Tension variation in sectional warping, pt. 1 : mathematical modeling of yarn tension in a creel

The warping process is one of the weaving preparation processes to produce weaver’s beams which uses on weaving machines to produce grey fabrics. In sectional warping several hundreds of yarn from supply packages placed on a creel are wound onto a sectional warping drum as sections and then beaming off all warp yarns from the drum to the warper's beam, which is used for fabric production with or without the subsequent process known as sizing. The uniform and even yarn tension in warping process is vital to produce high quality fabrics on looms with high efficiency. The authors attempted to theoretically interpret in terms of mathematical modeling the warp yarn tension in the yarn path of the creel with due consideration to various parameters in sectional warping. Further theoretically model the warp tension variation according to the geometrical position of the package on a sectional warping creel. This paper reports a study of tension variation of cotton yarn unwinding from the supply package up to the exit point of the creel of a Kakinoki sectional warping machine. Authors have developed a mathematical model to analyze tension variation within the warping creel for the packages with variable diameters at different positions. Based on the developed mathematical model, tension was calculated at various places along the yarn path