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Weaving Calculations · Lecture 06
Sett Calculations – Beams and Warping Production
How many warper’s beams an order needs, how many ends go on each, and how long the warper will take.
Creel capacityBeamsWarping productionOrder time
From total ends to beams
A sized weaver’s beam is made from several warper’s beams run together on the sizing machine. The warper’s creel holds a limited number of cones (here 840), so the total ends — including selvedge ends — are divided over an even number of beams (beams are paired on the sizing creel).
beams = round-up-to-even( total ends ÷ creel capacity ) · ends per beam = total ends ÷ beams
| A | B | C | |
|---|---|---|---|
| 1 | Fabric A | Fabric B | |
| 2 | Ends per inch | ||
| 3 | Width (in) | ||
| 4 | Extra selvedge ends | ||
| 5 | Creel capacity (cones) | ||
| 6 | Total ends incl. selvedge | 3,820 | 8,104 |
| 7 | Beams calculated | 4.55 | 9.65 |
| 8 | Beams used (round up to even) | 6 | 10 |
| 9 | Ends per beam (average) | 636.67 | 810.40 |
| 10 | … in practice | 2 beams × 636 + 4 beams × 637 | 6 beams × 810 + 4 beams × 811 |
blue = input (edit me)grey = formula (click to see it)
Warping production and time for an order
| A | B | ||
|---|---|---|---|
| 1 | Warper | ||
| 2 | Warping speed (yd/min) | ||
| 3 | Efficiency | ||
| 4 | Shift (hours) | ||
| 5 | Ends per beam | ||
| 6 | Warp count Ne | ||
| 7 | Yards warped per shift | 268,800 | |
| 8 | Weight warped per shift (lb) | 10,187 | |
| 9 | Weight warped per hour (lb) | 1,273 | |
| 10 | Order | ||
| 11 | Fabric ordered (m) | ||
| 12 | Warp contraction | ||
| 13 | Total ends in fabric | ||
| 14 | Fabric (yd) | 21,872 | |
| 15 | Warp length required (yd) | 24,059 | |
| 16 | Warp weight required (lb) | 5,413 | |
| 17 | Warping time (hours) | 4.3 | |
blue = input (edit me)grey = formula (click to see it)
A 20,000 m order of fabric A needs 5,413 lb of warp and keeps the warper busy for only about 4.3 hours — warping is rarely the bottleneck; sizing and loom capacity are (Lecture 10).
Original lecture material
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