Section 4.1 Negative Tappet Cam Shedding Motion

4.1.1 Levelling Operation...... 4.1-3 [ 1 ] Preparatory Operation ...... 4.1-3 [ 2 ] Levelling Operation...... 4.1-4 [ 3 ] Levelling Tool Maintenance ...... 4.1-6 4.1.2 Shed Close Timing ...... 4.1-7 [ 1 ] Shed Close Timing ...... 4.1-7 [ 2 ] Shed Size ...... 4.1-7 4.1.3 Shed Size ...... 4.1-8 [ 1 ] Shed Size ...... 4.1-8 [ 2 ] Cam Combination...... 4.1-9 [ 3 ] Adjusting the Shed Size ...... 4.1-10 4.1.4 Springs and Related Sections ...... 4.1-11 [ 1 ] Rope Installation Position...... 4.1-11 [ 2 ] Springs ...... 4.1-11 4.1.5 Healed Frames ...... 4.1-15 [ 1 ] Height of Heald Frames...... 4.1-15 4.1.6 Modifying the Fabric Texture...... 4.1-17 [ 1 ] Removing and Installing the Negative Tappet Cam ... 4.1-17 [ 2 ] How to Assemble Negative Tappet Cams ...... 4.1-20 [ 3 ] Number of Tappet Cams Required for Fabric Textures ... 4.1-31 [ 4 ] Replacement Parts Required for Fabric Texture Change ...... 4.1-31 [ 5 ] Arrangement of Tappet Cams and No. of Gear Teeth ... 4.1-32 4.1.7 Replacement of Shedding-related Components...... 4.1-34 [ 1 ] Shedding Timing Belt ...... 4.1-34 [ 2 ] Replacing Lower and Side Shedding Ropes...... 4.1-36 [ 3 ] Cam Lever...... 4.1-38

MARCH, 2010 Ver. 2.02 4.1 - 1 4. SHEDDING MOTION

4.1 Negative Tappet Cam Shedding Motion (1) Rotation transmitted from the main motor drives the driving pulley 1 at the right-hand side of the weaving machine. Mounted to the driving pulley 1 is timing belt 2 which drives tappet cams 4 via gear train 3. As a particular cam 4 rotates, cam lever 5 oscillates so as to drive heald frame 7 via ropes 6 which tie the cam lever 5 to heald frame 7. (2) Upper springs 8 give tension to jack lever 10, rope 6, and cam lever 5 so that cam follower 9 mounted on cam lever 5 is pressed against the surface of tappet cam 4.

NEVER touch jack lever 1, rope 2, or other moving parts during operation, since they are vibrating at ultra-high speed even though they appear to be static.

4.1 - 2 4.1 Negative Tappet Cam Shedding Motion

4.1.1 Levelling Operation The levelling operation should be done when changing the number of heald frames, replacing tappet cams (Subsection 4.1.6 “Modifying the Fab- ric Texture”), or modifying the shed size (Subsec- tion 4.1.3 “Shed Size”, [ 3 ] in this chapter). This operation requires the manual hydraulic levelling tool (J8207-05011-00).

[ 1 ] Preparatory Operation (1) Turn adjusting bolt 2 on top of shedding motion bracket 1 to make dimension “a” from face 1A of bracket 1 to the head of bolt 2 satisfy 18 mm on the front side, and 23 mm (or 28 mm when the filament cam and spun cam are used in combination) on the back side, on each of the LH and RH sides. (2) Make tool pin 4 (J8207-03010-00) ready for use, which is to be inserted between jack lever 3 and adjustment bolt 2.

(3) Keep manual hydraulic levelling tool 5 (J8207-05011-00) ready beside the weaving machine. (4) Lock relief valve 5a of levelling tool 5.

4.1 - 3 4. SHEDDING MOTION

[ 2 ] Levelling Operation (1) Set the crank angle to the shed close timing at which the heald frames become aligned. (Refer to Subsection 4.1.2 “Shed Close Tim- ing”.) (2) Loosen warp yarns. (3) Turn off the main switch. (4) Insert cylinder 5b of hydraulic levelling tool 5 into the upper section of tappet box 6 through the window provided in the right-hand frame of the weaving machine. (5) Fit the forked end of cylinder 5b over fixing pin 8 located on stay 7 inside the machine. (6) Place the other end of cylinder 5b on pin 9a provided on levelling lever 9. (7) Check that relief valve 5a of levelling tool 5 is locked. (8) Release handle lock 5c, then pump handle 5d. This activates cylinder 5b so as to turn cam lever 10 towards the cam via levelling lever 9.

Jack lever 13 is turned downward via rope 11 and heald frame 12. (9) Insert tool pin 4 (J8207-03010-00) into the slot between adjust bolt 2 located at the upper part of shedding motion bracket 1 and jack lever 13. REFERENCE: Pump handle 5d until tool pin 4 is completely inserted into place. (10) Carefully unlock relief valve 5a of levelling tool 5 halfway. (11) Check that rope 11 is loose. (12) Perform the work in question such as tappet cam replacement.

4.1 - 4 4.1 Negative Tappet Cam Shedding Motion

NOTE: At the time of levelling, turn the cam lever 14 15 down carefully so as not to bring connector lever bolt 14 into contact with tappet cam 15. Especially be careful for the front frame.

Restoring operation NOTE: Prior to proceeding to the restoring operation, make sure that the lower shedding ropes are fitted in the grooves of the guide rollers. Restoring operation with the lower shedding ropes slipped out of the grooves will break the nylon cover of those ropes, resulting in broken ropes. (13) Pump handle 5d and remove tool pin 4 inserted in step (9). (14) Carefully unlock relief valve 5a of levelling tool 5, then remove the tool 5 from the machine. NOTE: Do not unlock the valve 5a quickly; otherwise, the tappet cam may bump the cam follower, resulting in damage. (15) When levelling lever 9 returns to the original position completely, remove cylinder 5b. REFERENCE: Cylinder 5b will not be removed unless levelling lever 9 is placed in the original position.

4.1 - 5 4. SHEDDING MOTION

[ 3 ] Levelling Tool Maintenance NOTE: Before starting to use the levelling tool, make sure that cylinder head 5e and cylinder 5b are not loosened. Use in the loosened state may result in damage.

Retightening method (1) With levelling tool 5 in the independent state, lock relief valve 5a, move handle 5d up and down and pull cylinder 5b to the full stroke position. Cylinder 5b is locked and not rotated. (2) Retighten cylinder head 5e with a wrench.

5e 5b

Inspection upon oil leakage detection (1) Make sure that joints (5f and 5g) are not loosened. If loosened, retighten 5g.

5f 5g (2) Make sure that no foreign matter is entrapped between joints 5f and 5g. If any, remove it.

4.1 - 6 4.1 Negative Tappet Cam Shedding Motion

4.1.2 Shed Close Timing [ 1 ] Shed Close Timing The shed close timing refers to the crank angle where the heald frames are aligned. The standard setting is 350°. The close timing may be changed slightly depending on the weaving condition. It is also possible to change the shift angle for plain weaving fabric for which warp separation is poor. (The shift angle refers to the difference in close timing between head frames 3 and 4 and heald frames 1 and 2. The standard shift angle is 20°.) The shed close timing may be advanced for fabric for which picking is hard.

[ 2 ] Shed Size (1) Adjust the crank angle to the shed close timing where the head frames are aligned. (2) Lock the emergency stop push-button switch. (3) Loosen all four bolts 3 that secure timing pulley 2. (4) Set hand-wheel 4 (J8201-02010-00). (5) Unlock the emergency stop push-button switch, and press the RELEASE BRAKE switch to release the main motor brake.

2 (6) Adjust the crank angle to the desired angle. REFERENCE: If timing pulley 2 is rotated with 1 3 crank angle shaft 1 at the time of crank angle adjustment, tap timing pulley 2 a few times with a plastic hammer. Also, it is recommended that you apply grease or other lubricant to the mounting portion of the timing pulley for smooth rotation. (7) Lock the emergency stop push-button switch. (8) Tighten fixing bolts 3.

4 (9) Rotate the angle in the forward and reverse directions by step (6) operation to check the crank angle where the heald frames are aligned.

4.1 - 7 4. SHEDDING MOTION

4.1.3 Shed Size [ 1 ] Shed Size (1) Shed angle a° and shed width H are deter- H: Shed width (mm) mines as shown in the table according to the a: Shed angle (°) cam lever connector position. H (2) The shed size for the same connector position will vary with the tappet cam for the spun yarn a (large shed size) and that for the filament yarn (small shed size). Both the tappet cams for the spun and filament yarns may be used, but use them in combination according to the shed angle. The portions enclosed by thick frames are the standard settings for shed angles of spun cams and filament cams.

Shed Yarn shed angle a° by frame for each connector position Connector Cam type width position Frame 1 Frame 2 Frame 3 Frame 4 Frame 5 Frame 6 Frame 7 Frame 8 Frame 9 Frame 10 H (mm) 2254.923.7————————— 2156.424.4————————— 2058.025.222.5———————— 1959.626.023.2———————— 1861.1—23.8———————— 1762.6—24.522.1——————— 1664.1—25.122.7——————— 1565.7—25.823.3——————— 1467.2——23.9——————— 1368.7——24.522.3—————— Filament cam 1270.2——25.122.9—————— (small shed 1171.7——25.723.4—————— size) 1073.2———23.922.0————— 9 74.7———24.522.5————— 8 76.2———25.023.0————— 7 77.8———25.623.5————— 6 79.3 — — — 26.1 24.0 22.2 — — — — 5 80.7————24.422.6———— 4 82.2————24.923.1———— 3 83.7————25.423.5———— 2 85.2————25.924.022.3——— 1 86.7—————24.422.7——— 0 88.2—————24.923.2——— 2270.731.227.925.323.0—————— 2172.7———23.8—————— 2074.7———24.522.5————— 1976.7———25.223.1————— 18 78.7 — — — 25.9 23.8 22.0 — — — — 1780.6————24.422.6———— 1682.6————25.123.2———— 1584.6————25.723.822.1——— 1486.6—————24.422.7——— 1388.8—————25.023.3——— Spun cam 1290.6—————25.623.822.3—— (large shed 1192.5——————24.322.8—— angle) 1094.5——————24.923.3—— 9 96.4——————25.423.822.4— 8 98.4———————24.322.8— 7 100.3 ———————24.823.3— 6 102.3 ———————25.323.822.4 5 104.2 ———————25.824.322.9 4 106.1 ————————24.723.3 3 108.0 ————————25.223.7 2 110.0 ————————25.724.2 1 111.9 —————————24.6 0 113.8 —————————25.1

4.1 - 8 4.1 Negative Tappet Cam Shedding Motion

[ 2 ] Cam Combination (1) The table below shows standard cam combinations. The warp shed angle can be set between 22° and 26°.

Frame Frame Frame Frame Frame Frame Frame Frame Frame Frame Fabric texture Cam 1 2 3 4 5 6 7 8 9 10 Plain (1/1) Filament {{{{{{ Spun ({)({) {{{{ 3-yarn twill (1/2) Filament {{{{{{ Spun ({)({)({) {{{ 4-yarn twill (1/3) Filament {{{{({)({) (2/2) Spun {{{{ Satin elastic Filament {{{{{ webbing (1/4) Spun {{{{{ NOTE: In case of leveling by combining filament cams and spun cams, the spun-cam mounted frames are aligned above the filament-cam mounted frames because of the connector position relative to the cam lever. If middle hook installation upon looming is difficult, first install middle hooks on filament-cam mounting frames in leveled state, manually rotate the machine after releasing leveling, and install the middle hooks on the spun-cam mounting frames. (2) Caution when combining spun cams only: Sine spun cams involve much oscillation, installation on frames 1 to 3 will with the connector at the low- est position of the cam lever will set the shed angle at 31.2°, 27.9°, and 25.3° for frames 1, 2 and 3, which are greater than for frames 4 and on, resulting in failure in adjusting sheet alignment upon warp shedding. Because the shed angle is great at frame 1, the warp yarn will interfere with the channel portion unless the reed vertical dimension is great. Note that a reed smaller than 89 mm in vertical size (102 mm in case of reversible reed) cannot be used since the yarn at frame 1 interferes with the reed channel (coil portion).

4.1 - 9 4. SHEDDING MOTION

[ 3 ] Adjusting the Shed Size The shed size is determined by the mounting position of connector 2 on cam lever 1, as listed in the tables on the previous page. Connector 2 should be set by aligning top end 2A with one of the notches provided in both faces of cam lever 1. The left figures show numbering of the notches provided in top face “A” and bottom face “B” of cam lever 1. Top face “A” has notches numbered 4, 8, 12, 16, and 20: bottom face “B” has notches numbered 2, 6, 10, 14, 18, and 22. To set connector 2 to any of the odd positions rang- ing from 1 to 21, align top end 2A with the center of the next higher and next lower even positions in top and bottom faces.

When adjusting the shed size, follow the procedure given below. (1) Set the crank angle to the shed close timing at which the heald frames become aligned. (2) Turn off the main switch. (3) Perform levelling operation. (Refer to Subsec- tion 4.1.1 “Levelling Operation”.) (4) Loosen bolts 3 securing connector 2 to cam lever 1. (5) Shift connector 2 to the desired notch according to the table in [ 1 ]. (6) Tighten bolts 3 with a torque wrench to the torque of 9.8 to 11.8 N·m (100 to 120 kgf·cm). (7) Perform restoring operation from the levelled state. REFERENCE: After adjusting the shed size, be sure to check the shed close timing (see Subsec- tion 4.1.2 “Shed Close Timing”, [ 2 ] “Shed Size”).

4.1 - 10 4.1 Negative Tappet Cam Shedding Motion

4.1.4 Springs and Related Sections [ 1 ] Rope Installation Position The top ends of each upper rope 2 are secured to 3 jack lever 1 so that they protrude by “a” mm from the end of nut 3 as shown at left. The bottom ends 2 are secured to clamper base 7 so that they become 3 flush with clamper base 7 as shown at left.

Length of nut B (L) “a” 6 mm 16 ± 1 mm The lower ends of the two spring hanger ropes 6 7 are installed on spring hanger 4 so that the lower threaded end of each rope is flush with bottom end 5A of block 5. If any abnormal rope vibration or shedding failure is noted in the trial run, check or adjust the rope installation position.

[ 2 ] Springs [ 2.1 ] Number of Springs The approximate number of springs to be used is listed below. For the details, refer to the tables on the following pages: When changing the number of heald frames, shed size, or crank rpm, check lower ropes 1, side ropes 2, and springs 3 for vibration. If lower ropes 1, side ropes 2, and springs 3 abnor- mally vibrate during operation, add springs. (Rope vibration which can be stopped by pressing lightly with fingers may be regarded as normal vibration.)

Number of springs to be used Less than 6 to 8 700 Machine Less than speed 7 to 9 800 (rpm) Less than 8 to 11 950 Shed size Small Large Reed space 190 cm 230 cm Weave structure Plain Twill and Satin REFERENCE: When using 7th and 8th heald frames for selvage weave, apply the same number of springs as for the 6th heald frame; when using those for ground weave, apply the number of springs for the 6th heald frame plus one spring.

4.1 - 11 4. SHEDDING MOTION

Number of springs to be used The table below shows the number of springs on each side. Install the same number of springs on each of the left and right sides.

Machine R/S Frame Frame Frame Frame Frame Frame Frame Frame Frame Frame Fabric texture speed (cm) 1 2 3 4 5 6 7 8 9 10 (rpm) Plain (1/1) Up to 600Up to 2106666667777 (0/0) 2307777778888 (0/60) Up to 650Up to 2107777778888 23088888899—— Up to 700 Up to 210 9 9 9 9 9 9 10 10 — — 2309999991010—— Up to 750 Up to 210 9 9 9 9 9 9 — — — — 23099 9 9 —————— Up to 800 Up to 210 9 9 9 9 9 9 — — — — Up to 850 Up to 190 9 9 9 9 9 9 — — — — Up to 900 Up to 190 10 10 10 10 — — — — — — Up to 950 Up to 150 10 10 10 10 — — — — — — Plain (1/1) Up to 700 Up to 210 8 8 10 10 — — — — — — (0/140) 23099 1010—————— 28099 1010—————— Up to 750 Up to 210 8 8 10 10 — — — — — — 23099 1111—————— Up to 800 Up to 210 10 11 12 12 — — — — — — 23011121313—————— REFERENCE: The allowable machine speed varies with the tappet cam stopping angle.

Machine R/S Frame Frame Frame Frame Frame Frame Frame Frame Frame Frame Fabric texture speed (cm) 1 2 3 4 5 6 7 8 9 10 (rpm) 3-yarn twill (1/2) Up to 550Up to 2107777788899 4-yarn twill (1/3) 2308888899910— Satin elastic webbing (1/4) Up to 600 Up to 210 8 8 8 8 8 9 9 9 9 — (0/0) 230 9 9 9 9 9 10 10 10 — — (0/60) Up to 650 Up to 210 9 9 9 9 9 10 10 10 — — 230101010101011———— Up to 700 Up to 210 9 9 9 9 9 10 11 11 — — 230101010101111———— Up to 750 Up to 210 10 10 10 10 11 11 — — — — 230111111111212———— Up to 800 Up to 190 12 12 12 12 12 13 — — — — 230—————————— 3-yarn twill (1/2) Up to 700Up to 2106667778888 4-yarn twill (1/3) 2306667778888 Satin elastic webbing (1/4) Up to 800Up to 2106667778888 (0/–30) 2307778889999 REFERENCE: The allowable machine speed varies with the tappet cam stopping angle.

4.1 - 12 4.1 Negative Tappet Cam Shedding Motion

The table below shows the number of springs on each side. Install the same number of springs on each of the left and right sides.

Machine R/S Frame Frame Frame Frame Frame Frame Frame Frame Frame Frame Fabric texture speed (cm) 1 2 3 4 5 6 7 8 9 10 (rpm) 4-yarn twill (2/2) Up to 500 Up to 210 8 8 8 8 8 8 9 9 — — (0/0) 2309999991010—— Up to 550 Up to 210 8 8 8 8 8 9 9 10 — — 23099999101011—— Up to 600 Up to 210 9 9 9 9 9 9 10 10 — — 23010101010—————— Up to 650 Up to 210 9 9 9 9 9 10 — — — — 230—————————— Up to 700 Up to 210 10 10 10 10 10 10 — — — — 230—————————— Up to 750 Up to 190 11 11 11 11 11 11 — — — — —————————— REFERENCE: The allowable machine speed varies with the tappet cam stopping angle.

4.1 - 13 4. SHEDDING MOTION

[ 2.2 ] Changing the Number of Springs Without weaving pattern change Increase or decrease the number of the springs with tool 2 (J8207-04010-00).

With weaving pattern change (1) Perform leveling operation (see Subsection 4.1.1 “Levelling Operation”) and remove the target tappet cam. (2) Perform restoring operation from the levelled state. (3) Increase or decrease the number of the springs 3. (In this case, springs can be installed or removed by hand without using tool 2.)

In case of double-pump specification Since there is a weft insertion piping under the spring of the left-hand side of the loom, manual spring installation or removal is dangerous. Always use tool 2 (J8207-04010-00) shown at left to increase or decrease the number of springs.

[ 2.3 ] Spring Arrangement When changing the number of springs for weaving pattern change or other purposes, observe the spring arrangement listed below.

Installation position No. of Center springs 123456789101112131415 6 {{{ {{{ 7 {{{ { {{{ 8 {{{{ {{{{ 9 {{{{{{{{{ 10 {{{{{ {{{{{ 11 {{{{{{{{{{{ REFERENCE: The above installation positions are numbered 1, 2, 3, ... 15 from shedding motion bracket 1. NOTE: If additional springs are installed, apply grease on new springs for anticorrosion. Do not store spare springs in a place exposed to high humidity, but store them with grease application in a place kept at low humidity.

4.1 - 14 4.1 Negative Tappet Cam Shedding Motion

4.1.5 Healed Frames [ 1 ] Height of Heald Frames [ 1.1 ] Installing a Heald Frame (1) Check that the turn buckle located beneath 4 1a the heald frame is adjusted to the specified length (114 mm). (Refer to Subsection 4.1.7 [ 2 ] (10).) 2 1 (2) Set the crank angle to the shed close timing at which the heald frames become aligned. B (3) Turn off the main switch. (4) Perform levelling operation. (5) Put clamper 4 on stopper 1a of clamper base 1.

A (6) Put parallel pin 3b provided on the upper section of side stay 3a of heald frame 3, onto face B of clamper base 1, then support heald frame 3 with clamper 4. (7) Perform restoring operation to release the levelled state. REFERENCE: After restoring operation, make sure that the lower ropes do not work out of the grooves of the guide rollers. 3 C (8) Turn bolt 2 to provide the specified heald 3b 0 frame height, A –3 mm. 3a (9) Align the top of clamper 4 with the top C of heald frame 3, and tighten bolts 5 with a standard wrench (torque wrench: 77105-00001, 4 socket: 77111-05002) by hand. The tightening torque will be within the range 5 D from 2.5 to 3.4 N·m (26 to 35 kgf·cm).

Dimension A

A Heald frame manufacturer Nankai R/S 230 or less 280 mm 330 mm rod rod Frame type replacement replacement type type Dimension A (mm) 129.5 154.5

4.1 - 15 4. SHEDDING MOTION

[ 1.2 ] Adjusting Heald Frames Relative to Their Guides After installing the heald frames, adjust them relative to the position of the heald frame guides according to the procedure given below. REFERENCE: During the procedure below, do not move LH heald frame guide bracket 10. (1) Loosen bolt 12 on RH heald frame guide bracket 11. (2) Press heald frame 5 fully against LH heald frame guide 3. (3) Move RH guide bracket 11 to the right and left so that the total of right and left clearances “a” comes to 2 mm between heald frame guides 3 and heald frame 5. Then, tighten bolt 12.

[ 1.3 ] Adjusting the Height of Heald Frames (1) Adjust the crank angle to the shed timing. (2) Loosen bolts 5.

NEVER remove bolts 5. If bolts 5 are removed, clamper base 1 (which is pulled up by the spring) will pop up, bumping the operator. It is dangerous.

(3) Turn bolt 2 to provide the specified heald frame height A. See [ 1.1 ] “Installing a Heald Frame”. (4) Tighten bolts 5 with a standard wrench by hand. (Do not use any pipe wrench.) The tightening torque will be within the range from 2.5 to 3.4 N·m (26 to 35 kgf·cm). REFERENCE: Adjust bolt 2 also if the rope is stretched after a trial run.

4.1 - 16 4.1 Negative Tappet Cam Shedding Motion

4.1.6 Modifying the Fabric Texture [ 1 ] Removing and Installing the Negative Tappet Cam (1) Perform the levelling operation. REFERENCE: Make sure that there is gap “a” between tappet cam 1 and cam follower 2. (2) Remove bolt 3, bolt 12 and shaft caps 4, then take out tappet shaft 5 and idle shaft 6.

REFERENCE: For easier removal of those shafts, screw the tappet shaft hoist tools 7 (J8207-06010-00) into taps provided in both ends of each shaft and hoist the tappet shaft. 7 7 or 8 If the main motor position makes hoisting difficult, use hoist tool 8 (W8207-06010-00).

5, 6

NOTE: To prevent the cam shaft from needing oil, clean filter 10 inside the shedding box at the inter- vals specified below. CLEANING INTERVAL: At every tappet cam replacement or every 6 months. If filter 10 gets clogged, the oil level at the pump side lowers so that it becomes impossible to pump up oil, resulting in tappet shaft 5 breaking.

4.1 - 17 4. SHEDDING MOTION

(3) Assembly-change the tappet cams on tappet shaft 5 on the workbench according to the desired fabric texture, by referring to [ 2 ] “How to Assemble Negative Tappet Cams”. NOTE: For rust prevention, store the removed cams, bushings, gears, etc. with oil application in a place kept at low humidity.

(4) Replace change gear 8 on idle shaft 6 with a gear having the desired number of teeth according to the fabric texture. (5) Shift coupling 9 to the left which secures change gear 8.

(6) Install assembled idle shaft 6 and tappet shaft 5 into tappet cam box 11 in this order. REFERENCE: Use the tappet shaft hoist tools (J8207-02610-00, W8207-06010-00) which have been used in step (2). (7) Tighten shaft caps 4 with the bolt 3 in tightening torque 73.5 N·m (750 kgf·cm) and with the bolt 12 in tightening torque 130 N·m (1325 kgf·cm).

4.1 - 18 4.1 Negative Tappet Cam Shedding Motion

(8) Check that the center of tappet cam 1 is aligned with that of cam follower 2. (9) Set the crank angle for the shed close timing suitable to the fabric style.

(10) Bring cam follower 2 into contact with tappet cam 1, then turn tappet gear 13. When two cam levers 12 are almost aligned with each other, engage change gear 8 with 12 tappet gear 13 and tighten bolts 14 on coupling 9. (11) Adjust the shed close timing, by referring to Subsection 4.1.2 “Shed Close Timing”. (12) Cancel the levelling operation.

4.1 - 19 4. SHEDDING MOTION

[ 2 ] How to Assemble Negative Tappet Cams [ 2.1 ] For Plain Weave (with 4 Tappet Cams) Phase-shift of tappet cams Phase-shifting between the two front and two rear tappet cams is possible in case of cams for plain weaving, but no phase-shifting is done in case of a water jet loom.

How to assemble tappet cams (1) Fit tappet bush 6 to tappet gear 5. REFERENCE: Roughly align four bolt holes in the tappet gear and tappet bush. (2) Insert bolt 7 into tappet gear 5 and bushing 6 in this order, then place the assembly on the workbench with the gear facing down.

(3) Set tappet cam 1 (for the 1st heald frame) over tappet bushing 6 and bolt 7. REFERENCE: To secure the following work and make it easier, set the tappet cam with the larger diameter being in the lengthwise or widthwise direction (never diagonal). (4) Fit tappet cams for heald frames 2, 3 and 4 sequentially, with 90° offset each time. (5) Insert gauge pin 8 (J8207-01010-00) into the gauge holes from tappet cams 4 through 1. REFERENCE: Use hole A as the gauge hole for insertion.

4.1 - 20 4.1 Negative Tappet Cam Shedding Motion

(6) Set washer, spring washer, and nut 9 onto bolt 7 inserted in step (2), then temporarily tighten the nut. Lay the assembly down horizontally. (7) Insert the other three bolts into the assembly from the gear side, then set washer, spring washer, and nut. Firmly tighten all of the above four nuts. (8) Pull out gauge pin 8. REFERENCE: Make sure that all of the four nuts 9 are firmly tightened on bolts 7.

(9) Apply sufficient amount of oil (same oil as for the tappet cam box) to inside A (needle bear- ing) of tappet bushing 6. REFERENCE: For the details of the lubricants to be used, see Chapter M, Section M.3 “Lubrication”. 30 mm

In case of single-speed specification (1) Set gear-side hoop 11 to tappet shaft 10 so that the distance from the end of the tappet shaft to that of hoop 11 comes to 30 mm as shown at left.

30 mm

(2) Insert tappet shaft 10 into tappet bushing 6. Secure shaft 10 with hoop 12 so that gap “c” between tappet bushing 6 and hoop 12 comes to 0.4 mm when hoop 11 is in contact with tappet bushing 6 (gap “b” = 0 mm). (3) Tighten four set screws for hoops 11 and 12 to a torque of 40 N·m (408 kg·cm).

c=0.4 mm b=0 mm

4.1 - 21 4. SHEDDING MOTION

In case of 2-speed specification (1) Set and install tappet 2 on the cloth fell side of 7 5 tappet shaft 1 at 30 mm from the end face of 4 the tappet shaft. 30 mm Apply tappet box lubricant on tappet shaft 1 before assembly.

1 2

6 3

Cloth fell ⇒

(2) Insert ground cam gear 5, and ground cam 0.9 mm tappet bush 3 tightly without any clearance into hoop 2 on the cloth fell side. Then insert selvage cam tappet bush 6 and selvage cam gear 7. Selvage can gear 7 should be positioned on the cloth rear side. Fix tappet hoop 4 on the cloth rear side for a clearance between ground cam 8 and selvage cam 9 of 0.9 mm. (3) Tighten four set screws for hoops 2 and 4 to a torque of 40 N·m (408 kg·cm).

9 8 Cloth fell ⇒

Relationship between tappet cams and fabric texture (plain weave) Symbols: (For 4 heald frames) : Rotating direction of tappet cams , : Tappet cam number 1, 2 : Warp number 1 , 2 : Pick number (1), (2) : Heald number

4.1 - 22 4.1 Negative Tappet Cam Shedding Motion

[ 2.2 ] Tappet Cams for Twill and Satin

Assembling procedure The tappet cams for twill, satin, and corduroy should be assembled in the almost same manner as for plain weave explained in [ 2.1 ] “For Plain Weave (with 4 Tappet Cams)”, except for the following differences:

Differences Corresponding steps for plain weave • The setting order of the tappet cams differs depending [ 2.1 ] “For Plain Weave (with 4 Tappet Cams)”, ■ “How to upon the fabric texture. assemble tappet cams” step (4) Refer to Relatonship between tappet cams and fabric texture explained later. • The tappet cams have no special holes intended for the [ 2.1 ] “For Plain Weave (with 4 Tappet Cams)”, ■ “How to gauge. The gauge type and the number of the required assemble tappet cams” steps (1) to (3) bolts are different. Use the gauge (J8207-01020-00) and insert it into the bolt holes.

Sample assembling procedure 1 2 3-shift twill () for 6 heald frames (1) Insert bolt 7 and gauge 8 (J8207-01020-00) into tappet gear 5, then place the assembly on the workbench as shown at the left. (2) Fit tappet bushing 6 over tappet gear 5 with flange B facing down, along bolt 7 and gauge 8 so that the holes provided in the tappet bushing are aligned with those in the tappet gear. (3) On tappet bushing 6, set tappet cam 1 (for heald frame No. 1) with the oil groove (boss protrusion) facing down. (4) Fit tappet cams 2 and on (2 to 6) for frame 2 with proper shifting to bush 6, bolt 7 and gauge 8.

(5) Lay the tappet cam assembly 10 on its side on the workbench, then tighten the nut on bolt 7 described in step (1). (6) Insert bolts 7 into the remaining bolt holes from the gear side. Pull out gauge 8 and tighten the bolts firmly. (7) Perform the same steps as steps (9) and on in ■ “How to assemble tappet cams” in [ 2.1 ] “For Plain Weave (with 4 Tappet Cams)”.

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Relationships between tappet cams and fabric textures (twill and satin weaves) 2 2 twill () for 4 heald frames (For 4 heald frames) Symbols: : Rotating direction of tappet cams , : Tappet cam number 1, 2 : Warp number 1 , 2 : Pick number (1), (2) : Heald number

2 2 twill () for 4 heald frames (For 4 heald frames) Symbols: : Rotating direction of tappet cams , : Tappet cam number 1, 2 : Warp number 1 , 2 : Pick number (1), (2) : Heald number

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1 2 2 twill (3-twill, back cams) and 1 selvage for (For 4 heald frames) 4 heald frames Symbols: : Rotating direction of tappet cams , : Tappet cam number 1, 2 : Warp number 1 , 2 : Pick number (1), (2) : Heald number NOTE: Using back cams produces fabric with twill .

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1 3 3 twill (4-twill, back cams) and 1 selvage for (For 5 heald frames) 5 heald frames Symbols: : Rotating direction of tappet cams , : Tappet cam number 1, 2 : Warp number 1 , 2 : Pick number (1), (2) : Heald number NOTE: Using back cams produces fabric with twill .

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1 4 4 satin (warp 2 skip) and 1 selvage for 6 (For 6 heald frames) heald frames Symbols: : Rotating direction of tappet cams , : Tappet cam number 1, 2 : Warp number 1 , 2 : Pick number (1), (2) : Heald number

1 4 4 satin (warp 3 skip) and 1 selvage for 6 (For 6 heald frames) heald frames Symbols: : Rotating direction of tappet cams , : Tappet cam number 1, 2 : Warp number 1 , 2 : Pick number (1), (2) : Heald number

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1 4 satin (warp 2 skip) for 5 heald frames (For 5 heald frames) Symbols: : Rotating direction of tappet cams , : Tappet cam number 1, 2 : Warp number 1 , 2 : Pick number (1), (2) : Heald number

1 4 satin (warp 3 skip) for 5 heald frames (For 5 heald frames) Symbols: : Rotating direction of tappet cams , : Tappet cam number 1, 2 : Warp number 1 , 2 : Pick number (1), (2) : Heald number

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1 satin (warp 2 skip) and, 3 2 selvage for 7 (For 7 heald frames) 4 2 3 heald frames Symbols: : Rotating direction of tappet cams , : Tappet cam number 1, 2 : Warp number 1 , 2 : Pick number (1), (2) : Heald number

1 3 2 4 satin (warp 3 skip) and, 2 3 selvage for 7 (For 7 heald frames) heald frames Symbols: : Rotating direction of tappet cams , : Tappet cam number 1, 2 : Warp number 1 , 2 : Pick number (1), (2) : Heald number

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[ 2.3 ] Idle Shaft and Gear Installation In case of single-speed specification (1) Assemble to make the distance between the 1 shouldered portion of idle shaft 1 and end face of change gear 2 satisfy 55 mm. (2) Assemble so that the end face of gear 3 is flush with the end face of change gear 2 on the ground cam side.

55 mm

Cloth fell

In case of 2-speed specification (1) Assemble to make the distance between the ← Cloth fell 3 5 shouldered portion of idle shaft 1 and end face of change gear 2 satisfy 55 mm. (2) Assemble so that the end face of gear 3 is flush with the end face of change gear 2 on Flush Flush the ground cam side. 6 (3) Also on the selvage cam side, assemble to align end faces of gear 5 and change gear 4. The dimension from the shaft end face to the gear end face are as illustrated at left. 7-frame specification NOTE: The installing directions of selvage cam 2 4 81 change gear 4 and hoop 6 are different between 7-frame and 8-frame specifications.

8-frame specification 6 66

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[ 3 ] Number of Tappet Cams Required for Fabric Textures

Number of tappet cams Remarks Fabric texture Ground Selvage Total 4 4 Draw waste-selvage yarns Plain weave 1 through the heald frames for 1 66ground weave. 3 2 4 1 (1 ) 3-twill weave* 1 With reverse-twill selvage 2 6 2 7 1 (1 ) 1 4 3 5 With reverse-twill selvage 3 1 (1 ) 4-twill weave* 2 4 4 Mat selvage 2 5 4 6 With reverse-twill selvage 1 (1 ) Satin weave* 1 4 5 2 3 7 Special mat selvage** 2 (3 , 2 ) * : Waste-selvage yarns for 3-twill, 4-twill, and satin weaves should be drawn through the heald frames for ground weave. 3 2 **: Special mat selvage means the combination of 2 and 3 .

[ 4 ] Replacement Parts Required for Fabric Texture Change

No. in Parts name the figure Reasons at left The shape and the number of Tappet cams 1 the tappet cams differ with the required fabric texture. Multi-hole bushing for eight Tappet 2 frames are applicable to all bushing fabric textures. The number of the gear teeth Tappet gear 3 differs so that the rotation ratio of the tappet camchanges. Change gear 4 Same as above. The length and the number of the bolts differ with the number Bolt 5 of the tappet cams to be used and with the required fabric texture, respectively. Number of It differs with the required fabric heald frames texture.

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[ 5 ] Arrangement of Tappet Cams and No. of Gear Teeth

1 1 For plain weave (single weaving-rate models)

Cams for ground 4 cams* Gear A 48 teeth Gear B 36 teeth * : 6 cams for a machine with 6 heald frames

2 2 For 4-twill weave with waste-selvage cams (single weaving-rate models)

Cams for ground 4 cams Cams for waste selvage 2 cams* Gear A 48 teeth Gear B 36 teeth * : 2 cams are not necessary for selvage specification. Selvage yarns should be drawn through heald frames prepared for the ground so as to form mat selvage.

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1 For satin weave and special mat sel- 4 3 2 vage (2 , 3 ) (single weaving-rate models)

Cams for ground 5 cams Cams for mat selvage 2 cams Gear A 50 teeth Gear B 30 teeth a : Cams for ground b : Two cams for selvage are different in shape.

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4.1.7 Replacement of Shedding-related Components [ 1 ] Shedding Timing Belt [ 1.1 ] Without Using the Belt Tension Gauge (1) Remove side cover 2 of timing pulley 1 1 located on the right side of the weaving machine. 2 (2) Turn adjustment bolt 5 located beneath timing pulley lever 4 in order to release the tension of b timing belt 3, then remove the timing belt. (3) Remove any deposit from timing pulley 1 and A 3 the shedding drive pulley. (4) Set a new timing belt onto the pulleys, then 7 make sure that the belt peaks are fitted into the pulley grooves. (5) Turn off the machine brake for the job in this 5 step in order to apply uniform tension to the 4 timing belt 3. Turn adjustment bolt 5 loosened in step (2) so that belt deflection “b” comes to 3 to 4 mm when you push the center of the belt span between timing pulley 1 and tension pulley 7 with your thumb.

How to measure the deflection 1) Hook pawl 6a of tape measure 6 at right angles onto timing belt 3, as shown at the left. 2) While keeping the position of tape measure 6, perform step (5) and read deflection “b”. (6) Adjust the shed close timing. (7) Before putting side cover 2 back into place, run the machine to see that the timing belt travels without deflection. If the timing belt deflects, the tension may be low, so adjust the belt tension again. REFERENCE: What should be most careful is to avoid applying excessive tension to the belt. Too hard tension will break the belt.

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[ 1.2 ] Using the Sonic Tension Gauge Tension gauge: UNITA U-505 (1) When using the sonic tension gauge, set the crank angle to 0°. (2) As shown at the left, measure the belt tension on point P of the center of the belt span between two pulleys specified in the table below, where P is on the right edge of the belt width when viewed from the front side of the machine.

S (3) After measurement and before putting the cover back into place, run the machine to see S P P 2 that the timing belt travels without deflection. If the belt deflects, adjust the belt tension again. REFERENCE: What should be most careful is to avoid applying excessive tension to the belt. Too hard tension will break the belt. Periodical cleaning S : Length of span to be measured is also necessary, since the timing belt will become P : Measuring point entangled with fly or fleece so that the tension may become too tight.

Length of Shedding Tension Belt width Unit load span to be Part No. of belt Measuring point motion (kg) (mm) (gf/mm) measured (mm) Tappet shedding 72202-40005 75 ± 15 55 6.1 177.1 motion

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[ 2 ] Replacing Lower and Side Shedding Ropes (1) Perform the levelling operation. 2 (2) Loosen bolts 2 on connector 1, then remove connector 1 from cam lever 3.

(3) Shift rubber boot 15 at the joints between lower rope 4 and side rope 5, on each of the lower left and right sides of the heald frame, in 5 4 the direction of the arrow, loosen turnbuckle 6 and nut 7, and disconnect the lower and side 15 ropes. 7 4 (4) Loosen screw 8 on connector 1 and remove A press rod 9 to take out two lower ropes 4. 6

1 9 4 8

(5) Release upper rope 14 by loosening nut 11 13 which secures it onto clamper base 10 and by removing nut 13 which secures it onto jack 14 lever 12, then pull up upper rope 14.

10 11

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(6) Hold new short and long lower ropes (4a and 4b) at the right-hand and left-hand sides, respectively, then fully insert their ends (having no metal cap) into slot A in connector 1. (7) Put on press rod 9 from under ropes 4a and 4b, then tighten screw 8 to a torque of 19.5 N·m (200 kgf·cm). (8) Install connector 1 onto cam lever 3 with bolts 2.

(9) Install new upper rope 14 on clamper base 10 14 and jack lever 12. (The installation procedure 5 is the reverse of step (5).)

12 (10) Adjust turnbuckle 6 to set distance “a” 15 between the metal caps of lower rope 4 and 7 side rope 5 to 114 mm. Then lock turnbuckle 6 with nut 7, and protect the joint with rubber 10 6 boot 15. (11) Perform the restoring operation. a=114 mm a=114 7

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[ 3 ] Cam Lever (1) Install set sleeve 1 to cam lever shaft 2 so that: 2 1 • distance “A” between the end face of cam 1 lever shaft 2 and machined end of set sleeve 1 becomes 43.5 mm. 0.4 ± 0.1 • the tap of cam lever shaft 2 becomes parallel to that of set sleeve 1 at both the front and rear sides of the machine, as viewed 0 from arrow “B”. 0 • at the front side of the machine, gaps Parallel A between the set sleeve and all cam levers Viewed from come to 0 mm; at the rear side, the gap arrow “B” between the set sleeve and the cam lever Front of the B comes to 0.4 mm. machine (2) Install the cam lever assembled in step (1) to the tappet box so that: • the gap between the leveling lever and the machined end of the tappet box becomes 0mm. • the tap of the cam lever shaft faces straight up. NOTE: When using a new cam lever, it is necessary to lubricate it before installation as follows: Soak the cam follower roller and LBC3 metal section in oil bath for 24 hours or more and rotate the cam follower to cover the entire circumference with oil film.

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