Teaching Plan

WEAVING

Total teaching hours: 416=64

1st week Chapter 1 Overview of the Weaving Process

(2 hrs) Teaching requirements of Chapter 1 This chapter will provide the basic knowledge of woven fabric formation and the development of weaving technologies. Through the contents of this chapter, the students are required to be familiar with the interlacing structures of woven fabrics, their possible applications, and the processing technologies. In addition, the students are asked to learn the vocabularies and some basic technical terms of weaving in English. Teaching hours for the chapter: 2 hrs Contents General introduction Woven fabric Formation Materials Types of fabrics Development of woven fabrics Weaving process Key points Definition of woven fabric Flow chart of weaving process Vocabularies weaving, weaving preparation, weaving machine, warp yarn, filling yarn, woven fabric, gray fabric, dyed yarn fabric

Chapter 2 Winding (1)

(2 hrs) Teaching requirements of Chapter 2 Winding is the first processing of weaving and an important processing stage to ensure a success weaving. Through this chapter, the students are required to understand the objectives and the technical requirements of the process, to be familiar with the working principles of winding machine, and typical technical parameters. To provide them a theoretical background, they are asked to understand the built-up of the winding package. In addition, the students are asked to learn the vocabularies and basic technical terms of winding in English. Teaching hours for the chapter: 8 hrs

Contents Objectives and requirements Description to winding process Three regions in winding Unwinding Methods of yarn withdrawal Tension and tension variation Balloon and balloon breaker Key points The path of the yarn in winding process Yarn tension variation and influencing factors Vocabularies winding, unwinding, side withdrawal, over-end withdrawal, yarn package, bobbin, cone, grooved drum, tension, tensioner, yarn clearer, balloon

2nd week Chapter 2 Winding (2)

(2 hrs) Contents Three regions in winding (Cont.) Tensioning and clearing Tension device Clearing device Yarn defects Splicing device Winding Types of package drives Types of wound package Key points Working principle of tensioner Package drives and their features Vocabularies splicing, yarn hairiness, spindle drive, friction drive, cross wound package, parallel wound package

Chapter 2 Winding (3)

(2 hrs)
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Contents Winding (Cont.) Winding angle Winding speed Winding methods Key points Formation of winding angle Winding method and the package built-up Vocabularies winding angle, constant angle of winding, constant pitch of winding, precision winding, step precision winding,

3rd week Chapter 2 Winding (4)

(2 hrs)
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Contents Winding (cont.) Cone winding (inc. driving radius, driving point, driving ratio, winding density) Patterning and anti-patterning (inc formation of winding pattern, results problems, anti-pattern methods) Key points Parameters determining the built-up of the cone package Problems associate with the winding pattern Anti-pattern methods Vocabularies driving radius, driving point, driving ratio, winding density, winding pattern, anti-patterning, driving radius, driving point

Practice 1
(2 hrs) General description Yarn is the basic building block in weaving. In practice, the condition of yarn produced on the spinning machine is not always good enough to be used directly for fabric formation. Package size, yarn surface characteristics, and other factors make it necessary for both filling yarn and warp yarn to be further processed for efficient fabric formation. Winding is the first processing of weaving and an important processing stage to ensure a success weaving. Requirements In this practice, through a number of select questions, the key points and possible difficulties during lecturing are reviewed to promote further understanding of the contents. The students are required to answer the questions. In addition, the students are encouraged to ask questions of their own and try to make commons. Questions Refer to Questions in the section of Winding

4th week Test 1

(2 hrs) The test is in written form and includes three parts, vocabularies involved in winding process, working principle of the processing equipment and the processing technologies. The students are asked to finish the test within 2 hours. The score of this test will account for 10 % of the final examination.

Chapter 3 Warping (1)

(2 hrs) Teaching requirements of Chapter 3 In this chapter warping process is introduced. The key point in this chapter is the control of warping tension. Through this chapter, the students are required to understand the objectives and the technical requirements of the process, to be familiar with the working principles of warping machine, and typical technical parameters. They are asked to understand the reasons causing the variation of warping tension and the possible measures to ensure a uniform warp tension. In addition, the students are asked to learn the vocabularies and basic technical terms of warping in English. Teaching hours for the chapter: 4 hrs Contents Objectives and requirements Warping methods Direct warping Section warping Warping process Creel Types Tensioner and other devices Key points Path of yarn in warping process Features of different warp methods Vocabularies warping, direct warping, section warping, creel, single end creel, magazine creel, parallel creel, V-creel, headstock, extensible reed, warp beam, beaming, static eliminator, stop motion

5th week Chapter 3 Warping (2)

(2 hrs) Contents Warping tension Tension variation when yarn withdrawal from the package Other factors influencing the variation of warping tension Measures for a uniform warp sheet tension Technical information in warp winding Direct warping Section warping Key points Factors influencing the tension variation in high speed warping Methods for a uniform warping tension Vocabularies warping tension, tension washer, surface friction drive, direct drive, warp band, pattern drum, warp separation, separation reed

Chapter 4 Slashing (1)

(2 hrs) Teaching requirements of Chapter 4 The contents of this chapter include two parts, slashing processing and size materials. Through this chapter, the students are required to understand the objectives and the technical requirements of the process, to be familiar with the working principles of slashing machine, and typical technical parameters. Tor size materials, the students are required to know the chemical structure and basic properties of major size film formers, i.e. starch, polyvinyl alcohol, and polyacrylic acid based sizes. Also, they are asked to know various types of additives. By select examples of size formula, the students are taught to understand how to chose the film former and additives according to the types of fiber, yarn and fabric to be processed. In addition, the students are asked to learn the vocabularies and basic technical terms of warping in English. Teaching hours for the chapter: 12 hrs Contents Objectives and requirements Slashing process Principle

Size penetration and encapsulation How yarn are sized

Key points Path of yarn in slashing process Size penetration and encapsulation Vocabularies slashing, sizing, weavability, beam creel, size box, drying uint, lease rod, size penetration, size encapsulation, size solution

6th week Chapter 4 Slashing (2)

(2 hrs) Contents Slashing process (Cont.) Controlling parameters General description to controlling parameters Size take-up How to control the size take-up Key points Size take-up and its controlling factors Vocabularies size take-up, size add-on, size concentration, sizing roller, squeezing roller, squeeze pressure, immersion roller, cover coefficient, desizing

Chapter 4 Slashing (3)

(2 hrs) Contents Slashing process (Cont.) Controlling parameters Elongation rate How to control the elongation rate Moisture regain How to control the moisture regain Key points Yarn elongation and its controlling factors Moisture regain of the sized yarns and the controlling factors Vocabularies moisture regain, elongation rate, hot air dryer, cylinder drying chamber, withdraw tension, immersion tension, wet tension, drying tension, winding tension, desizing

7th week Chapter 4 Slashing (4)

(2 hrs) Contents Size materials - Film formers Starch Modified starches Polyvinyl alcohol (PVA) Polyacrylic acid based sizes Key points Feature of starch as a film former and its modifications Degree of hydrolysis of PVA Vocabularies sizing film, film former, adhesive, starch, modified starch, derivatives of cellulose, polyvinyl alcohol, polyacrylic acid based sizes, acrylate, acrylamide, viscosity, hydrophilic, hydrophobic

Chapter 4 Slashing (5)

(2 hrs) Contents Size materials (Cont.) Additives General description of additives Categories of additives Size formulation Factors determining the selection of size ingredients Selection of additives according to the film former Key points Principle of size formulation: The size materials (esp. the film formers) should be similar in construction to the fibers to enhance adhesion. Vocabularies additive, thinning agent, surface active agent, surfactant, lubricant, Anti-static agents, preservative, humectant, anti-foam agent

8th week Chapter 4 Slashing (6)

(2 hrs) Contents Filament sizing New slashing technologies High pressure sizing Pre-wet sizing Solvent sizing Foam sizing Hot melt sizing Cold sizing Key points The technique of high pressure sizing and the features The technique of pre-set sizing and the features Vocabularies high-pressure sizing, pre-wet sizing, solvent sizing, foam sizing, hot melt sizing, cold sizing

Chapter 5 Drawing-In and Tying-In

(2 hrs) Teaching requirements of Chapter 5 Through this chapter, the students are required to understand the objectives and the technical requirements of the process, to be familiar with the working principles of the process, and typical technical parameters. They are asked to understand the relationship between the interlacing structure of yarns and drawing-in process. In addition, the students are asked to learn the vocabularies and basic technical terms of warping in English. Teaching hours for the chapter: 2 hrs Contents Drawing-In Tying-In Dropper, heald frame and reed Key points The tasks of the processes Vocabularies

drawing-in, tying-in, splitting, dropper, heald shaft, heddle, heald frame, harness, heald eye, heald wire, reed

9th week Practice 2

(2 hrs) General description Warp preparation involves winding, warping, slashing and drawing-in or typing-in. Modern weaving machines have placed increased demands on warp preparation due to faster weaving speeds and the use of insertion devices other than the traditional shuttle weaving. Warp yarn must have uniform properties with sufficient strength to withstand stress and frictional abrasion during weaving. Requirements The practice of Winding has already been conducted in Practice 1. In this practice, the rest processes of warp preparation are involved. Through a number of select questions, the key points and possible difficulties during lecturing are reviewed to promote further understanding of the contents. The students are required to answer the questions. In addition, the students are encouraged to ask questions of their own and try to make commons. Questions Refer to Questions in the sections of Warping, Slashing and Drawingin.

Test 2
(2 hrs) The test is in written form and includes three parts, vocabularies involved in winding process, working principle of the processing equipment and the processing technologies. The students are asked to finish the test within 2 hours. The score of this test will account for 20 % of the final examination.

10th week Chapter 6 Weaving Fundamentals

(2 hrs) Teaching requirements of Chapter 6 In this chapter the fundamental motions in a weaving machine is introduced. Through this chapter, the students are required to understand the reason why modern shuttleless weaving machines are gradually replacing traditional shuttle weaving machine. They are asked to know various types of shuttleless filling insertion systems. In addition, the students are asked to learn the vocabularies and basic technical terms of warping in English. Teaching hours for the chapter: 2 hrs Contents Presentation of woven fabric Weaving process Basic motions in weaving Classification of weaving machine Problems of shuttle weaving Features of shuttleless weaving Key points Path of warp and filling yarn in a weaving machine Features of shuttle and shuttleless weaving Vocabularies shuttle, shuttleless, projectile weaving, rapier weaving, air-jet weaving, waterjet weaving

Chapter 7 Shedding (1)

(2 hrs) Teaching requirements of Chapter 7 In this chapter shedding process is introduced. Through this chapter, the students are required to understand the formation of shed geometry, the shed geometry and warp yarn stress, timing synchronization of shedding and other motions in a weaving machine. The students are asked to be familiar with the working principles of three shedding mechanisms, i.e. cam shedding mechanism, dobby shedding mechanism and Jacquard shedding mechanism. The working principles of modern electronic dobby and electronic Jacquard are also introduced.

In addition, the students are asked to learn the vocabularies and basic technical terms of warping in English. Teaching hours for the chapter: 6 hrs Contents Shed opening Shedding and yarn stress Shed geometry Terms and definition Warp yarn stress Clear shed and unclear shed Key points Shedding motion and warp yarn stress Shed geometry and warp tension Vocabularies shedding, shed, front shed, back shed, top shed, bottom shed, clear shed, unclear shed, back rest, front beam, weaves beam

11th week Chapter 7 Shedding (2)

(2 hrs) Contents Shedding motion Stages of shedding motion Timing of weaving process Shed timing Key points Timing diagram Shedding motion and shed timing Vocabularies shed timing, shed level, warp line, period of shed opening, period of dwell, period of shed closing, diagram of loom timing

Chapter 7 Shedding (3)

(2 hrs) Contents Shedding mechanism Cam shedding Dobby shedding Jacquard shedding Key points Description of shedding motions Features of different shedding mechanisms Vocabularies Cam shedding, dobby shedding, Jacquard shedding

12th week Chapter 8 Filling Insertion (1)

(2 hrs) Teaching requirements of Chapter 8 In this chapter filling insertion process is introduced. Through this chapter, the students are required to understand the timing synchronization of filling insertion and other motions in a weaving machine. Various filling insertion systems are explained, together with their technical details. The students are asked to be familiar with working principles of the typical shuttleless weaving machines. In addition, the students are asked to learn the vocabularies and basic technical terms of warping in English. Teaching hours for the chapter: 8 hrs Contents Timing of filling insertion Shuttle weaving Tasks of the shuttle Picking mechanism Timing synchronization Controlling parameters Average velocity of the shuttle Selvedges of woven fabrics Key points Timing synchronization of filling insertion with shedding and beating up Picking principle and shuttle motion Vocabularies filling insertion, filling insertion rate, picking device, picking stick, picker, shuttle box, checking device, picking time

Chapter 8 Filling Insertion (2)

(2 hrs) Contents Projectile weaving Processing description Picking process picking energy generation and release Features of projectile filling insertion

Selvedges in shuttleless weaving Key points Torsion rod and picking principle Vocabularies griper projectile, torsion rod, projectile guide, tacked-in selvage, fringe selvage, leno selvage, melt selvage

13th week Chapter 8 Filling Insertion (3)

(2 hrs) Contents Rapier weaving Processing description Forms of rapier Transfer of filling yarn Features of rapier filling insertion Filling yarn accumulator Key points Positive control of filling yarn in rapier weaving Vocabularies rigid rapier, flexible rapier, weft storage unit, prewinder, selvedge, filling feeder

Chapter 8 Filling Insertion (4)

(2 hrs) Contents Air-jet weaving Processing description Filling insertion system Principle of Air-jet filling insertion Air flow Yarn tension Dynamics of yarn insertion with air Performance of yarns in air-jet insertion Effect of yarn structure Effect of yarn count, twist and ply Features of air-jet filling insertion Water-jet Weaving Processing description Major characteristics of water-jet machines Key points Interaction between air flow and yarn structure Filling yarn tension in air-jet weaving Vocabularies nozzle, main nozzle, relay nozzle, supplementary nozzle, profile reed, confusor guide

14th week Chapter 9 Beating-Up (1)

(2 hrs) Teaching requirements of Chapter 9 In this chapter the process of beating up is introduced. Through this chapter, the students are required to understand the formation of fabric by beat-up mechanism. The relationship between warp tension, cloth tension and weaving resistance is explained. The students are asked to be familiar with the working principles of beating up mechanisms. The timing synchronization of beating up, shedding and filling insertion is emphasized. Some parameters, such as the basic warp tension, position of the back rest and the shed timing, are introduced, together with their effects on fabric formation. In addition, the students are asked to learn the vocabularies and basic technical terms of warping in English. Teaching hours for the chapter: 6 hrs Contents Tasks and requirements Beat-up mechanism Fabric formation The cloth formation zone Contract of cloth at the cloth fell Key points Movement of filling yarn at the cloth fell Vocabularies beating up, reed, cloth formation zone, yarn crimping, pick spacing

Chapter 9 Beating-Up (2)

(2 hrs) Contents Fabric formation (Cont.) The weaving resistance Bumping condition Beating up strip Key points Beat-up force and weaving resistance Variation of warp tension and fabric tension during beat-up Vocabularies

weaving resistance, beat-up force, beating up strip, bumping, pick spacing

15h week Chapter 9 Beating-Up (3)

(2 hrs) Contents Fabric formation (Cont.) Parameters influencing fabric formation Basic warp tension Vertical position of the back rest Shed timing Key points Warp tension and weaving resistance Position of back rest and shed asymmetry Shed timing and shed unbalance Vocabularies beating up strip, basic warp tension, position of back rest, reed mark, shed asymmetry, shed unbalancing

Chapter 10 Take-Up and Let-Off (1)

(2 hrs) Teaching requirements of Chapter 10 In this chapter working principles of various mechanisms of fabric take-up and warp let-off are introduced. Through this chapter, the students are required to understand the principle of warp tension regulation, formation of fabric and pick spacing regulation in weaving machines. In addition, the students are asked to learn the vocabularies and basic technical terms of warping in English. Teaching hours for the chapter: 4 hrs Contents Fabric Take-Up Take -up mechanism Operating principles Filling density Key points Take-up rate and the control of pick spacing Vocabularies take-up mechanism, negative take-up, positive take-up, on-loom filling density, off-loom filling density

16th week Chapter 10 Take-Up and Let-Off (2)

(2 hrs) Contents Warp Let-off Let-off mechanism Operating principles Warp tension regulating device Key points Warp tension regulation in a weaving machine Vocabularies let-off mechanism, positive let-off, negative let-off, warp tension regulating device

Practice 3
(2 hrs) General description Although there are many mechanisms on a modern weaving machine for various purposes, there are five basic mechanisms that are essential for continuous weaving: shedding, filling insertion, beat-up, warp let-off and fabric take-up. Shedding is the movement of some warp yarns up and some down to make an angled opening for the filling yarn to be inserted through. After each shed change, the filling yarn is inserted through the shed by means of carriers of various types. The newly inserted filling yarn needs to be brought to its final position by beating up. Warp let-off mechanism releases the warp yarn from the warp beam and applies tension to the warp yarns by controlling the rate of flow of warp yarns and the take-up mechanism removes cloth at a rate that controls filling density. Requirements In this practice, the weaving process is involved. Through a number of select questions, the key points and possible difficulties during lecturing are reviewed to promote further understanding of the contents. The students are required to answer the questions. In addition, the students are encouraged to ask questions of their own and try to make commons. Questions Refer to Questions in the sections of Weaving.