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Application of NA200 on a Circular Loom
Release date:
2020-04-07
Plastic woven bags have a production and manufacturing history of more than two decades in China. Thanks to fierce market competition within the plastic weaving industry, the sector has experienced rapid growth. In recent years, both the scale of enterprises and the quality of their products have significantly improved, enabling the plastic weaving industry to gradually evolve into a cross-industry field that bridges the textile and chemical industries. As China joined the WTO, the expansion of international logistics and trade has dramatically boosted demand for plastic woven container bags, driving continuous annual growth of around 15%. Today, annual production has reached 150,000 tons.
Plastic woven bags have a production and manufacturing history of more than two decades in China. Thanks to fierce market competition within the plastic weaving industry, the sector has experienced rapid growth. In recent years, both the scale of enterprises and the quality of products have significantly improved, enabling the plastic weaving industry to gradually evolve into a cross-industry sector that bridges the textile and chemical industries. With China's entry into the WTO, international logistics and trade have surged, dramatically boosting demand for plastic woven container bags. As a result, the industry has maintained steady growth of 15% annually over the past several years, now reaching an annual output of 150,000 tons.
(Image sourced from the internet)
The plastic weaving process consists of two major stages: the manufacturing of plastic woven flat yarn and the plastic weaving itself. This article discusses automation issues related to plastic weaving machines built on Nanda Aoto's technology platform. Plastic cylindrical weaving machines (circular looms) are essential equipment for plastic weaving enterprises. Automation of plastic weaving machines plays a crucial role in boosting production output, enhancing product quality, and reducing labor costs in plastic weaving manufacturing.
Plastic Woven Tube Fabric Processing Equipment
The process of producing plastic woven fabric from plastic flat yarn involves interweaving the flat yarns both horizontally and vertically to create the fabric. For tubular fabric weaving, a circular loom is used. The warp beam of the circular loom holds numerous spindles, and depending on the desired width of the woven fabric and the thickness of the flat yarn, a specific number of warps is selected. Before entering the circular loom, these warps are guided through cross-opening devices called reed frames, which systematically separate them to form the shed. Meanwhile, the weft shuttle moves in a circular motion, passing back and forth through the shed created by the separated warps, thus weaving the fabric into a seamless tubular shape.
A circular weaving machine is textile equipment that uses PP (polypropylene) or HDPE (high-density polyethylene) flat yarns as raw materials to produce cylindrical woven fabrics. The machine employs multiple shuttles to simultaneously weave multiple weft threads into the fabric, creating an interlaced structure of warp and weft yarns. On the warp beam, numerous spindles hold the warp threads; depending on the desired width of the fabric and the thickness of the flat yarns, a specific number of warp threads is selected. Before entering the circular weaving machine, these warp threads are guided through a reed frame, which creates alternating openings for efficient weaving. As the warp threads are lifted, the weft threads are evenly wound around the cylindrical surface, forming a seamless tubular fabric. If裂膜丝 (split-film filament), double filaments, or folded filaments are used instead of conventional flat yarns during weaving, the resulting fabric can achieve exceptionally high strength—perfect for manufacturing heavy-duty bulk bags and ton-bag fabrics. In the production process of woven fabrics, key technical indicators typically include: weaving density, fabric width, tensile strength, and the fabric's weight per unit area.
Mechanical and Electrical Principles of the Circular Weaving Machine
The circular weaving machine consists of three main motion mechanisms and two auxiliary motion mechanisms.
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The let-off rollers are mostly driven, featuring their own torque motors, gear reducers, and transmission chains that power the rotation of the rollers. In contrast, passive let-off systems rely entirely on the traction force from the main machine to drive the flat filaments into motion, making them suitable for high-linear-density flat filaments. The actively driven let-off roller is also known as the automatic let-off roller. In this project, the let-off mechanism is powered by a motor controlled via a frequency inverter, ensuring precise adjustment of the yarn feed rate while maintaining consistent tension throughout the process. Typically, the warp beam consists of a frame made from steel pipes or structural steel profiles, supporting individual warp yarn tubes arranged in rows and columns, along with backing plates that secure the tubes in place.
Host section
The main unit of the circular loom consists of a motor, a reduction system, and a base that form the transmission system. The main turntable drives the slider, which in turn moves the reed (reed frame). Combined with sisal cords and supplemented by components like tension rods and gauge rings, this forms the shedding mechanism. Meanwhile, the weft insertion mechanism is composed of elements such as the shuttle push rod and the shuttle itself. Notably, the circular loom does not have a dedicated reed-beating mechanism—instead, the tension rod attached to the shuttle drives a front-mounted roller as the shuttle moves in a circular motion, guiding the flat yarn into the shed and pulling it toward the gauge ring (shed opening), thereby completing the reed-beating process. The rotation of the main turntable, essential for weaving, is controlled by an inverter-driven motor.
Enhancement section
The circular weaving machine's take-up mechanism includes the upper drawing system and the winding unit. The upper drawing system is driven simultaneously by the main motor, which adjusts the weft density via a variable bevel gear, slows down the speed through a gearbox, and pulls the woven fabric using a pair of flat rollers. The resulting fabric is then wound into rolls by the winding unit, which consists of a torque motor, a gearbox, and a set of two-planar rollers for efficient roll formation.
System Configuration
This set of circular weaving machines uses the NanDa Aoto NA200 series PLC and its corresponding frequency converters as the control core, with the PLC configured as shown in the diagram below.
Figure 1: PLC Module Configuration
Figure 2 PLC Program
Figure 3: PLC On-site Installation Diagram
Figure 4: Working Diagram of the Circular Weaving Machine
The NA200 PLC is a compact PLC series independently developed by Nanjing Aotuo. Its application in circular knitting machines fully demonstrates the NA-PLC's outstanding features, such as stable performance, reliable communication, and convenient debugging. With its excellent capabilities and exceptional cost-effectiveness, the NA series PLC provides optimal solutions for industries across the industrial control sector.
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