INTRODUCTION:

Handloom weaving provides livelihood to millions of weavers in India.

The study has found that number of handloom weavers, number of looms

has come down over the years.

The reasons attributed are low production, low income and health problems

faced by the weaver due to the strains.

In this project an attempt has been made to reduce strain and fatigue of the

weaver during the weaving process and to increase the production and

quality of the product.

OBJECTIVE:

To identify the mechanism for simplifying the handloom.

To reduce the stress and strain of the worker.

To increase the production

To increase the profit

SCOPE OF THE PROJECT:

The attachment of the pneumatic equipment for the lifting of the jacquard

eliminates the load on the weaver. These results in

Reduction of stress and strain of the weaver.

Increasing the productivity.

Achieving better quality by uniform shedding.

Preventing the health problems faced by the weaver due to continuous

working.

NEED FOR REDUCTION OF WEAVER’S FATIGUE:

The handloom weavers in the past years are migrating to the other jobs as

handloom weaving involves great strain in case of jacquard looms for the

shedding operation.

The production is also less and it is a time consuming process which brings

very low income for the weaver.

The handloom weavers face many health problems like joint pain,

backbone pain, leg pain, shoulder pain etc…

The weaver must be protected from such health hazards in the future, so a

simplified mechanism is needed to facilitate the weaver in the process of

weaving.

IMPORTANCE OF NEW MECHANISM:

The handloom weavers are declining year by year due to the difficulties of

the job and time consuming with low production and health hazards.

There is a need for improving the sustainability of the sector for longer

more years as it is a sun set industry.

It is important for improving the mechanism by simple automations for

simplifying the work of the weaver and reducing fatigue through enhanced

operations leading to higher production.

Ergonomics-The comfort zone in Handlooms

Ergonomics is a scientific study of the relationship between the man and the

working environment.

The reduction of fatigue and stress by of way of restriction of energy

expenditure in non-productive areas, will improve the quality and quantity.

POSTURE:

Ergonomics have attempted to define postures, which minimizes

unnecessary static work and reduce the force acting on the body.

Injuries in workplace are mainly due to back problem because of repetitive

stress.

In handloom sector most of the activities are manual, right from winding,

warping, sizing and weaving. And the poor handloom weaver has to bear a

lot of stress and strain while performing these functions.

Ergonomics thus being a economic issue plays an important role on any

industry’s productivity and profitability, improvement in working

conditions, better human resource management and enhanced financial

gains.

Categories of Automation:

In general automations can be done in the following categories.

Pneumatics

Hydraulics

Electrical

Mechanical

In most cases low cost automation is achieved by pneumatic system in

reducing labor cost, machine investment and increasing productivity

AUTOMATIONS AND MODIFICATIONS DONE IN HANDLOOM SO FAR:

Handlooms modified for handicapped people without legs. All the motions

are operated by the beat-up action by using hands only.

Handlooms modified for handicapped people without hands by only

operating the pedals which will carry out the primary and secondary

motions.

Looms altered with multi shuttle box for using double colour weft without

changing the pirn.

Double mats can be woven on the same loom at the same time.

Many places handlooms which are pedal operated are being driven using

electricity and functions like the power loom in all aspects.

  

 

 

 

 

      

 

 

  

Study of various types of handloom

Selection of handloom for alteration

Study of Industrial Automations 

Simplification of the Handloom using Pneumatics

Study on the Improvements in Handloom afterSimplifying its Operations

METHODOLOGY

DESCRIPTION OF PNEUMATICS:

In Greek language, “PNEUMA” means breath or air.

The study related to the utilization of compressed air is termed as

Pneumatics.

FORM OF OUTPUT:

Pneumatic system and equipments used compressed energy and produced

linear motion output.

This resultant linear motion may sometimes be used for obtaining rotary and

semi-rotary motion also, according to the application.

APPLICATION:

Pneumatic equipments can be used for applications, where operation cycles

need certain routine functions like

Pushing

Pulling

Lifting

Feeding

Clamping

Pressing

Forming, etc. PNEUMATIC CLAMPING SCREW MOULDING

MACHINE

OPERATION AND CONTROL OF A DOUBLE ACTING CYLINDER:

A B A B

EXTENDING RETRACTING

1 CHAMBER 2 CHAMBER 1 2

When the high pressure air is supplied through port A, a particular load acts

on the piston thus extending the piston rod. And simultaneously the air in the

chamber 2 is exhausted through port B.

Similarly when the high pressure air is supplied through port B, the piston

rod reacts and simultaneously the air in the chamber 1 is exhausted through

port A.

COMPONENTS USED:

Air Cylinder (40 DIA and 300 MM Stroke Length)

Air Compressor (2HP for 3 Looms) Varies With Design

Foot Operator Valve

Quick Exhaust Valve

Silencer Cum Flow controller

Filter Regulator Combination

Male Elbow (Connector)

Air Flow Tube (6MM)

STEPS INVOLVED IN AUTOMATING THE LOOM:

The connections of the pneumatic system and its components are given below

From the air compressor the outlet is connected to the foot operated valve’s input

supply.

The output port of the foot operated valve is connected to the air cylinder on its top.

The silencer cum flow control valve is connected to the end of the tube in which the

air is exhausted.

The quick exhaust valve is connected to the top of the cylinder where the air enters

the cylinder so that the used air is immediately released and increases the number of

strokes of the piston.

The filter regulator combination is fitted to the compressed air from the storage tank

of the air compressor which function is to filter the air before supplied to cylinder.

The piston is connected to the jacquard lifting rods using a belt.

PROCEDURE:

The air compressor functions automatically when the pressure of air in its storage tank is

reduced and refills depending on its usage.

The compressed air is filtered and passed on to the foot operated valve. The normal

position of the piston is raised and its connected to the jacquard rods. At this position the

jacquard is not in function.

When the foot operated valve is pressed the air is passed into the cylinder and forces the

piston down and this motion raises the selected hooks in the jacquard depending on the

design given. The shedding action takes place as the rod is forced downwards due to the

action of the piston.

When the foot operated valve is released the piston is moved upward due to the weight.

The used air from the piston is emitted out through the same port as a quick exhausted

valve is connected in the supply.

Its function is to speed up the operation and increase the strokes of the piston. A silencer

is connected at its end so to avoid the noise of the compressed air into the atmosphere.

JACQUARD HANDLOOM PNEUMATIC AIR CYLINDER

LOOM IN OPERATION

NORMAL POSITION OF JACQUARD

JACQUARD IS LIFTED USING PNEUMATIC

WORKING OF CYLINDER

COSTING:

The cost details of the pneumatic system components are 

SNO COMPONENTS QUANTITY COST

01 Air Cylinder 40dia, 300mm SL

1 1874.00

02 Foot Operated Valve 1 1300.00

03 Quick Exhaust Valve 1 411.00

04 Silencer cum Flow Control

1 192.00

05 Filter Regulator Combination

1 865.00

06 Male Elbow (connector) 5 215.00

07 6mm Pneumatic Tube 7 MTR 203.00

GRAND TOTAL IN RUPEES 5060.00

PRODUCTION AND PROFIT COMPARISION

Before Automating the Loom:

Time taken to complete one saree of a particular design - 6 days

Total number of sarees can be produced in a month - 5 to 6

Cost paid to weaver for producing one saree - Rs. 800-1000

Monthly earnings of the weaver - Rs. 4500-5500

 

After Automating the Loom:

Time taken to complete one saree of the same design - 4 to 4.5 days

Total number of sarees can be produced in a month - 7 to 8

Cost paid to weaver for producing one saree - Rs. 800-1000

Monthly earnings of the weaver - Rs. 6500-7500

RESULTS:

Decrease in operator stress and strain.

Increase in operator productivity.

Better quality can be achieved due to uniform shedding.

Prevents the weaver from health hazards in the future.

Easy to operate and maintain.

With all the above advantages of the simplified handloom with pneumatic

mechanism, the few drawbacks found are

The cost of the pneumatic mechanism is high

The air compressor is expensive which is the primary input for the functioning

of this mechanism

The electricity charges are increased by RS.200 per month.

CONCLUSION:

More number of looms (approximately 4 looms) can be automated with this

mechanism with the single air compressor of 2HP Capacity.

As per the saying “PREVENTION IS BETTER THAN CURE” by

implementing this pneumatic mechanism in handloom, the health problems

associated with the weavers strain and fatigue in lifting the jacquard is

reduced, thus preventing weaver from health problems.

By using this pneumatic system the production is considerably increased to

about 20%.

Earnings of the weaver are increased around RS.2000 – 2500 per month.

Initially the air pressure is used for both lifting and lowering of jacquard hooks

and the compressed air used for this purpose is also more. Then on usage it was

found that the lowering of jacquard hooks takes place automatically by its own

weight when the pressure used for lifting is released. Hence the compressed air

required for lowering is thus neglected.

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