Drawing-in System DELTA 100/110 Basic functions DELTA 100/110 General information DELTA 100/110 draws in automatically the individual ends of a warp into the healds, drop wires (only DELTA 110) and reed The drawn-in healds may be distributed on up to 20 heald frames or 16 heald carrier rods as the case may be, and the drop wires on up to drop wire carrier rods 1) Heald module: The healds are arrayed stack wise on the two magazine paths The separation device separates the healds one at a time, after which they are transferred onto the conveyor belt of the heald carousel This then takes the heald to the drawing-in position Before drawing-in the thread the heald is centered by the thread eye centering After drawing- in the thread the healds are taken on to the desired heald frame or heald carrying rod as the case may be The ejectors then push the healds onto the frames or heald carrying rods according to the draw-in repeat 4) Reed module: The reed is mounted on the reed transportation unit, which conveys the reed while drawing-in The optical reed monitoring and control checks the reed transport according to the reed ineness and the desired denting The reed blade enters between the dents into which the draw-in hook draws in the yarn, opening the dent wide enough so that the draw-in hook and yarn can pass unobstructed 5) Control cabinet: This cabinet accommodates the electrical control of the system and the central power supply, which provides all voltages needed for operation The hierarchically built-up control system communicates via individual module processors with the motors and incremental digitizers and via distribution circuits with solenoid valves and sensors 2) Yarn module: From the warp sheet stretched over the thread frame the yarn is separated by a separation unit and presented to the drawin hook, which moves through the reed, heald and drop wire thread eye, takes over the yarn and moves back again After drawing-in through the drop wire, heald and reed the yarn is ejected from the draw-in hook and held by the suction nozzle The yarn sensor veriies whether the yarn has been drawn in correctly 3) Drop wire module: The drop wire stack is prepared in the drop wire magazine The drop wire separation separates the drop wires, which are then seized by the drop wire twisting head and taken to the drawing-in position After drawing-in the thread the drop wires are taken over by the drop wire slide, ejected and arrayed on the desired drop wire contact bars 6) Operator console: DELTA 100/110 is operated and programmed via the keyboard on the pillar of the operator console The display screen shows the required information, with text in the language of the par¬ticular country and partly in graphic form The machine status and progress of drawing-in are displayed all the time Programming the draw-in repeat and parameters are done likewise through the operator console, which also provides statistical data on the running behaviour of the machine and information on maintenance If necessary the machine may be stopped quickly with the emergency stop button Located under the cover of the console are master computer and a diskette drive Drawing-in trucks Drawing-in trucks types BASIC and COMFORT spindle the thread sheet is adjusted to the optimal inclination The purpose of the drawing-in truck is to guide the warp for drawing-in The lease cord holders tension the lease cords beam and the prepared warp sheet along the drawing-in ma- in the correct position To take down the drawn-in harness the chine during drawing-in The warp beam must be on a warp drawing-in truck is moved out of the drawing-in machine beam truck that is coupled to the drawing-in truck This can be pushed together with the warp beam truck by the handles to preparation and takedown at a workplace After stretching the warp sheet on the thread frame (7) the drawing-in truck is coupled to the DELTA 100/110 for drawing-in By the angling Usability of the various drawing-in trucks Type BASIC 2.3 m COMFORT 2.3 m COMFORT 4.0 m DELTA 100 ● DELTA 110 ● DELTA 110-4 ● ● ● = Standard = on request On DELTA 110-4 the alternate use of drawing-in truck types COMFORT 2.3 m and 4.0 m is possible Drawing-in truck type BASIC 2.3 m With the BASIC type the harness is lifted without powered assistance The BASIC type is suitable for lower weights and not for taking down drop wires Drawing-in truck type COMFORT 2.3 m The drawing-in truck type COMFORT has an electrically driven lifting device (8) for the thread frame (7) and takedown arms (9) for lifting off the harness The COMFORT type is used especially for heavier harnesses and in general when drawing-in drop wires Drawing-in truck type COMFORT m On the COMFORT type truck for m warp beams an electrically powered handling device can be coupled, thus simplifying the maneuverability and moving (see accessories) Drawing-in performance Drawing-in performance in number of drawing-ins / h Drawing-ins / h The drawing-in performance depends on the average number 50000 of ends per warp, on the warp material, and on the number of operators and drawing-in trucks The performance is higher if 40000 warps with a high number of ends are to be drawn-in, because DELTA 100/110 Speedpack of fewer changes With the use of warps that need to be checked 30000 DELTA 100/110 frequently while drawing-in (e.g colour repeat), or require longer 20000 preparation times the performance will decrease Maximum performance may be reached with drawing-in trucks in alternate 10000 use, and operators At a lower drawing-in need drawingin truck is suficient, and a second operator is advantageous for some particular manipulations only, such as preparation or 4000 6000 8000 take-down work The following data are to be understood as 10000 Number of ends / warp guidelines Drawing-in performance in no of warps / h No of drawingType of warp (examples) No of in trucks Filament with 8000 ends Filament with 8000 ends Coloured Cotton with 6000 ends Denim / plain cotton with 4500 ends Denim / plain cotton with 4500 ends Wool with 5000 ends Wool with 5000 ends DELTA 100 operators ( )* DELTA 110 Speedpack Speedpack 3–4 4–5 4–5 — — 5–6 ( )* — — 5–6 6–7 — — 6–7 7–8 ( )* — — 3–4 — — 4–5 5–6 Approximate times for individual operations DELTA 100 Material Wharp sheet prep (min) Setting-up/running-in (min) Running-out/takedown (min) Machine efficiency (%) Filament 10 10 90 Plain cotton 10 10 90 Coloured Cotton 20 10 15 80 Wool 30 10 15 70 Approximate times for individual operations DELTA 110 Material Wharp sheet prep (min) Setting-up/ running-in (min) Running-out/ takedown (min) Mounting warp stop motion, welding, correcting Machine efficiency (%) Filament 10 10 10 20 90 Plain cotton 10 10 10 20 90 Coloured Cotton 20 15 15 20 80 Wool 30 15 15 20 70 * ( ) = 2nd operator max 20% Calculation examples for throughput times in the drawing-in department 1) DELTA 100 with one drawing-in truck and one operator, without Speedpack and without UNI-PORT Filament warp with 8000 ends Warp A B C D Warp A B C D Warp A B C ( )* 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 h 2) DELTA 110 with two drawing-in trucks, two operators, without Speedpack, welding with WARPLINK and warp stop motion completed in the drawing-in with UNI-PORT Coloured cotton warp with 6000 ends Warp A B C D Warp E A B C D Warp E A 0.5 1.0 1.5 2.0 2.5 3.0 B 3.5 C 4.0 h 3) DELTA 110 with two drawing-in trucks, two operators, with Speedpack, welding with WARPLINK and warp stop motion completed in the drawing-in with UNI-PORT Grey cotton warp with 6000 ends Warp A B C Warp D A E B C Warp D A E B C D Warp A E B C Warp D A 0.5 Legend: A) Warp sheet preparation B) Setting-up/running-in C) Drawing-in D) Running-out/takedown E) Mounting warp stop motion, welding, correcting 1.0 1.5 2.0 2.5 3.0 E B 3.5 C 4.0 h Calculation (Example 2): ø Drawing-ins/min = max drawing-in speed x eficiency ^ = 100 x 0.8 = 80 draw-ins/min Drawing-in time = Number of ends ^ 6000 = = 75 ø draw-ins/min 80 Total troughput time = A + B + C + D + E = 20 + 15 + 75 + 15 + 20 = 145 Technical features of each module: Yarn module Yarn separation with separation needle from the yarn layer Yarn separation device for warps with or without lease Drawing-in with hook for yarn counts of 3–250 tex Heald feed from two magazine paths to the separating position Optical checking and positioning of the thread eye Drop wire feed to the separating position with automatic reill Checking for double-separated drop wires Opening of the reed gap with plastic knife Camera system for optical checking of the reed gap Heald module Healds with open or closed end eyes (type J, C, O) of 260–382 mm length Drop wire module Open or closed drop wires of 125–180 mm length and 7–11 mm width Reed module Flat, double or tunnel reeds of 2–50 dents/cm Accessories Magazine- and transporting rails for healds Storage truck for healds and drop wires Adsorption air dryer Magazine- and transporting rails for drop wires Tool rack (two-piece) Drop wire press Assembly truck for warp stop motion Unloading truck for longitudinal parts Warp beam truck* with drawn-in warp on UNI-PORT Electrical handling device for m drawingin truck * warp beam trucks are not Stäubli products Options Drawing-in performance DELTA 110 without/with Speedpack Number of draw-ins / h Speedpack 50000 The optional Speedpack raises the drawing- 40000 in speed from 100 to 140 draw-ins per minute, equivalent to a capacity increase by some 25 to 30000 DELTA 110 without Speed- 30% for the installation 20000 pack (100 draw-ins/min.) DELTA 110 with Speedpack 10000 (140 draw-ins/min.) 4000 6500 10000 Number of ends / warp Colour repeat monitor and control a) Colour repeat monitor The colour repeat monitor is for checking the draw-in visually At every colour change the installation stops, allowing the operator to check the divided thread The corresponding colours are also displayed on the screen b) Colour repeat control The colour repeat control enables warps to be Separation cord Separation cord drawn in without lease but with two colour layers separated by a cord max max 15 mm 15 mm Example 1) Warp drawing-in from the warp sheet The two colours are separated by a cord No particular preparations are needed for the automatic drawing-in Maximum stripe width is 15 mm x Sheet B 1) Example 2) Warp drawing-in from the warp sheet The two colours are separated by a cord The warp ends must be counted in on the sizing machine Any stripe widths are possible if countingin is done properly 2) Sheet A Sheets A and B are separated by the cord (2) At lease change the ends of the sheet not to be separated are pushed away by the pusher (1), on sheet A in the example The dimension x is the maximum offset of the two sheets Options Electronic double end detection The electronic double end detection enables double threads to be detected at separation from the warp, even if there is no lease Measurement is based on force measurement on the thread to be separated If two threads are separated by mistake, the double end detection triggers a machine stop and the error can be put right In this way the drawing-in quality of sized warps without lease for example can be improved F enormously Lease module LD1-110 / LD2-110 With the optional lease module it is possible to lease while LD1 drawing-in a lease into the warp to be drawn in, behind the drop wires, or if these are lacking, behind the heald frames This lease may be used for example to insert lease rods while weaving Moreover the lease facilitates knotting when changing warps The lease module is available in two different versions, i.e with one or two independent leases in the sheet Lease module LR1 LD2 With the optional lease module LR1 a 1:1 lease may be drawn in instead of the reed This may be necessary for example if the reed cannot be drawn in automatically (very ine reeds or other reeds that not comply with the speciications of the drawing-in machine), or the reed is not to hand at the time LR1 of drawing-in This option is likewise helpful where for other reasons the reed is to be drawn-in on the weaving machine Fine range reed module With this option it is possible to deal with reeds of counts above 350 up to 500 dents/dm The drawing-in speed is then reduced to 100 draw-ins per minute For further details see harness speciications Electrical handling device Network connection With the electrically powered handling device a single person Data exchange to transmit drawing-in programs and operat- can move the m drawing-in truck into the machine and out ing data via Ethernet/TCP/IP-connections Coniguration on again request Technical Data / Model Basic version DELTA 100 DELTA 110 DELTA 110-4 Overall installation for a max warp width [cm] 230 230 400 Draw-in truck with warp frame [cm]; – with lifting device (Comfort type) – without lifting device (Basic type) 230 230 ● 400 ● ● ● ● Yarn draw-in module with hook ● Yarn separation for one yarn layer ● ● ● Heald module with two magazine paths ● ● ● 4–20 4–16 4–20 4–16 4–20 4–16 (c) Control module with master computer and floppy disc drive ● ● ● Reed module (Standard range) ● ● ● Drop wire module with drop wire contact rods – ● ● Heald frame adapter, expandable in groups of four – max N° of frames, (J/C-type healds) – max N° of supporting rods (O-type healds) Warp beam transport truck Options Yarn module for coarse yarns, tapes, slub and bouclé yarns – Drop wire distribution on contact rods (max drop wire width = mm) – Draw-in truck with warp frame and lifting device type Comfort Draw-in truck with warp frame without lifting device type Basic Electrical tractor for heavy warps – – – Electronic double end detection (Yarn range tex 3–100) Colour repeat monitor Colour repeat monitor and control Lease module LR1 for inserting a lease in place of the reed Lease module LD1 for inserting a lease behind the drop wires – Lease module LD2 for inserting or leases behind the drop wires – Reed module (fine range) for reeds up to 50 dents per cm Ethernet/TCP/IP-connection to transmit drawing-in programs and operating data Drawing-in capacity max draw-in speed of 100 threads/min ● ● ● · Cotton and blends (carded, combed) · Wool (worsted and woolen yarns) · Silk, Mono- and multifilament yarns · Tapes up to 4,5 mm width, slub and bouclé yarns (with option for coarse yarns) · Special yarns (on request) ● ● ● Count range Tex 3–250; with option for coarse yarns tex 3–500; other ranges on request ● ● ● Warps max nominal width [cm] 230 230 400 max flange diameter of the warp beam [cm] 120 120 110 ● ● ● Yarn material max draw-in speed of 140 threads/min with Speedpack one yarn layer with or without lease two layers with colour repeat control max weight (incl beam truck) [kg] Healds * with open or closed end eyes 1200 1200 3000 Heald length 260 to 382 mm (11” to 15”) ● ● ● Heald thickness 0.25 to 0.38 mm ● ● ● Type Simplex and Duplex Type of end loops Thread eye 1.2 x 5.5 mm - with option for coarse yarns 1.8 x 6.5 mm Thread eye offset max 10 mm Legend: 10 ● Standard Option ● ● ● J/C/O J/C/O J/C/O* ● ● ● ● ● ● On request (c) Version COMBI – not available Technical Data / Model Heald frames * DELTA 100 DELTA 110 DELTA 110-4 with detachable side supports ● ● ● frames with positioning nut (on the right as viewed from the reed side) ● ● ● Frames without positioning nut on request Reeds * Drop wires * Maximum reed width [cm] ● ● 230 400 ● ● ● Reed count (Standard) 20 to 350 dents per dm Reed count (fine range) 351 to 500 dents per dm ● ● ● Dents height 40 to 100 mm ● ● ● Reed height 80 to 150 mm ● ● ● Dents depth up to 16 mm ● ● ● Profile flat, tunnel or double reeds ● ● ● – ● ● Drop wire width to 11 mm open or closed type (with option contact bar to mm) Drop wire length 125 to 180 mm – ● ● Drop wire thickness 0.2 to 0.65 mm – ● ● – ● ● One magazine path Control module ● 230 Software DOS 6.22 operating system Printer (Option) Parallel interface LPT1 Languages German, English, French, Italian, Spanish, Chinese, Korean, Japanese, Turkish, Portuguese, Czech, Flemish; other languages on request Electrical connection values Three-phase grid with protective earth, without zero conductor External fuse protection 10 A per phase Power consumption approx 1.6 kVA DELTA voltage (phase-phase) x 200 VAC / x 220 VAC / x 400 VAC / x 440 VAC, ± 10% wired ex works; 50 or 60 Hz Drawing–in truck Single phase with protective earth with lifting device External fuse protection 10 A Type Comfort 200–230 VAC ± 10%; 50 or 60 Hz Pneumatic connection values Room climate Supply pressure to 10 bar overpressure Pressure variations < ± 0.5 bar Minimum quantity of air DELTA 100: Machine 550, Suction Nozzle 500, Total 1050 NL/min DELTA 110: Machine 850, Suction Nozzle 500, Total 1350 NL/min Pressure dew point: ≤ -17 °C at atmospheric pressure (this value can only be attained with an adsorption air dryer) Oil content basically oil-free Residual oil content < 1mg/Nm3 < 0.8 ppm Dirt particles solids content < mg/m3, particle size < μm Air quality ISO 8573.1; Quality class The climatic conditions depend upon the same parameters generally applying for weaving mills No abrasive substances such as glass dust and the like Humidity 30–95% relative, non-condensing Ambient air acid-free Temperature max temperature change in 10 h for operation + 18 to + 40 °C, for storage + to + 45 °C 15 °C Room height In travel area of drawing-in truck BASIC type: 210 cm Floor characteristics Floor material cast concrete floor having a compact, load-carrying thickness of 16 cm in the region of the drawing-in machine Flatness max level difference of ± 15 mm or total 30 mm In travel area of drawing-in truck COMFORT type DELTA 100/110: 245 cm; DELTA 110-4: 260 cm Surface characteristics: roughness within the range of conventional concrete floors with a peak-to-valley height Rfmax ≤ mm Floor loading capacity DELTA 100: ≥ 900 kg/m2 / DELTA 110: ≥ 900 kg/m2 DELTA 110-4: ≥ 1100 kg/m2 Lighting 700 Lux at work level Noise Level 81 dBA; measured at the operator’s stand * for detailled information see „harness speciications“ 11 Layout samples Example of layout with drawing-in truck DELTA 100/DELTA 110 for 2.3 m warp width Example of layout with drawing-in trucks DELTA 100/DELTA 110 for 2.3 m warp width Legend: 1) Drawing-in machine 2) Drawing-in truck Preparation/ taking down 3) Drawing-in truck Drawing in 4) Longitudinal parts for clamping 5) Control cabinet 6) Adsorption dryer 7) Table for healds / drop wires (not delivered by Stäubli) 8) Rack for support rods, heald frames and reeds (not delivered by Stäubli) 9) Tool cabinet 12 Layout samples Example of layout with drawing-in truck DELTA 110-4 for m warp width Example of layout with drawing-in trucks DELTA 110-4 for m warp width or drawing-in truck DELTA 110-4 for m warp width and drawing-in truck DELTA 100/DELTA 110 for 2.3 m warp width Required space when moving with the electrical truck 13 2400 Dimensions and weights Drawing-in truck COMFORT type m Drawing-in truck COMFORT type 2.3 m 390 160 Drawing-in truck BASIC type 2.3 m Dimensions DELTA 100/110/110-4 Length [mm] B = Width [mm] Height [mm] Weight [kg] Overall system DELTA 100 8000 2600 1850 1600 (without drawing-in truck) DELTA 110 8000 2850 1850 1900 (without drawing-in truck) 12 700 3850 1850 2400 (without drawing-in truck) 700 650 2000 200 DELTA 110-4 Control cabinet Drawing-in truck Type BASIC 2.3 m 3900 1600 2000 950 Type COMFORT 2.3 m 3900 1600 2400 1150 (360 kg load cap of lifting device) Type COMFORT 4.0 m 5900 2400 2540 1300 (850 kg load cap of lifting device) Space requirements (minimal) Length [mm] B = Width [mm] Height [mm] Surface [m2] DELTA 100 with drawing-in truck 9000 5400 2100 ca 50 m2 DELTA 100 with drawing-in trucks 9000 7100 2100 ca 70 m2 DELTA 110 with drawing-in truck 9000 5600 2450 ca 50 m2 DELTA 110 with drawing-in trucks 9000 7700 2450 ca 75 m2 DELTA 110-4 with drawing-in truck 14 000 7200 2600 ca 100 m2 DELTA 110-4 with drawing-in trucks 14 000 9300 2600 ca 130 m2 14 What benefits does automatic drawing-in offer? Enhanced productivity in drawing-in due to: High productivity of DELTA 100/110 to times better How is weaving affected? Short throughput times than manual drawing-in depending on application Lower costs through reduced inventories Shortened throughput times between warp beam of harnesses and warps production and weave room Higher exibility in product range Reduced personnel costs in drawing-in – fashion trends followed without delay Full drawing-in performance even with complex draw-ins – special customer wishes met Variable personnel deployment depending on production – speedy execution of urgent orders desired (1 or persons) by drawing-in several warps at once Bigger pro t margins through lucrative orders More flexibility in drawing-in thanks to: Simpler achievement of just-in-time production Wide application range of DELTA 100/110 regarding Enhanced weaving machine ef ciency harnesses and warps and fewer second quality, because – Practically all heald types, no separating aids needed, – more frequent drawing-in allows better care of the used and worn healds still accepted – Drop wires with different dimensions, head and foot forms, thread eyes etc., without separating aids – Reeds up to the highest counts, different proile shapes, double reeds, irregular gauge – Frames for healds with J- or C-shaped end loops of harness and weaving machine and timely elimination of defective harness, and hence improved running behavior of the weaving machines – fewer weaving machine stoppages due to crossed warp ends – no fabric produced with faulty drawing-in practically all proile heights and widths, or carrying rods for healds with O-shaped end loops – Warps in all widths up to 400 cm useful width as well Ergonomics DELTA 100/110 drawing-in machines are designed for as twin beams, with virtually all yarn materials from optimal ergonomics 250 to tex, special yarns on request Virtually all manipulations needed during drawing-in are Quick response to changing drawing-in needs thanks to performed from near the operator console capacity reserve and lexible personnel deployment Programming and entries via function keyboard On the Exact scheduling of drawing-in jobs to the stipulated screen the progress of drawing-in and status displays are deadlines shown graphically and with text in local language Quality in drawing-in Maintenance Faultlessly drawn-in warps even with complex draw-ins Regular maintenance of the DELTA 100/110 will enhance its Constant draw-in quality regardless of personnel reliability and lower its operating costs For the weekly and Safe storage and transport of the drawn-in harness and monthly maintenance tasks there is a schedule available perfect thread order in downstream processing thanks to Depending on the amount of dirt, maintenance takes less UNI-LINK system components than ½ to hour 15 Global presence of the Stäubli Group Stäubli Units Agents www.staubli.com Z340193 02 Staubli is a trademark of Stäubli International AG, registered in Switzerland and other countries © Stäubli, June 2009 – Subject to technical modifications ... with drawing -in truck DELTA 100 /DELTA 110 for 2.3 m warp width Example of layout with drawing -in trucks DELTA 100 /DELTA 110 for 2.3 m warp width Legend: 1) Drawing -in machine 2) Drawing -in truck... with drawing -in truck 9000 5400 2100 ca 50 m2 DELTA 100 with drawing -in trucks 9000 7100 2100 ca 70 m2 DELTA 110 with drawing -in truck 9000 5600 2450 ca 50 m2 DELTA 110 with drawing -in trucks 9000...Basic functions DELTA 100/ 110 General information DELTA 100/ 110 draws in automatically the individual ends of a warp into the healds, drop wires (only DELTA 110) and reed The drawn -in healds may