Karl Mayer: High warping quality using electr...
Karl Mayer

High warping quality using electronic control system

(Source: Karl Mayer)
(Source: Karl Mayer)

A universal direct warping machine that can be used to process all conventional staple fibers is offered by Karl Mayer. The Prodirect has a maximum warping speed of 1,200 m/min, top-quality warping and even yarn tensioning forces. It is often paired with the Prosize sizing machine.
The Prodirect features include the smart reed automatic warp comb, which automatically adjusts to the warping parameters, and a pressing roller system with electronic system build-up control for high warp quality. The pressing roller system uses a defined pressure to compress the winding, thus ensuring that the winding builds up in a controlled manner that keeps it very straight. Furthermore, electronic length measurement and monitoring are used to ensure that the threads are identical in length. The tolerance range for deviations is below 0.10%.
With the Prodirect, the regulation of peripheral speed and the contact pressure on the winding is organized either by a laser sensor or, as a new option, by a pressure sensor in the pressing roller system. The pressure sensor bases its regulation on a defined set value for the contact pressure. At the same time, a displacement transducer measures the exact position of the pressure roller. The laser sensor focuses on the product and can be used as an alternative to calculate the winding density and use that to decide which actions to take. The diameter is the value measured for this process.
In addition to this, the calculated build-up height is used to precisely calculate the length of the warped threads. The laser and pressure sensor systems both use a torque that can be equipped with a drive as an option. The version of the system with an active-drive torque and a laser sensor is particularly well-suited to efficient warping of warp beams with low yarn tensions and extremely even winding densities.
During manufacturing of the dyeing beams, the driven torque increases the difference in speed between the yarn draw-off and the yarn wind-up in order to reduce the yarn tension. At the same time, the laser sensor ensures that the measurement is reliable and slip-free so that the density is always under control.
As hydraulic units are generally high-maintenance, expensive and not particularly beneficial for the environment, this system has been replaced with new solutions. The Prodirect’s pressing roller system used to generate the pressure is now positioned using electric motors. The active positional adjustment based on the beam diameter guarantees even adjustment without any sudden jerking. The speed of the torque is also regulated electrically, and the warp beam is equipped with tried-and-tested, zero-maintenance, hydro-pneumatic brake system from Karl Mayer Group, Obertshausen/Germany. This hybrid component uses a hydraulic main brake cylinder that is controlled by a pneumatic cylinder.

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