Warp Knitting Preparation | DS 21/30 EC Karl Mayer

The DS 21/30 EC – a new computer-controlled direct warping machine developed
by KARL MAYER for the warp knitting sector.

Source KWP 1/2009

KARL MAYER’s DS machine series represents highly efficient technology for use in warp preparation
for warp knitting. A well-thought-out construction and intelligent design features enable high speeds of up to 1,200 m/min to be achieved when producing sectional warp beams having identical circumferences and lengths, whilst guaranteeing accurate and reliable operation at the same time.
KARL MAYER's high-speed direct warping machines operate using optimally coordinated creel systems, feed units and synchronised braking systems. All the operating conditions, start/stop and running phases are 100 % computer-controlled,and any variations in the circumference of the sectional warp beams are extremely small. The maximum variation is no more than a millimetre, even when extremely delicate yarns are being processed. If the machine has to be braked, highly innovative synchronized braking systems stop the
machine in just 0.6 seconds, and the running of the yarn sheet is fully controlled,even when the machine has been operating at high speed. These performance features can all be utilised very easily via the KAMCOS® machine control system.
The Operator Interface with touch screen facility gives a clear view of what is happening, and enables all the machine functions to be accessed easily. An Ethernet interface permits the data acquisition and Teleservice
modules to be connected up. These performance features have ensured that all the models in KARL MAYER’s range of direct warping machines have become real bestsellers on the market.
DS 21/30 EC A new model in the successful DS series is the DS 21/30 EC. This new warping machine
is based on a rational design concept, is relatively cheap, and is designed to produce standard articles on a price-oriented market. These features mean that it is perfectly matched to suit the requirements of
KARL MAYER’s TM2 and TM3 machines.
The performance features of these two basic tricot machines, which are designed to appeal to manufacturers who are new to this sector, can be fully utilised by using them in combination with the DS 21/30 EC.
The construction of the DS 21/30 EC has been logically designed to provide practical solutions. The technology for producing the sectional warp beams enables a warping speed of up to 1,000 m/min to be achieved, and yarn tension values up to a maximum of 200 N to be processed. The special technical
features include computer-controlled band build-up, a master beam/successive beam control system, an integrated MMI operator console, an intelligent, synchronized braking system, the tried-and-tested
KAMCOS® control system, and facilities for connecting-up additional units. The touch screen monitor is an easy-to-use man/ machine interface and can be used to display the process parameters and input the
beam data.
A range of different functions can also be activated and master lists can be stored - simply by pressing buttons.
The DS 21/30 EC is a rational, robust production machine, which meets all the requirements of conventional warp preparation and is another contribution from KARL MAYER for producing standard articles economically. When used in conjunction with the TM2 or TM3 machines especially, the efficiency, synergistic effects and performance features of all the machines from this renowned manufacturer can be utilized to the full in warp knitting.
This new model in the DS range has been used successfully on the Asian market since
August 2008, and has been available on the world market since January of this year.

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Electro Static on The Yarn Sheet During Warping Process

The surface of  isolated material such like polyester yarn,nylon yarn,elastomeric yarn or others synthetic material is normally not charged. When the yarn surface moves towards another material, or get frictions with others parts surface on warping machine during warping process , e.g :a yarn sheet moving on  reed  ,tension tube or ceramic eyelet , electrons can be transported from the surface layer of these part  to the yarn sheet. This is called triboelectric effect and causes an imbalance of the electric charge of the material, the surface layer of one material becomes positively charged and the other one negatively charged. As the yarn sheet  and warping parts is isolated, the charge cannot be conducted away through the yarn or parts which get friction with the yarn sheet itself, the charge is then called static electricity. The ability of the electric charge to attract one with the opposite polarity or to repel another with the same polarity may then cause problems,  e.g.:Broken filaments on the yarns,hairness or the yarn sticky together.Different hardness and outer circumference in one set of warp beam when warp a textured yarn often occurred due static electricity or electro static.The most problem due electro static on the yarn sheet during warping process are :

• Broken filament.
• Un-even warp beam surface.
• Different outer circumference in one set of warp beam,mostly for textured yarn.
• Yarn hainess.
• Short life time of the latch needle for the warp knitting machine used latch needle.

The charged surface of the yarn sheet can be neutralized by ionizing the air uses anti static equipment  or electro static discharger (ESD),i.e. air particles are charged by positive and negative polarity.
The negatively charged air particles can then give off an electron to a positively charged particle in the surface of an isolated material, thereby neutralizing particles both in air and material. In the same way the positive air particles are neutralized by the negative particles in a charged material.
The anti static equipments uses a high voltage electrode to ionize air particles through corona discharge to both positive and negative polarity.

 Picture 1,showing the ESD rod installed below the yarn sheet after every separator reed on warping machine.

Picture 2,showing the ESD installed below the yarn sheet before and after main reed ,before the yarn sheet warp onto  the beam.





Wherever ESD are used to control static discharge,the effectiveness of an ESD system depends on the type of ionizers used and how they are installed on warp knitting machines. Measuring the static in the area
before and after a ESD is installed helps determine how well the system performs.
It’s also important to periodically monitor the area or process to detect unacceptable levels of charge accumulation and verify that the system is working properly.

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