The Rapier Loom Display Warp Stop Motion Warp Break Stop Device is designed to monitor the on/off, tension, and operation status of the warp yarn in real time. Once abnormalities such as warp yarn breakage, single/multiple warp yarn relaxation/sudden change in tension, and warp yarn deviation are detected, the loom will immediately stop and issue a warning. It is the core supporting device of the rapier loom to ensure weaving quality, reduce raw material waste, and reduce equipment failures. Its function revolves around the three core functions of "preventing defective products, reducing losses, and protecting equipment", and is adapted to the working conditions of various warp yarns such as cotton, linen, silk, synthetic fiber, and fiberglass (such as the fiberglass belt you previously focused on) on the rapier loom. The specific practical functions and adaptability values are as follows:
1.Prevent the production of defective fabrics from the source and improve the weaving qualification rate
The warp yarn is the longitudinal basic yarn of a fabric. If a single/multiple warp yarns break, if the weaving machine continues to operate, the weft yarn will form defects such as skipping, holes, and sparse paths at the broken warp. Subsequent repairs are not only time-consuming and laborious, but serious defects can also lead to the scrapping of the entire fabric. The warp stop device can stop the machine at the moment of warp yarn breakage, allowing operators to repair the yarn in a timely manner, eliminating the occurrence of broken warp defects from the source, greatly improving the qualification rate of finished fabrics, especially suitable for high-end fabrics, industrial fiberglass belts/carbon fiber belts and other weaving scenarios that require extremely high flatness and defect free points on the fabric surface.
2.Reduce waste of warp and weft yarn raw materials and lower production costs
If the weaving machine continues to operate after the warp yarn breaks, ineffective weft yarns will continue to be woven in the broken warp area. At the same time, the broken warp yarns will experience pulling and tearing of adjacent warp yarns due to the pulling of the weaving machine, resulting in double waste of warp and weft yarns; And the defective fabric segments that are not woven effectively need to be cut and removed later, further increasing the loss of raw materials. The instant stop function of the warp stop device can minimize the ineffective weaving after warp breakage, resulting in extremely short fabric loss, while avoiding adjacent warp yarn damage, greatly reducing the waste of yarn raw materials, especially suitable for the weaving of high-value yarns (such as fiberglass yarn, silk, high-end synthetic fibers), with a more significant cost reduction effect.
3.Protect key components of the weaving machine to avoid secondary equipment failures
The components of the rapier loom, such as the rapier head, rapier belt, warp stop frame, and tension roller, are precision and vulnerable parts. If the warp yarn breaks and is not stopped in time, the broken warp yarn head will wrap around the rapier head, rapier belt, or tension roller, causing the rapier to run stuck and the tension roller to slip. In severe cases, it can cause equipment failures such as wear and tear on the rapier belt, deformation of the rapier head, and bending of the warp stop frame pins. This not only increases equipment maintenance costs, but also affects production efficiency due to downtime maintenance. Timely shutdown of the warp stop device can prevent yarn from winding around equipment components, protect the normal operation of the weaving machine's precision mechanism, and reduce equipment downtime due to malfunctions.
4.Adapt to multiple working conditions for warp yarn monitoring, compatible with different yarn characteristics and weaving processes
At present, the stopping devices of rapier looms are divided into two types: electrical (photoelectric/capacitive) and mechanical (stopping piece/stopping needle), which can adapt to warp yarns of different thicknesses and materials: mechanical type is suitable for conventional yarns such as cotton, linen, and synthetic fibers, and electrical type is suitable for special yarns such as fiberglass yarn, metal wire yarn, and fine denier yarn that are not easily monitored by mechanical pieces; At the same time, some high-end warp stop devices can simultaneously monitor warp yarn breakage and abnormal warp yarn tension. If the warp yarn becomes loose or experiences a sudden increase in tension (such as warp yarn knots or uneven yarn thickness), it will also trigger a stop, avoiding problems such as warp yarn breakage and uneven fabric tension caused by abnormal tension. It is suitable for different weaving processes such as high speed, low speed, wide width, and narrow width on rapier looms.
5.Reduce the intensity of operator inspections and improve workshop production efficiency
The rapier weaving machine room is usually produced by multiple devices connected in pieces. If the operator manually inspects whether the warp yarn is broken, they need to frequently travel back and forth between each weaving machine, which not only increases labor intensity but also easily leads to missed inspections. The stop device is a fully automatic real-time monitoring device, which will synchronously emit sound and light warnings in case of abnormalities. Operators can accurately locate faulty looms based on the warnings, without frequent inspections, and can simultaneously monitor more looms, greatly improving the per capita production efficiency of the workshop.
