number of warp thread breaks during the weaving process

Abstract

The properties of cotton yarn which will be used as the warp were investigated before the weaving process. The results of the breaking forces served to make an empirical and approximated diagram of the normal distribution. Yarn tests were performed by yarn passing through a weaving process simulator with electronic force measurement, speed, and the number of wefts. The number of breaks was registered during the yarn test. Measurements were performed simulating different conditions of the weaving process (change in reed density, higher dynamic tensile forces, lower dynamic tensile forces, and shed height changes). Data computer processing gave approximate diagrams of dynamic forces normal distribution under the test conditions, which do not show significance according to the χ2-test. By pairing a diagram of the breaking force and a diagram of one of the conditions in the weaving process, shown in the same line of forces, their intersection or surfaces overlap is expressed. Based on the integration of the intersection area of the breaking forces approximated diagrams and dynamic forces in the weaving process, the value of the intersection area according to the test conditions was obtained. A high degree of correlation was found by correlating the actual number of thread breaks registered at the time of testing and the intersection of areas for the corresponding condition. This makes it possible to predict the number of breaks in the warp threads during the weaving process if the yarn characteristics and the weaving conditions are known.