Development of high strength core and sheath ropes using weaving technology

Fieldtrials observing the use of woven ropes show encouraging performance, say Pradeep Kulshrestha, Dharmendra Goswami,Chandrakant Nakum, Jagdish Patel

Woven ropes are strongercompared to braided, conventional ropes. The Ahmedabad Textile Industry's ResearchAssociation (ATIRA) developed woven ropes with core and sheath arrangements.Comparison was carried out with the same type of braided ropes in terms ofmaterial and diameter. In this way we can get the strength of the core yarn.For example, aramid fibres can be covered with polyester to use in the marineindustry. Glass fibre can be covered with cotton for aesthetic propertiesduring handling.

The developmentalactivities carried out in the area of high strength ropes using varieties ofhigh tenacity yarns were carried out to:

1.       To ascertainrequirements of different specified industries using ropes. For instance, inthe fields of transport, marine, fire fighting, rescue and sports

2.      Testingconventional ropes to analyse raw material used

3.      To evolve cost-effectiveconstruction and design of woven ropes with judicious combinations of specifichigh strength yarn to meet requirements

4.      Developingropes with equal/higher strengths with the substitute and/or cost-effective rawmaterials using weaving techniques

Manufacturingwoven ropes at ATIRA Incubation Centre

Weaving rope withcore-sheath structure of pre-decided design using varieties of yarn:

a)     Rewindingyarn from big package to smaller packages on Sahm Winding Machine

b)     To put thosespools on creel as per core and sheath plan on Jakob Muller Narrow Rope WeavingMachine

c)      To draw yarnends in Heald wires and Reed

d)     To takeforward all ends and insert them in guide rollers

e)     To apply opentype of Drop Pins in warp stop motion or insert each yarn through close drop pin

f)       To draw weftin needle

g)     To startweaving rope with process monitoring and controls

Manufacturing braided ropes

* Making ropes by conventional braiding process entails:

a)     Creeling of yarn as per plan on Susmatex Braiding Machine

b)     To insert individual ends in needles

c)      To adjust settings

d)     Complete the braiding

Comparison of woven and braided ropes: Set 01

Comparison of woven and braided ropes: Set 02

Comparison of woven and braided ropes: set 04

Comparison of woven and braided ropes: Set - 05

Comparison of woven and braided ropes: Set - 06

Comparison of woven and braided ropes: Set 07

Comparison of woven and braided ropes: Set - 08

Analysis of results:

In every case, woven ropes are stronger (average tensile strength approximately 7.24 KN) compared to braided ropes (average tensile strength approximately 2.46 KN) indicating superior performance of woven ropes.

Woven ropes with required properties as that of braided ropes would be approximately at least 30 per cent lighter.

Due to core and sheath arrangement of yarn in woven ropes, they are more comfortable and more aesthetic in practical use.

Plans to utilise the equipment facilities in future

Indian Railways for luggage handling

A porter using woven rope to tie luggage on the trolley at Ahmedabad Railway Station found woven rope much more comfortable over traditional HDPE packing strips. It also had better handling comfort and strength

Experiments at ATIRA

During trial to assess the strength of woven rope, we have seen that only two woven ropes with same diameter and material are sufficient as against a number of non-woven ropes required to carry the same weight.

We can weave a variety of cost-effective samples on narrow looms with limited consumption of expensive yarn. This technology is important to produce specified application products like high strength ropes. Investment in narrow machines for ropes will give confidence to owner of a self-employed business.