Weaving Machine

Weaving Machinery in the Textile Industry

Weaving machinery refers to the machines used in the textile industry to produce fabric by interlacing warp and weft threads. These are mechanical devices designed specifically for weaving fabric. In other words, these machines are used exclusively for fabric production. Within the textile industry and its subset, weaving, various types of machinery are employed for this purpose. You can find the available weaving machinery in this category at the top of the page.

Classification of Weaving Machinery

Weaving machinery can be categorized based on the system used to form the shed (warp thread formation) or the weft insertion system. Below are explanations regarding these classifications.

Classification Based on Weft Insertion System

Weaving machines can be divided into two main categories based on the weft insertion system: shuttle weaving machines and shuttleless weaving machines. The table below provides an overview of these categories.

Shuttle Weaving Machines: These machines use a shuttle to carry the weft thread across the warp threads. The shuttle consists of a wooden body weighing approximately 150 to 250 grams, with a bobbin of weft yarn placed inside it.

Disadvantages of Shuttle Weaving Machinery:

• Low speed
• Heavy weight
• Frequent interruptions due to bobbin changes

On the other hand, shuttleless weaving machines replaced shuttle weaving machines due to their advantages. These machines are further subdivided into different types, such as:

• Projectile Weaving Machines
• Air Jet Weaving Machines
• Water Jet Weaving Machines
• Rapier Weaving Machines

You can view all possible weft insertion systems in the image below.

Classification Based on Shed Formation Mechanism

Weaving machinery can also be classified based on the mechanism used to form the shed. In this case, the machines are divided into three distinct categories:

1. Jacquard Weaving Machines
2. Dobby Weaving Machines
3. Leno Weaving Machines

Dobby weaving machines use levers to control the heddles, and the warp threads are raised according to the predetermined pattern to create the fabric. The advantages of dobby weaving machines include:

• Simple mechanism
• Low initial cost
• Easy maintenance

The number of heddles in a dobby weaving machine is determined based on the repetition of the weave pattern. For example, to weave a 3/1 twill, four heddles are required. However, dobby weaving machines have some limitations, such as:

• The inability to use heddles designed for one weave pattern for another.
• Changing heddles is time-consuming.

The control of heddles in a Jacquard weaving machine is managed by a Jacquard cord, which manipulates the warp threads, allowing for an unlimited variety of patterns, including animal, floral, or geometric designs. The Jacquard mechanism is more complex than the dobby mechanism, leading to higher initial costs and maintenance expenses.

Hand Weaving Machines

Hand weaving machines are often made of wood. Below is an example of such machines.

Components of Hand Weaving Machines:

• Frame: The frame is the structural foundation of the weaving machine, supporting all other components.
• Warp Roll: The warp threads are wound onto a roll in a specific manner according to the weaving pattern.
• Division of Warp Threads: To weave, warp threads need to be divided into two groups, with one moving upwards and the other downwards according to a predetermined design. These threads pass through the eyelets of thin heddles to create the shed for weft insertion.
• Number of Heddles: Weaving machines vary in the number of heddles. The simplest machines have two heddles, weaving only plain fabric, while most machines have eight heddles. Below is an illustration showing the movement of heddles.

Weaving Machine Terminology

• Weft Insertion: The process of inserting the weft thread into the shed formed by the warp threads is known as weft insertion. This is done using a tool called a shuttle, which holds a bobbin of weft yarn. By moving the shuttle through the shed, the weft is placed in position.
• Beating-up: Beating-up is a process in the weaving machine where the weft thread is pushed against the fabric edge using a device known as the reed. The reed has metal or wooden teeth, and it can be easily replaced. The number of threads passing through each reed tooth is essential. The number of reed teeth per meter is used to measure the reed in weaving machines.
• Fabric Winding: Once the fabric is woven, it is wound onto a special roller called the fabric roller. If the winding tension is too high, the space between the weft threads increases, and if the winding tension is insufficient, the weft threads will be too close together.

Electric Weaving Machines

The introduction and use of electric motors in weaving machines significantly increased the speed of the weaving process, enabling faster fabric production. Although electric motors provide rotary motion, the shuttle requires a striking force to operate. Additionally, the fabric weave needs to be precise and fine, requiring a gentle and continuous winding of the fabric. The rotation speed of electric motors in weaving machines typically ranges from 200 to 400 revolutions per minute (RPM). To address this, gear systems, pulleys, and belts are used. Although the weft insertion process still uses the shuttle, its speed has considerably increased, resulting in faster fabric production.

Advantages of Electric Weaving Machines over Hand Weaving Machines:

• Uniformity in the weave
• Higher weaving speed
• Wider woven fabrics
• Reduced human labor for weaving fabric

Disadvantages of Electric Weaving Machines:

• High noise levels
• Risks of electric shocks
• Risks of shuttle impact injuries

Automatic Weaving Machines

A significant advancement in the weaving industry has been the development of fully automatic weaving machines. These machines are designed with full intelligence and are capable of performing operations based on predetermined programs and designs. Below is an example of such a machine.

Weaving Cycle in Automatic Weaving Machines:

To weave a weft thread, a series of specific operations, known as the weaving cycle, is performed. The weaving cycle includes the following steps:

• Shed Formation: Involves the up-and-down movement of heddles to create space for weaving.
• Weft Insertion: Placement of the weft thread into the shed.
• Beating up: Compressing the weft thread against the fabric edge.
• Warp Thread Release: Adjusting the warp threads according to the required weft density.
• Fabric Rolling: Winding the fabric onto the roller according to the required density.

The processes above are repeated for each weft thread, which is why it is called a weaving cycle. For weaving ten weft threads, these steps will be repeated ten times. In automatic machines, the control of weft insertion and the tension adjustment of the warp threads are also integrated into the process.