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The Automatic Drawing-in Machine is capable of simultaneously drawing warp yarns through drop wires, heddles, and reeds in a single operation; it is simple to operate, highly efficient, and serves as an excellent substitute for traditional manual drawing-in. However, when processing fabric varieties that require the warp yarns to be separated into upper and lower layers and drawn in according to a specific ratio, the yarns on the warp beam must first undergo processing by a warp dividing machine—the acquisition cost of which is substantial. In response, our company has mobilized its technical staff to develop a "Double-Layer Yarn Preparation Device." This device enables the proportional drawing-in of two distinct yarn layers; a detailed description follows below.
The double-layer yarn preparation device organizes the yarn from the weaver's beam into distinct upper and lower layers; these two layers must be separately clamped within the device. During the warp drawing process, the clamping plate for the upper yarn layer remains fixed, while the lateral position of the clamping plate for the lower yarn layer is flexibly adjustable. The specific structural components include the yarn frame support, upper and lower yarn clamping plates, pressure bars, clamping bars, a brush roller, a tension adjustment mechanism, and a drive mechanism for the lower yarn clamping plate. The primary operational workflow consists of the following steps: yarn guiding → yarn separation → yarn fixation → tension adjustment → yarn combing. The yarn is drawn from the weaver's beam stand to the position of the yarn preparation frame, where a lease cord is utilized to separate the yarn into distinct upper and lower layers. The yarn is then secured using the upper and lower sets of clamping plates on the preparation frame; the clamping tension between the two yarn layers can be uniformly adjusted via the tension adjustment mechanism. Once the yarn tension has been properly set, a steel reed is used to comb the yarn within the preparation frame in both upward and downward directions, thereby completing the yarn preparation process.
Prior to the development of the double-layer yarn preparation device—and in the absence of a yarn separation mechanism—double-layer yarns could not be threaded on the automatic warp drawing machine in the correct proportions, thereby failing to meet production process requirements. Consequently, operators were required to manually separate the upper and lower yarn layers thread-by-thread at the loom's warp beam position, strictly adhering to the specified proportions—a task that was both time-consuming and labor-intensive. While simple upper-to-lower warp ratios required relatively little time, complex ratios demanded significantly more; moreover, any error necessitated restarting the entire process from scratch, severely compromising production efficiency.
Following the development of the double-layer yarn preparation device, the warp drawing operator—when commencing operations—needs only to monitor changes in the vertical positioning of the yarn layers. Should any positional deviation be detected, the operator uses a remote control to adjust the lateral position of the lower-layer yarn clamping plate, thereby ensuring the yarn remains consistently within the designated separation zone. A dedicated remote control is used to manage the lower-layer yarn clamping plate located on the upper beam of the yarn preparation frame, while a separate remote control is used for the clamping plate situated on the lower beam. These two clamping plates are thus controlled independently. Taking as an example a specific fabric variety with a total warp count of 5,100 ends and a layer distribution ratio of 11,111:53,454, the warp drawing speed can reach 130 ends per minute, completing the entire drawing process in approximately 45 minutes. Once the warp beam has been fully drawn, the operator moves the yarn creel trolley away from the drawing machine to facilitate the beam doffing process. The doffed beam is then handed over to the beam loading crew, who use a harness-and-beam loading trolley to transport it to the designated loom for installation. Upon mounting the beam onto the loom, the operator performs the necessary installation and adjustment procedures, after which the machine is ready to commence weaving operations.
The double-layer yarn reserve device can significantly reduce loom downtime, save on labor and equipment investment costs, and enhance production efficiency, yielding highly effective results.
