Field trials observing the use of woven ropes show encouraging performance, say Pradeep Kulshrestha, Dharmendra Goswami, Chandrakant Nakum, Jagdish Patel

 

Woven ropes are stronger compared to braided, conventional ropes. The Ahmedabad Textile Industry's Research Association (ATIRA) developed woven ropes with core and sheath arrangements. Comparison was carried out with the same type of braided ropes in terms of material and diameter. In this way we can get the strength of the core yarn. For example, aramid fibres can be covered with polyester to use in the marine industry. Glass fibre can be covered with cotton for aesthetic properties during handling.

 

The developmental activities carried out in the area of high strength ropes using varieties of high tenacity yarns were carried out to:

 

1.       To ascertain requirements of different specified industries using ropes. For instance, in the fields of transport, marine, fire fighting, rescue and sports

2.      Testing conventional ropes to analyse raw material used

3.      To evolve cost-effective construction and design of woven ropes with judicious combinations of specific high strength yarn to meet requirements

4.      Developing ropes with equal/higher strengths with the substitute and/or cost-effective raw materials using weaving techniques

 

Manufacturing woven ropes at ATIRA Incubation Centre

Weaving rope with core-sheath structure of pre-decided design using varieties of yarn:

a)     Rewinding yarn from big package to smaller packages on Sahm Winding Machine

b)     To put those spools on creel as per core and sheath plan on Jakob Muller Narrow Rope Weaving Machine

c)      To draw yarn ends in Heald wires and Reed

d)     To take forward all ends and insert them in guide rollers

e)     To apply open type of Drop Pins in warp stop motion or insert each yarn through close drop pin

f)       To draw weft in needle

g)     To start weaving rope with process monitoring and controls

 

Fig. Rope Weaving Machine at Incubation Center-ATIRA

 

Manufacturing braided ropes

* Making ropes by conventional braiding process entails:

a)     Creeling of yarn as per plan on Susmatex Braiding Machine

b)     To insert individual ends in needles

c)      To adjust settings

d)     Complete the braiding

 

http://www.susmatex.com/images/products/full_size/fast_knit_braiding.jpg

 

Comparison of woven and braided ropes: Set 01

SAMPLE No.

MATERIAL

DESCRIPTION

TENSILE STRENGTH (KN)

ELON

GATION%

ROPE DIA (MM) Actual

OBSERVATION

01

Glass Fibre-2 ply as Core / Polyester as Sheath

Woven Rope with 40 ends in core and approx. 9 mm dia

9.269

4.78%

8.9

Woven rope has significantly more tensile strength and elongation properties compared to braided rope

02

Glass Fibre-2 ply as Core / Polyester as Sheath

Braided Rope with 40 ends in core and approx. 9 mm dia

1.795

1.65%

8.7

 

 

Comparison of woven and braided ropes: Set 02

SAMPLE No.

MATERIAL

DESCRIPTION

TENSILE STRENGTH (KN)

ELONGATION%

ROPE DIA (MM) Actual

OBSERVATION

03

Aramid as Core / Polyester as Sheath

Woven Rope with 56 ends in core and approx.9 mm dia

4.1

35.61%

9.1

Woven rope has significantly more tensile strength and elongation properties compared to braided rope

04

Aramid as Core / Polyester as Sheath

Braided Rope with 56 ends in core and approx. 9 mm dia

3.2

24.21%

9.1

 

 

Comparison of woven and braided ropes: Set 03

SAMPLE No.

MATERIAL

DESCRIPTION

TENSILE STRENGTH (KN)

ELONGATION%

ROPE DIA (MM) Actual

OBSERVATION

05

50 K Carbon as Core & 3000 Denier Polyester as Sheath

Woven Rope with 12 ends in core and approx. 9 mm dia

6.31

27.59%

9.3

Woven Rope has significantly more Tensile Strength.

 

 

06

50 K Carbon as Core & 3000 Denier Polyester as Sheath

Braided Rope with 12 ends in core and approx. 9 mm dia

2.55

33.18%

9.0

 

Comparison of woven and braided ropes: set 04

SAMPLE No.

MATERIAL

DESCRIPTION

TENSILE STRENGTH (KN)

ELONGATION%

ROPE DIA (MM) Actual

OBSERVATION

07

50 K Carbon & 100 % jute on sheath

Woven rope with 12 ends in core and approx. 9 mm dia

10.8

1.08%

9.0

Woven rope has very high tensile strength

 

08

50 K Carbon & 100 % Jute on sheath

Braided Rope with 12 ends in core and approx. 9 mm dia

2.4

2.66%

8.6

 

Comparison of woven and braided ropes: Set - 05

SAMPLE No.

MATERIAL

DESCRIPTION

TENSILE STRENGTH (KN)

ELONGATION%

ROPE DIA (MM) Actual

OBSERVATION

09

woven rope with 4s/10 ply Aramid(Core) & 1000 Denier Polyester (Sheath)

10 ends in core , 43 ends in sheath

2.99

48.68%

9.4

Woven rope has significantly more tensile strength compared to braided rope

 

09

woven rope with 4s/10 ply Aramid(Core) & 1000 Denier Polyester (Sheath)

10 ends in core , 43 ends in sheath

2.99

48.68%

9.4

Woven rope has significantly more tensile strength compared to braided rope

10

Braided rope with 4s/10 ply Aramid(Core) & 1000 Denier Polyester (Sheath)

10 ends in core , 43 ends in sheath

2.08

66.00%

9.5

 

Comparison of woven and braided ropes: Set - 06

SAMPLE No.

MATERIAL

DESCRIPTION

TENSILE STRENGTH (KN)

ELONGATION%

ROPE DIA (MM) Actual

OBSERVATION

11

woven rope with 4s/10 ply Aramid (Core) & 6s / 5 Ply PC (Sheath)

10 ends in core , 43 ends in sheath

1.91

38.83%

8.6

Woven rope has significantly more tensile strength compared to braided rope

12

Braided rope with 4s/10 ply Aramid (Core) & 6s / 5 Ply PC (Sheath)

10 ends in core , 43 ends in sheath

1.23

38.37%

8.4

 

Comparison of woven and braided ropes: Set 07

SAMPLE No.

MATERIAL

DESCRIPTION

TENSILE STRENGTH (KN)

ELONGATION%

ROPE DIA (MM) Actual

OBSERVATION

 

SAMPLE No.

MATERIAL

DESCRIPTION

TENSILE STRENGTH (KN)

ELONGATION%

ROPE DIA (MM) Actual

OBSERVATION

13

Woven rope 1000 Denier Polyester (White)Core & 2000 Denier Polyester (Blue) Sheath

10 Core ends, 52 sheath ends

3.01

43.13%

11.8

Woven rope has significantly more tensile strength compared to braided rope

 

Comparison of woven and braided ropes: Set - 08

SAMPLE No.

MATERIAL

DESCRIPTION

TENSILE STRENGTH (KN)

ELONGATION%

ROPE DIA (MM) Actual

OBSERVATION

14

woven rope with Dyneema core/ Polyester Sheath

2000 Denier Polyester & 1750 Denier Dyneema yarn

4.861

11.98%

6.2

Woven rope has significantly more tensile strength compared to braided rope

15

Braided rope with Dyneema Core/ Polyester Sheath

2000 Denier Polyester & 1750 Denier Dyneema yarn

2.45

25.75%

6.3

 

20140118_152137-1.jpg20140118_152249-1.jpg

 

Analysis of results:

In every case, woven ropes are stronger (average tensile strength approximately 7.24 KN) compared to braided ropes (average tensile strength approximately 2.46 KN) indicating superior performance of woven ropes.

 

Woven ropes with required properties as that of braided ropes would be approximately at least 30 per cent lighter.

 

Due to core and sheath arrangement of yarn in woven ropes, they are more comfortable and more aesthetic in practical use.

 

Plans to utilise the equipment facilities in future

Indian Railways for luggage handling

 

A porter using woven rope to tie luggage on the trolley at Ahmedabad Railway Station found woven rope much more comfortable over traditional HDPE packing strips. It also had better handling comfort and strength.

 

 

Experiments at ATIRA

During trial to assess the strength of woven rope, we have seen that only two woven ropes with same diameter and material are sufficient as against a number of non-woven ropes required to carry the same weight.

 

 

Conclusion

We can weave a variety of cost-effective samples on narrow looms with limited consumption of expensive yarn. This technology is important to produce specified application products like high strength ropes. Investment in narrow machines for ropes will give confidence to owner of a self-employed business.