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Karl Mayer develops system to evaluate warping machines
Feb '13
The Multi-Matic produces sample warps and medium-length warps, and guarantees top quality as well as maximum efficiency – when used for the right application. With its technical configuration, this automatic short-, medium- and sample-warping machine operates optimally when used to bridge the gap between the GOM 24 and the Nov-O-Matic.

For example, when processing 8,000 cotton yarns having a length of 406 m and a count of Nm 80 to produce a warp beam having a width of 1.800 m, the Multi-Matic 128 can increase productivity by 332% compared to the GOM 24. The GOM automatic sectional warping machine operates at its best when processing a small number of yarns and short warp lengths. It therefore operates at the lower limit of the spectrum of uses of the Multi-Matic. When processing articles having longer warp lengths and more bobbins, the NOM automatic sectional warping machine is increasingly more efficient.

KARL MAYER has developed the special Expert-System for evaluating which sectional warping machine is the most suitable for the particular job in hand. This performance check can be used as the basis for assessing the production costs, productivity and economic feasibility of jobs. If required, it can be carried out by KARL MAYER’s sales department. The following example shows how it works.

Example of using the Expert-System for evaluating jobs

Calculating the economic viability of jobs using this new tool is based on the performance features of the Multi-Matic. These include its speed of 800 m/min for both warping and leasing, and of up to 150 m/min when beaming. Colour changing also takes place at an ubraked speed of 800 m/min. The machine is available in versions having 64 or 128 running yarns, operates at a maximum working width of 2.200 mm and takes off yarn from standard creels - thus offering a specific performance profile.

The following example of the calculations produced by the Expert-System shows the results of evaluating the speed, costs and operators’ time involved in processing a shirting product on the Multi-Matic 64 and a Multi-Matic 128 compared to processing it on the GOM. The parameters of the warp were as follows:

• Warp length – 406 m
• Total number of yarns – 6,974
• Width – 1.800 mm
• Yarn count – Nm 83/1
• Material – 100% cotton
• Number of different colours – 10

The performance results produced by the Expert-System show that the production rate of the Multi-Matic is three times higher than that of the GOM when processing the same article. At the same time, the labour and amortisation costs of this new machine in KARL MAYER’s range of sectional warping machines are lower.

There is basically no difference in the setting-up times, but the machine running time of the GOM is considerably higher. This is particularly true when patterning broad coloured stripes.

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