During the week 12 - 16 March Picanol introduces its latest rapier weaving machine, the OptiMax. The new machine offers weavers a combination of great versatility and highly productive weaving.
Higlights of the OptiMax rapier weaving machine:
· Optimized shed geometry in combination with guided gripper or free flight insertion system, for unequalled industrial speeds and maximum yarn friendliness
· Insertion with up to 12 colors
· Accurate, user-friendly machine setting using the keyboard or interactive display at insertion side
· Reed width of 190, 210, 220, 230, 250, 300, 320, 340, 360, 380, 400, 430, 460 and 540 cm
· Electronic setting of shed crossing
· Easy width changes
· Sumo main motor with direct machine drive is standard
Stimulating weavers to get the most out of their market
Never before has any weaving machine been so modular in design. In the new OptiMax concept, each machine is based on a common platform designed to accommodate future extensions or conversions. This modularity safeguards the weaver’s investment: no other weaving machine is so easy to adapt in order to take advantage of new market opportunities.
Optimized shed geometry
In developing the OptiMax special attention was paid to the shed geometry. The short stroke of the sley and the frames and the redesigned rapier heads, allow the machine to weave with smaller shed opening. Less stress is put on the warp ends, resulting in increased warp friendliness especially in case of filament weaving. The optimized shed geometry leads to uniform fabric characteristics over the whole width. The location of the sley cams below the fabric allows heavier beat-up forces, so fabrics with real high cover factors can be woven with ease.
OptiMax can be fitted with a Guided Gripper system for maximum speeds or a Free Flight system for maximum versatility. Both systems are interchangeable.
Guided Gripper system
The Guided Gripper system (GC) is the standard solution for weaving spun yarns. The rapier tape of the newly designed light-weight Guided Gripper system is perfectly guided by one-piece hooks. Together with the small shed and small rapier head, industrial speeds are obtained that were never reached before. The stroke of the guiding hooks through the lower shed has been optimized for extreme warp friendliness, widening the field of application in filament weaving.
Free Flight system
The Free Flight system (FF) is specially designed for weaving delicate fabrics, providing maximum warp friendliness and filling versatility. Free Flight means that the rapier tape is no longer guided by hooks, so the yarns cannot be damaged by hooks diving into the warp yarns. The machine has a covered raceboard for gentle treatment of filament warp yarns, as used for e.g. upholstery weaving, or the rapier is guided by supporting hooks, as used for e.g. wool or worsted weaving. The stability of the Free Flight rapier head is assured by an enlarged tape.
Quick Step filling presenter for up to 12-color insertion
The weft presenter is fully modular, allowing weavers to start with e.g. 4-color insertion and to add more channels later. OptiMax is available with up to 12-color insertion (specially for necktie, upholstery and label weaving). The color and weave pattern are controlled by microprocessor or jacquard.
Finally, the Quick Step modules are interchangeable, and there are no mechanical drives, so no maintenance or lubrication is required.
Exchangeable shed formation
The OptiMax can be fitted with a positive cam motion, electronic positive dobby or electronically driven jacquard. The basic machine structure for the cam, dobby and jacquard versions is identical, making it possible to change the shed formation system at any time in the future.
OptiLeno
Based on an entirely new future-oriented concept, the OptiMax also offers the possibility to produce leno fabrics without the need for a superstructure or leno heddles. With the OptiLeno module (patented), it is possible not only to obtain fabrics with S-crossing or Z-crossing of the leno ends, but also to obtain alternatingly S- and Z-crossing in the same fabric, giving an additional special effect to the design. Even a combination of stripes of leno and plain weave is possible.
Superstructure-ready
In line with the “common platform” philosophy, the OptiMax is ready to have a superstructure mounted on it. The mountings are identical in all cases, making it possible to decide at some time in the future to add e.g. a fancy beam or jacquarette.
Fancy beam
The fancy beam is an additional warp beam with a separate let-off motion. The beam can be top-mounted or mounted in line (behind the machine on a separate creel or integrated in the machine frame). The system is mainly used for warp ends that give a certain aspect to the fabric, e.g. seersucker, and which have a different tension and/or a different woven length compared to the ground beam, e.g. upholstery or ties.
Electronic Right-hand Gripper Opener
Improved control of the weft insertion is afforded by the positive opening of the right-hand traction-gripper with the Electronic Right-hand Gripper Opener (ERGO) system. This allows individual setting of the moment of opening according to each type of weft inserted. Both the length of the weft tail can be adjusted and the degree of opening of the right-hand gripper during the release of the weft.
Tuckers
The OptiMax can be equipped either with a versatile mechanical tucker or with an air tucker, both designed for high speeds, in line with the high industrial speeds of the machine. Moreover, changing from a leno selvedge to tucker or vice versa is easy and quick with repeatable settings.
Stimulating weavers tot get the most out of their material
The mechanical components and advanced electronics of the OptiMax are designed for optimum fabric quality and minimum waste.
Rigid construction
The OptiMax has two cast-iron side frames connected by sturdy cross-members. This robust frame and the perfect balancing of the mechanical parts eliminate all vibration, enabling the machine to work continuously at high industrial speeds in all weaving widths while maintaining permanent stability.
High-tech reed drive for powerful beat-up
The sley is driven by 2 sets of conjugated cams with cam followers below the fabric, with continuous high pressure lubrication from the central lubrication system. A third sley cam unit is mounted in case of very wide weaving. The reed holder itself is made of light alloy with great stiffness. The sley with its reed holder is perfectly balanced by means of counterweights and provides a powerful beat-up over the whole weaving width. This results in uniform fabric characteristics over the whole width and makes it possible to weave heavier fabrics.
Quick Step filling presenter for low filling tension
The Quick Step filling presenter operates with independent modules, each consisting of an electronically controlled stepper motor with a presenter needle. After the left gripper has taken the presented yarn, the Quick Step needle returns to an intermediary position, so the course of the filling yarn is straight and the tension of the yarn is low and remains constant (patented). At a filling break the needle is presented automatically in the most convenient position for re-threading, thus saving time for the weaver.
The Electronic Disc Cutter cuts every filling yarn always at the right moment, while clamping the filling.
Programmable Filling Tensioner
Each prewinder can be equipped with a Programmable Filling Tensioner (PFL-TEC). This PFL-TEC (patented) is microprocessor-controlled and ensures optimum yarn tension during the complete insertion cycle. The tension control makes it possible to weave strong or weak yarns at even higher speeds. It also drastically reduces the amount of filling stops, and enables weavers to set an individual waste length per channel.
Electronic Selvedge System
The unique Electronic Selvedge System (ELSY – patented) full leno selvedge motions are electrically driven by individual stepper motors. They are mounted in front of the harnesses, so that all the harnesses remain available for the fabric pattern. The selvedge crossing and pattern are programmed on the microprocessor independently of the shed crossing, even while the machine is in operation, so the result of a resetting can be checked immediately.
Electronic Take-Up and Let-Off
The electronically controlled Take-Up (ETU) and Let-Off (ELO) are fitted as standard on OptiMax. A heavy duty ETU motor is optional for heavy fabrics.
Stimulating weavers tot get the most out of their energy
Energy saving technologies have been developed and implemented on the OptiMax, taking into account the rules and regulations concerning the environment. The OptiMax is equipped as standard with the energy-efficient Sumo motor.
Consuming less energy with the Sumo main motor
The oil-cooled Sumo main motor drives the weaving machine directly, without belt or clutch and brake. The combination of the highly energy-efficient Sumo motor with the direct drive (patented) of the main shaft and shedding motion results in power savings of more than 10% in comparison with conventional clutch and brake configurations. Moreover, the energy cost for air conditioning is also reduced as the Sumo motor dissipates less heat in the weaving mill.
The speed of the motor is controlled electronically, without a frequency converter, thus reducing power consumption and permitting greater flexibility. The very short drive train is simple and compact, and the machine is up to full speed right from the very first pick.
Removing heat with water cooling system (patented)
Fast running machines generate more heat than their slower predecessors. The consequences of this are particularly important in regions with a hot climate. As the weaveroom temperature rises, it gets harder to maintain the required air humidity at weaving machine level. Another consequence is that the sides of the warp tend to dry out because of heat radiation from mechanisms in the machine frames. With the water cooling option, half of the thermal load produced by the weaving machine is extracted from inside the machine. In this way, a new air-conditioning installation can be kept small and energy efficient, or an existing installation could still be compatible with high-speed weaving on OptiMax.
Stimulating weavers tot get the most out of their time
The OptiMax weaving machine is based on an entirely new concept, as a future-oriented platform whose components are designed for higher operating speeds and top productivity.
Unique Sumo main motor system (patented) fitted as standard
With the Sumo motor it is possible to continuously adapt the machine speed pick by pick to match the strength of the filling yarn. This combination of the Sumo motor with electronic settings makes it easy to obtain the highest possible industrial speeds, taking into account the yarn quality, number of harnesses and weaving pattern, and considerably reduces the set-up times.
Style changes in a minimum of time
Picanol has included many unique features on the OptiMax to keep machine downtimes ultra-short. They include the Picanol Quick Style Change system, the quick harness connections, the roll-away filling creel, the hand-operated quick snap locks for warp beam and cloth rolls, and the use of the microprocessor for modifying crossing time settings for selvedges and shed. These all increase the time available for what OptiMax is meant for in the first place: producing quality cloth at high speeds.
Fast width changes
Special attention has been paid to fast width changes, which may be either symmetrical or asymmetrical. All the components to be moved on the left and on the right are mounted on a single support whose position can be easily varied. Software-assisted procedures are available in case the transfer position of the rapiers is to be modified. The cylinder temples on top of the fabric hold the cloth at full width and are easy to set. For special fabrics, full-width temples can be fitted.
Electronic setting of shed crossing
A maximum number of settings can be carried out on the microprocessor. The electronic setting of the closed shed position (AKM) – a unique Picanol feature – allows the weaver to control the aspect and hand of the fabric without even touching the drive train of for instance the dobby. A few simple keystrokes on the display are all it takes to let OptiMax reset its crossing point. The crossing time not only influences the fabric quality, it also has an impact on stop figures.
Quick Style Change
The Quick Style Change (QSC) system (patented) enables a style change to be carried out by a single person in less than 30 minutes. The style change is done by replacing the entire rear part of the split frame, with the warp beam, backrest and support, warp stop motion, harnesses and reed. All the settings involved in preparing the article on the warp side are done before the style change, outside the weaveroom. The quick and easy adjustment of the backrest board (patented) is also unique.
Automatic full pickfinding
The machine has an automatic full pickfinder driven by the Sumo main motor. In case of a broken pick the machine stops and only the harness frames are brought in motion – automatically – so as to free the broken pick, without the reed touching the beat-up line.
Prewinder Switch-Off
The OptiMax has a piezoelectric filling detector that stops the machine in case of a filling break. With its optional Prewinder Switch-Off (PSO) system, the machine carries on weaving even if a filling break occurs on the bobbin creel or one of the prewinders.
Optimized harness frames and connections
The harness frames, connections and guides (DRC-2 and DRC-30) have been designed for weaving at high speeds. With the harness connection no manipulations have to be carried out under the fabric line when connecting the frames to the drive system in a single movement, and the unique harness height adjustment is done entirely at the top of the harness frames (patented).
Easy warp gaiting and cloth doffing
The warp beam is driven by an electronically controlled let-off system via a separate gearwheel that remains on the machine. Fitting the warp beam and changing the cloth roll are done by means of quick connections: no tools are required.
Picanol Batching Motion
The Picanol Batching Motion (PBM) systems have been designed for economical production of large cloth rolls. They ensure excellent fabric rolls and their operation is simple and efficient, with protection against too low or too high tension.
Perfect lubrication
Lubrication is by means of a central oil circulation system controlled by pressure, temperature and filter contamination sensors. Constant and adequate filtering of the oil ensures perfect lubrication. Bearings for the beat-up shaft are part of the forced oil lubrication circuit and are thus maintenance free.
Stimulating weavers tot get the most out of their talent
With the OptiMax, we have created the possibilities that weavers need to deploy and realize their utmost creativity. The machine is exceptionally ergonomic and offers immediate control of all possible settings for optimum fabric quality.
An ergonomic machine
The OptiMax weaving machine is unusually low at the front. The slight slope provides very easy access for the weaver. The pushbuttons are conveniently located, and all main settings are carried out above the fabric line.
The filling area is easily accessible from all sides, and all prewinders can be reached from the front. The shed opening and the height of the harness frames are adjusted from the outside, with easy accessibility, because the shedding motion stands free at the right-hand side and is not obstructed by the package creel or prewinders. Connecting the harness frames to the drive system is done in a single movement, thanks to the quick connections (DRC-2 and DRC-30).
Maximum control
All the machine functions are controlled by the microprocessor. Using the self-explanatory menus on the display, the operator can start the machine and carry out fine adjustments easily.
Mechanical settings have wherever possible been replaced with electronic ones. The electronic settings have several advantages: they are very accurate, can be checked directly, and are easy to transfer from one machine to another.
The microprocessor records, analyses and stores all the production data. The weaving machine itself can be linked to a central monitoring system (for example as integrated in LoomGate) by an Ethernet or bidirectional connection.
Interactive touchscreen
As an alternative to the keyboard display there is also an interactive touchscreen, which has the advantage that several article settings can be stored locally on the display. A transponder card gives immediate access to the machine settings, which can be transferred from the display to a computer or vice versa using USB memory sticks.
Picanol PC Suite
Picanol PC Suite is a collection of PC software applications.
LoomGate makes it possible to communicate between the PC and the weaving machines over the network. Using LoomGate, machine settings are transferred from the PC to the machines and vice versa, the weaving machine can be updated with new software, or the current settings and operating parameters of the weaving machines can be consulted. LoomGate also includes a monitoring function to consult and process machine data and shift production data on the PC.
Picanol Pattern Editor is used to create new designs on the PC, for transfer to the weaving machines. Picanol Style Administration is used to prepare settings while the weaving machine is running another style. EasyStyle helps to select the optimum machine settings: it generates the best settings for the specific style chosen, based on Picanol’s broad weaving experience. OptiStyle provides on-loom tools to improve efficiency or quality in a fast, interactive way: just enter the problem and corrective measures are suggested, taking into account the actual machine settings and specifications.
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The Picanol Group is an international group specialized in the development, production and sales of weaving machines and technology for the textile industry and others. The group’s activities are centered in two core divisions:
OEM Business develops, produces, and sells high-tech components and system solutions for Original Equipment Manufacturers in the textile and other industries. OEM Business markets its products via the brands PsiControl Mechatronics, Proferro, Te Strake Textile, Burcklé, Steel Heddle and Melotte. Weaving Machines is active in the development, production, and sales of high-tech weaving machines and complementary services and products for the aftermarket. Weaving Machines focuses on weaving machines based on air (airjet weaving machine) or rapier technology (rapier weaving machine). Picanol is the brand name of these weaving machines.
The Picanol Group’s headquarters is located in Ieper. In addition, the group operates major production plants in Europe, Asia, and the USA. The group is active worldwide and employs 2.430 employees. The Picanol Group has since 1966 been listed on Euronext Brussels (ticker: PIC) and is included in the NextPrime index.
For more information please contact Erwin Devloo, Ter Waarde 50, 8900 Ieper, Belgium, tel. + 32 57 222 090, edv@picanol.be.