Rapier weaving today exists in diversified forms. During the last two decades the developments in rapier weaving have been carried out in a rapid continuous way. Rapier weaving machine produces top- quality fabrics from spun yarns such as cotton-wool, camel hair, silk, synthetic fibres and fancy yarns. Todays rapier weaving machine has become fast and exceptionally flexible. It offers a choice of various reed widths, shedding motions, selvedges and filling insertion colours.
This makes it suitable for weaving an extended range of articles: fashion fabrics, shirting, denim, suiting, industrial or furnishing fabrics, in one to eight or twelve filling colours or yarns, with a maximum weight of 500 g/m2. Todays rapier weaving machine is designed with modern electronics, with total automation of weaving and central microprocessor control system, also ensuring maximum reliability, amazing user-friendliness, ease-of-operation, shorter style changing time, excellent fabric quality, low energy consumption, and optimized insertion cycle for unequalled industrial speed.
Picanol developed GamMax rapier weaving machine. The GamMax has fulfilled all the requirements of the market through technological innovations and addition of new technologies and options. The features are: -
· High productivity through high machine speed and low down time.
· The ability to weave a wide variety of textiles.
· Flexibility in switching from one article to another.
· Low weaving costs.
· Internet-enabled microprocessor controlled technology.
· Choice of various reed widths from 190 to 380 cm.
In GamMax rapier weaving machine most of the machine functions are digitally controlled. Picanol also offers GTXplus rapier, specially developed to achieve the best price/performance ratio, offering high-quality fabrics at low weaving costs.
The Lindauer DORNIER GmbH developed new rapier-weaving machine, type PS. The Dornier rapier-weaving machine reliably produces first quality fabric, even with the most difficult yarns. The unique application spectrum offered from exclusive silk fabrics for upholstery with 16 filling colours and jacquard upto 20,000 hooks, to coated fabrics, eg, snow retainment fences.
The Suizer Textil G6500 rapier-weaving machine has been developed based on Sultexs decades of experience and expertise. Through the use of leading edge CAD tools, precise matching of the individual component can be possible. The G6500s are available in ten-machine widths- from 170 cm to 360-cm. Excellent fabric quality, high machine performance and low production costs are the key features of G6500. The maintenance-free direct drive transfers the torque directly to the main shafts. Several functions are controlled by it, adjustment of machine speed, shed leveling and pick finding. In jacquard weaving upto 12 weft colours give a wide variety of patterning option. The G6500 offers a machine speed of upto 700 rpm and a maximum weft insertion rate of 1620 m/min. The G6500 also offers Internet ready touch-screen terminal.
The minimal yarn loading in rapier weaving machine results in top fabric quality. The electronically controlled warp let-off and fabric take-up ensures constant wrap tension and weft density.
Rapier weaving machine, today offers a wide range of options to every specific production need.
The modern rapier-weaving machine is built around two side frames in cast iron that are connected by sturdy cross-members. The robust frame and the perfect balancing of the mechanical parts eliminate all vibration, which high industrial speed with a permanent and long-term stability.
Weft transfer system
The heart of the Dornier rapier weaving machine, type P5, is tip-to-tip filling insertion with positively controlled centre transfer to entering to the shed, the left hand rapier with opened yarn clamp picks up the filling presented by the filling selector needle. After the positive closure of the thread clamp, a scissor cuts the filling at the fabric side. The transfer of the filling from the left-hand to the right-hand rapier takes place at the middle of the machine through a positive control of the yarns clamps. After transfer, the filling is transported to the right hand edge of the fabric by a taker rapier. During the filling insertion cycle, the shed remains open. The filling is only released by the positive opening of the yarn clamp when securely held by the catch selvedge.
In Dornier rapier weaving machine, the highest peak yarn tension is extremely low due to the low rapier speed and positive control. During centre transfer from the left-hand to the right-hand rapier, the filling is positively controlled and thus securely transferred. The filling is released after the rapier has exited the shed in the open shed position and under absolutely control conditions.
Yarn with low tensile strength can be processed without any problem and with minimal stop frequencies. The robust construction of the filling insertion elements enables heavy filling yarns to be processed. The rigid rapiers do not require guide elements in the shed. Thus high-density warps can be woven without any problem and filament damage in the case of filament warps is eliminated. Dornier developed Air Guide System, which allows the rapier rods to move contact-free on an aerostatic support. A guide strip guiding air to the rods replaces the previous rollers. Integral temperature monitoring provides automatic self-control and therefore ensures high process reliability.
Due to the open shed filling insertion, independent of shed closing, the friction of the filling on the warp ends is decisively reduced. This results in fewer broken picks, no over-tensioning, no jump-back picks, clean left and right hand selvedges and a constant inserted pick length, all contributing to best fabric quality. A double and multiple filling insertion, and pick-and-pick as well increase the productivity.
Picanol developed Free Flight Rapier in their GamMax rapier-weaving machine, which has been specially developed for weaving delicate fabric. Hooks no longer guide the rapier tape, so the yarns cannot be damaged by hooks dividing into the warp yarn. The machine has a covered race board for gentle treatment of the warp yarns during beat-up. The Free Flight version of GamMax is especially useful for production of lining, voile, curtains, upholstery fabrics, industrial fabrics, high- twist crepe, air-bags, computer ribbon, spinnaker (soil cloth), glass and Kevlar.
A special gripper for extremely coarse weft yarn is also available. GamMax also offers new, guided gripper system for maximum yarn friendliness. GamMax can be fitted with a guided gripper system or a Free Flight gripper system. Both the systems are interchangeable.
The new lightweight guided gripper version enables higher speeds, and since the easier presentation into the gripper clamp requires less filling tension, the number of filling stops is reduced. The light gripper is also smaller, which results in a smoother entrance of the gripper in the shed, ensures less friction on the warp yarns. This reduces the warp breaks.
Leonardo Vamatex offers "EK" Transfer version of rapier weaving machine, in which the rapier is fitted on flexible ribbons, guided on both sides by a discontinuous one-sided race consisting of hook guides. A left-hand rapier takes the weft to the centre of the machine where a right hand rapier takes it and extracts it at the other side.
Leonardo offers a new generation rapiers capable of handling even the most difficult of yarns, typical of the latest trends in fashion fabrics. The rapiers are lightweight and compact and mounted at the centre of gravity on the ribbons to reduce wear to the minimum and guarantee maximum accuracy in movement. The weft exchange also takes place in slow speed, thus making life far easier for those involved in adjusting the machine setting and at machine start-up.
In the "FTS" version, the rapiers are fitted on flexible ribbons that run over the lowered warp ends and are supported by cloth race. This unguided flight of the rapier ensures excellent results even when weaving parallel filament of fabrics that are particularly prone to shrinkage.
A perfectly efficient weft cutter mechanism is required for use of a wide range of yarn in rapier weaving machine on the Leonardo having direct gear drive, ensuring constancy and precision and reducing yarn wastage.
In Suizer G6500, in order to maximize the productivity and fabric quality, Sultex engineers focused on low load weft insertion and minimal warp loading.