Karl Mayer complements its DSE-HH machine series with the new direct warping machine, designated the DSE 21/21 EC, which is said to be well suited to the commodity business, addressing the elastane yarns production challenges, during warp preparation.

The capacity of the high-stretch synthetic yarns to stretch by as much as 700% demands that they be processed without any friction points, if possible, to avoid the uncontrolled distortion, which results in uneven dyeing.

Designed to deal with these issues, DSE-HH direct warping machine, according to the company, has been proving itself exceptionally well, especially in premium applications, and has now been complemented by a mid-range version to expand the machine series.

Differences

One of the main differences between the two machines lies with control of the cone curve, which can be equalised on the DSE-HH by an automatic cone curve adjustment system. Also, if the manufacturer stipulates the cone curve, the equalising process can be carried out on the basis of the data stored by the producer in the machine. The two processes can also be combined.

If the data supplied by the bobbin producer is used as the basis for the warp preparation process, good quality warp beams are produced. In this case, the characteristics of the beams depend on the correlation between the cone curve specified and the actual condition of the winding.

This also applies to the DSE-EC. According to Karl Mayer, the new price:performance-optimised machine controls the bobbin take-off tension during warp beam production on the basis of the manufacturer’s data alone, and thus also produces good quality products.

Both the DSE-HH and the DSE-EC produce warp beams having a width of 21", but operate at different speeds. Whereas the DSE-HH operates at creel speeds of 400rpm to produce beams having diameters of 30" and 21", the mid-range version operates at 300rpm to produce beams having a diameter of 21" only – but at an appropriate cost.

Performance features

Both the DSE-HH and the DSE-EC operate with automatic layer thickness control. When using this system, a master curve is produced first of all on the basis of the path of travel of a sectional warp beam and the circumference of every subsequent beam is subsequently matched to that of the master curve. This produces sectional warp beams having the same volume of yarn and circumference in each set. Positively driven bobbins supplying uniform yarn volumes also guarantee a uniform build over the entire width of the beam.

Other features of this new direct warping machine include a computer-controlled braking system for guaranteeing uniform braking paths, axis-controlled drives with individual motors, and the possibility of activating or deactivating individual creel arms during production. The DC link coupling on the machine is also said to conserve energy.

Market launch

The first prototypes of this mid-range direct warping machine left the conveyor belts at Karl Mayer in February and March with a total of nine machines being built.

The DSE-EC was unveiled at ShanghaiTex trade fair in June. It has already been released for sale in China and will be available to the rest of the world on 1 January 2014.

www.karlmayer.com