TireCord GB 07-02640.qxd
2007 14:41 Uhr Seite 1
DORNIER air-jet weaving machine for tire cord
Increasing volume requirements
and also higher claims on safety
and performance for vehicle tires
have necessitated the development
of a modern, high-speed and high-
precision tire cord weaving ma-
chine.
Tire cord installation AWSR 4 / E4
15.11.
The proven weaving machine concept for tire cord
The special characteristics of cord strict test conditions imposed by stable selvedges despite of mis- 1. Warp end feed
fabrics for motor car tires mean that the tire manufacturers with regard sing weft return as usual with shuttle The yarns delivered by the creel are
they claim a special status among to warp yarn strength and elonga- looms, arranged by a condenser board and
industrial fabrics. They are charac- tion, and also closely toleranced reliable selvedge formation at assembly rollers into a level warp sheet
terized by: warp end distribution. All the test maximum speeds, which runs into the feed frame up-
values from the beginning to the careful guidance of the slip- stream of the weaving machine. A
large quantities of yarn (number end of the woven batch, and also sensitive fabric over guide roll com- weavers platform connects the weav-
of ends and yarn counts) compris- from the left- to the right-hand fabric binations to the batching motion, ing machine and the feed frame for
ing viscose rayon and manmade selvedge must meet these require- adjustable winding hardness on easy access. The feed frame is
filaments in the warp ments in full. the fabric roll with no distortion or equipped with a rear reed or expan-
the utilization of filling yarns of skew in the batch, sion combs, the lease which keeps
fine, low-tenacity cotton or elastic cylindrical and flush selvedge the cord yarns in the usual one-to-one
yarns of polyamide/cotton blends Accordingly, if a weaving machine is build-up on batch roll, pitch, and a first warp stop motion or
for the cord fabric on the one hand, to be successful in this industrial easy handling when weaving, a laser stop motion which detects any
and coarse cotton plied yarns or fabric sector, it must meet the fol- automatic change-over to cord end breaks in the yarns arising from
filament glass core yarns with cot- lowing requirements: or tabby weave, the creel sufficiently early to ensure
ton or synthetic coverings for the high productivity with assured that the quality of the tire cord remains
tabbies on the other. In order to absolutely equal-length warp- quality standards. unimpaired for the downstream weav-
ensure that, when manufacturing end feed combined with high, uni- ing process.
the tire, the filling yarn in the car- form feed rates and high, uniform The DORNIER AWSR 4/E4 air-jet A compensating roller is also provided
cass causes no disruption, but still tension levels, weaving machine meets these here to ensure, perfect synchronisa-
retains the position and correct dis- exact end distribution over the requirements in a thoroughly tion between the high take-up speed
tribution of the warp yarns, pick entire weaving width, convincing manner. in the weaving machine and the ever-
densities of 5.0 14 per 10 cm are highly uniform, low-stress filling changing inertia of the bobbins in the
usually applied insertion, creel. If the weaving machine is
Feed frame with compensating roller
stopped, the compensator accumu-
lates a length of yarn for subsequent
release to enable trouble-free restart-
ing. A patented soft start is program-
able so that the machine starts at
approximately 320 rpm and acceler-
ates over 5 10 seconds to the final
machine speed. This reduces tension
peaks in the creel, especially with
heavy spools (10 12 kg) or an insuffi-
cient creel.
2. Electronically controlled warp
let-off and fabric take-up devices
The deflection roller and generously
dimensioned feed roll in the weaving
machine are integrated in the EWL,
electronic warp let-off device, as a
single unit in order to ensure that the
cord material is fed to the weaving
process slip-free and with precisely
controlled tension, regardless the pre-
tension from the creel. This control
assembly is capable of adjusting the
warp tensions to different values for
the cord and tabby weaving process-
es. The warp tensions are controlled
by a load cell. A second warp stop
motion or further laser stop motions
detect cord breaks because of knots
and spliced joints which may open
during the weaving process.
A triple roller assembly, comprising of
one driven and two idling rolls ensures
that the take-up operation of the
finished fabric is free of slip and filling
distortion. The pick density required is
controlled by the ECT, the electronic
cloth take up device, which is part of
Batching device
the computer integrated mechanical machine by the mechanical elements
and electronic functions. of the all-so-important tucking devices.
Depending on the specification, the Although speeds of up to 600 rpm are
pick densities tend to lie between 5.0 achievable nowadays, such values also
and 14 picks/10 cm for the cord, and tend to lead to frequent failure of the
40 to 100 picks/10 cm for the tabbies. tucking units and associated with
The pick density setting range of the repairs and downtimes or worse
weaving machine does, however, per- rejections of rolls owing to the selvedg-
mit for densities outside this range. es not being properly tucked to the
standard required.
3. Shedding But with DORNIERs patented pneu-
A robust cam motion with a 12 mm matic tucking unit, there is now an air-
pitch is in use for shedding. This unit jet weaving machine the type AWSR
is able to satisfy the requirement for 4/E4 capable for exceeding these
high yarn tensions coupled with performance limits. As the pneumatic
smooth machine operation. tuck-in has no movable parts, speeds
up to 800 rpm are possible without
4. Filling insertion maintenance or high spare part con-
The filling insertion system developed sumption. All settings are done while
by DORNIER for its range of air-jet the machine is in operation, so perfect
weaving machines is also being used selvedge formations are easy to
for tire cord machines. Here the yarn achieve.
length required for the fabric width is
pre-measured in the filling feeder, 6. Fabric winding-up
accelerated by the main nozzle and A special batching technology is
Trio of rollers for fabric transport
transported through the shed by required to enable the inherently
relay nozzles operating under group unstable cord fabric to be effectively
sequence control are fully electronical- wound. The main criteria in this
ly controlled. The filling stop motion respect are, in particular, the hard-
monitors yarn arrival and a stretch ness of wind, a flush-edge build-up
nozzle keeps the weft under tension and ensuring that the filling yarns in
until it is secured in the tuck-in motion. the fabric remain straight, i.e. free of
This enables all types of filling yarn distortion and skew. The DORNIER
employed in the weaving of tire cord batcher meets all these requirements
to be effectively processed. The sys- in full.
tem is able to accommodate not only The weaving machine and batcher are
the usual cotton filling yarns in the electronically synchronised and con-
count range 20 33 tex, which are stant fabric tensions are ensured dur-
usually employed for cord fabrics, but ing all weaving processes even at
also the high elastic Olboplast yarn standstill. A programmable batch
and the above-mentioned coarse weight compensation feature eliminates
yarns for the tabbies. the disadvantage of having a soft cen-
tre and hard outside in the final-wound
5. Selvedge formation roll.
The main problem encountered in prior
art weaving systems lies in the perfor-
mance limits imposed on the weaving
Technical Data:
Type: AWSR 4/E4
Temple support system and pneumatic tucking unit Nominal width: 190 cm
Working width: 1000 up to 1880 mm
Colors: 4
Shedding: cam motion
No. of heald frames: 4
Tucking unit: pneumatic
Space requirement: 4790 x 5790 *)
Speed: cord: up to 800 n1; tabby: 300-350 n1
Winding system: batcher, max. diameter 1800 mm
(2000 mm on request)
*) Feed frame, weavers platform, weaving machine, weavers platform
and winder covered with 1800 mm batcher
**) dependent on yarn character and yarn count
Tucked selvedge
TireCord GB 07-02640.qxd 15.11.2007 14:41 Uhr Seite 4

Extensive automation for easy handling

7. Automatic tabby weaving

A further important advantage avail-
able with this new machine lies in its
automatic tabby weaving facility. All
the production-specific data of a
batch, relating to the lengths and
changes between cord- and tabby-
weaving, are transferred together
with the relevant settings by floppy
disc or online to the computer of
the weaving machine, and then
automatically implemented. For the
tabby weaving process, the ma-
chine automatically changes the fill-
ing yarn without stopping, increas-
ing the pick density and warp Lindauer DORNIER GmbH

TireCord
tension to the pre-set values. The 88129 Lindau/Germany
speed is reduced to the programed
Telephone +49 8382 7030
level. At the pre-programed point,
Telefax +49 8382 703386
the temple swings in to the start of
the tabby fabric. At the end of the
tabby, the same functions are per- American DORNIER Machinery Corp.
formed again, but in reverse order. P.O. Box 668865
The DORNIER programing system
Charlotte, N.C. 28266, USA
offers free selectability in respect of
Pneumatically controlled swivel temple support in tabby position Telephone +1 704 394 6192
pick density, yarn tension, speed,
fabric length and batch build to Telefax +1 704 399 2018
accommodate all the cord fabrics
encountered in the market place. DORNIER Machinery (Shanghai) Co. Ltd.
After the weaving and machine con-
Area B G/F Block 45
trol data have been entered, they
are stored ready for reloading for 299 Fu TeZhong Road

repeat batches at a later date. WaiGaoQiao Tax Free Zone

Shanghai 200131, P.R. China

This air-jet weaving machine Telephone +81 21 5046 2838
in combination with the pneu-
Telefax +81 21 5046 2138
matic tucking units offers a
very simple handling, mini-
mum maintenance with a ma- DORNIER Machinery India
ximum output and producti- Private Limited
vity, with a minimum space
201-A, Sangeet Plaza
requirement, with a corre-
Marol Maroshi Road
sponding reduction in the re-
quisite capital outlay. Experts Andheri (East)
will be quick to recognize that Mumbai 400 059, India
these advantages also mean Telephone +91 22 859 8758
faster material throughput and
Telefax +91 22 859 8760
reduced capital tie-up in
inventories.
http://www.lindauerdornier.com
With full automation of the webmaster@lindauerdornier.com
cord conversion process, we
are able to offer to the tire
cord industry a technological

Subjet to change without notice

lead based on superior perfor-
mance characteristics coupled
with assured attainment of the
required quality standards.

4005/LD/11/07
Electric-electronic control