Research related to warp breaks has been limited to monitoring break frequency and the reason associated with breaks in order to improve warp yarn quality. While this approach leads to improvement in weaving efficiency, warp breaks still represent a major problem, especially for today's high-speed weaving machines. Researchers have been trying to develop commercial automated systems to repair warp breaks with no success. The goal of this study is to explore inexpensive methods to automate warp break repair in Jacquard weaving. To achieve the goal, the concurrent studies are being conducted: (a) Developing a method to detect warp breaks using MEMS (Microelectromechanical) sensors, (b) Identifying exact location of warp breaks using servo table by pointing at the reed dent of a broken warp yarn, (c) Performing in-plant investigation to study warp break locations and frequency and (d) Developing algorithms and conceptual designs to automate the process of warp repair based on the three studies above. In this paper, we briefly discuss the status of detecting warp break and its location using MEMS accelerometers and servo table. Additionally, the paper reports details of an in - plant study of warp breaks location and occurrence in Jacquard weaving. Data obtained from the study indicates that more than 75% of the breaks take place in the region between the harness tie and the cloth fell. However, 50% of the beam side ends of the broken warp yarns remained in this area and the other 50% were withdrawn to the region between the drop wires and the harness tie.
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