Electronic warp-break detection mechanism for manual looms

Abstract

Purpose The purpose of this study is to develop a system that detects warp breakage in manual looms using simple mechanisms combined with electronic circuitry. Design/methodology/approach This study used the universal design methodology model where results from observations and interviews aided in designing the appropriate blueprints for the mechanism. Findings Testing procedures revealed that the conductivity of steel bars coupled with the weight of the droppers affected the efficiency of the mechanism. Additionally, the weight of the drop wires influenced the rising of the warp threads during shedding. Considering this, a plate thickness of 0.06 mm was ideal for the droppers which did not affect warp shedding. Test outcomes at the weaving shed proved the workability of the mechanism for timely or prompt repair of a broken warp by weavers that ensured fabric quality. Originality/value The issue of warp breaks remains a critical problem at weaving on manual looms which influence the quality of fabrics. These looms are used by craftsmen in producing interesting fabrics for the market of which they depend on for their living. Premise on this, a two-way (light + sound) alert system was developed to assist weavers to effectively locate and repair broken yarns. Additionally, weavers with special needs (blind people) would be notified on a warp break for immediate repair from someone. This would limit the unnecessary challenges associated with broken warp yarns during weaving.