FIELD OF THE INVENTION
The present invention provides a system and method for double picks insertion in plain weave loom. More particularly, this invention relates to a warp and weft type weaving machine for weaving textile fabrics in which two separate filling yarn picks are inserted in two sheds formed one behind the other, to increase the production capacity of loom.
BACKGROUND OF THE INVENTION
A loom is a machine, which produces fabric from two sets of yarns by interlacing them in a desired order. These two sets of yarns are called as the WARP and the WEFT yarns. In order to interlace the warp and weft threads, the loom has to perform the following sequence of primary operations repeatedly i.e. (a) Shedding (b) Picking and (c) Beat-up.
Weaving is a textile craft in which two distinct sets of yarns and threads are interlaced to form a fabric or cloth. The threads which run lengthways are called the warp and the threads which run across from side to side are termed as weft/filling threads. The cloth is woven on a loom, a device that holds the warp threads in place while filling threads are woven through the warp threads. The pattern by which the warp and filling threads interlace with each other is called as weave. The majority of woven products are created through one of three basic weaving methods including plain weave, satin weave, and twill. The woven cloth is at least one of plain (in one color/a simple pattern) and with artistic designs, including tapestries.
A known type of warp and weft weaving machine comprises a means for providing a warp of parallel threads, a means for holding the formed woven fabric and at least one continuous row of heddles between these two means, actuated in turn from one end of the row to the other end to form a continuous shed which moves between the said two ends. These types of machines also incorporate a continuous row of drive plates for the weft-inserting means. These plates are

adapted to form a supporting guide for an inserting means. The warp and weft type weaving machine further comprises at least one undulating unit for moving the inserting means across the continuous shed in synchronism therewith so as to tension the weft threads, which are interlaced with the warp threads by inversion of the relative positions of the rows of heddles and the drive plates being arranged in a straight line or in a closed circle.
There already exists several years of history with the loom and there has been significant development of the loom, especially in the industrial revolution later, rapier loom has occurred, air jet loom, water jet loom, a variety of projectile weaving looms and with introduction of such mechanization, the loom gradually replaced the original manual intelligent application in the production of the fabric.
Currently, a good number of articles on various modifications of weaving machines have been published, but the basic principle of working and the structure of the loom are more or less identical. These modifications essentially employ a shedding mechanism to separate the warp yarns into two layers to form the shed, a weft insertion mechanism to insert the weft yarn into the shed, and a beat-up mechanism to push the newly introduced weft yarn close to the fell of the already formed fabric. As the fabric is formed continuously, it is moved away from the fabric forming zone and wound onto a roll by the fabric take-up mechanism. Certain other mechanisms like the let-off mechanism, brake mechanism etc., help in the production of quality fabric.
However, such types of weaving machines are generally limited to inserting just one pick at a time. This is a serious limitation on the rate of production of the loom. Therefore, there exists a need for the warp and weft type weaving machine, which is adapted to increase the production capacity by at least two times. Further, there is also a need for the warp and weft type weaving machine which consumes less energy and time for producing a given length of fabric.

OBJECT OF THE INVENTION
The main object of the present invention provides a system and method for double yarn picks insertion in plain weaving loom in order to increase the production capacity of the loom by doubling the rate of insertion of the picks.
Yet another object of the invention relates to the warp and weft type weaving machine for woven textile fabric having multiple-inserted filling yarn picks as well as and an apparatus for weaving the said textile fabrics.
Yet another embodiment of present invention is to provide a system with two picks yarn insertion in order to double the rate of production.
Yet another embodiment of present invention is to retain the sley beat-up system which can give a strong and powerful beat-up provided by the sley.
Yet another embodiment of present invention is to provide a system with no unnecessary movement of the warp ends in shed formation.
Yet another embodiment of present invention is to provide a system in which picking can be done by rapier or air jet method, wherein Rapier is preferred.
Yet another embodiment of present invention is to provide a modified weft insertion system, in which formation of a firm selvedge on both sides of the fabric (similar to cloth woven on shuttle looms) is possible.
SUMMARY OF THE INVENTION
The main object of the present invention provides a system and method for double yarn picks insertion in plain weave loom in order to increase the production capacity of the loom. More particularly, this invention relates to a warp and weft type weaving machine for weaving textile fabric and a method for multiple-inserted filling yarn picks using said warp and weft type weaving machine.

In yet another embodiment, a double yarn picks insertion loom is described capable of producing a plain weave fabric and the weave repeats on two warp and two weft threads. A double yarn picks insertion method using the double yarn picks insertion loom, which forms two sheds, one behind the other, for inserting a pick in each of these sheds simultaneously. Since both these sheds are formed in front of the loom, the shedding mechanism does not obstruct the picks from getting beaten to the fell of the cloth.
In yet another embodiment, a double yarn picks insertion method is described with front shedding device.
In yet another embodiment, the double yarn picks insertion loom comprises an opening structure, weft insertion mechanisms, warp insertion mechanism, shedding mechanism, picking mechanism and a beat-up mechanism, wherein the loom has a front shedding device.
In yet another embodiment, the double yarn picks insertion loom’s opening structure comprises of structural steel frame, panels and other auxiliary driving and supporting equipments such as, but not limited to like tensioners, pulleys, bearings, etc. with a transmission assembly which automate the whole unit.
In yet another embodiment, the double yarn picks insertion loom’s weft insertion mechanisms comprises of a yarn supporting frame with roller, over which weft yarn, spool, drum, etc. is mounted. Further, it comprises of weft tube or a similar weft storage system, ready for inserting the double pick.
In yet another embodiment, the double yarn picks insertion loom’s warp insertion mechanisms comprises of a yarn supporting frame with roller, over which warp yarn, spool, drum or beam is mounted.
In yet another embodiment, the double yarn picks insertion loom’s shedding mechanism perform a process of raising and lowering of warp yarns via at least one harnesses to make an opening for the filling weft yarn to pass through. Further, it comprises plurality of shedding plates, having sloping surface and pivoted on the frame to allow an up-down movement. The zigzag layer of the

warp is controlled by said shedding plates having preferred thickness so as to freely move in the gap between the reed wires but having sufficient strength so as to control the warp threads up and down. The shedding plates are acted upon by constant upward force acting on the ends of the plates which are behind the reed. Alternately a constant force may be applied on the shedding plates just in front of the reed so that the depth of shed formed will be sufficient for inserting the weft threads without difficulty. Further, a reed consists of a frame with lots of vertical slits using suitable thickness plates, which resembles a comb is provided to push the weft yarn securely into place as it is woven, it also separates the warp threads and holds them in their positions and help them in keeping them untangled. Further, a slay is arranged horizontally along the width of a loom which rocking continuously to and fro. The sley is driven to and fro by a crank arm by other means such as cams, but not limited to like hydraulic cylinders, pneumatic cylinders, motor, etc.
In yet another embodiment, the double yarn picks insertion loom’s picking mechanism employs rapier weft insertion system. The Rapier weft insertion system provides two weft threads by having a simple modification in the existing system. Moreover, by customizing the ‘Tip Transfer’ method of pick insertion, firm selvedges can be formed at both sides of the fabric conveniently without the use of any special selvedge forming devices.
In yet another embodiment, the double yarn picks insertion loom’s beat-up mechanism performs sley beat up of cloth.
In yet another embodiment, the double yarn picks insertion loom form convenient firm selvedge while using double pick insertion.
In yet another embodiment, a double yarn picks insertion loom is described with less time consumption and reduced manpower for producing plain weave.
In yet another embodiment, a double yarn picks insertion loom is described which is cost effective and with high production capacity with considerable energy saving.

In yet another embodiment, a method for double yarn picks insertion loom is described, which comprises of: a length of weft sufficient for inserting a double pick is measured, cut and wound on a spool, drum or a weft tube or a similar weft storage system, ready for inserting the double pick; the two ends of the length of weft are kept ready to be presented to the two left rapier heads of the weft insertion system; double headed rapier on left side of the loom will now act as ‘Giver’ rapier heads; a double headed rapier on right side of the loom will now act as ‘Taker’ rapier heads; the double pick is inserted into the two front sheds by the weft insertion system; after the weft insertion, the reed beats up the picks inserted to the fell of the cloth; a firm selvedge is formed on the left side of the cloth and the cut ends of the weft thread are protruding from the body of the cloth on the right side; the sequences of operations are repeated from the right side of the loom, which means that the weft is supplied from the right side of the loom; a firm selvedge is formed on the right side of the cloth and the cut ends of the weft thread are protruding from the body of the cloth on the left side; and in this way, firm selvedges are formed on both sides of the fabric as the loom continues to weave.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described with reference to the following drawings.
The drawings and the associated descriptions are provided to illustrate
embodiments of the invention and not to limit the scope of the invention:
Fig. 1 is a traditional schematic of a loom is shown; highlighting general
arrangement of 4 sheds formed simultaneously;
Fig. 2 is a general arrangement showing concept of double pick inserting loom
with an embodiment of the present invention;
Fig. 3 is a general arrangement showing arrangements of wrap layers in the
formation of front shed with an embodiment of the present invention;
Fig. 4 is a general arrangement of double pick inserting loom with an
embodiment of the present invention;

Fig. 5A is showing a general arrangement with an embodiment of the present
invention when traditional thin wire reed is used;
Fig. 5B is showing a general arrangement with an embodiment of the present
invention when a plate reed of proper width is used;
Fig. 6A, 6B and 6C is showing a sequence of weft insertion with an embodiment
of the present invention; and
Fig. 7 is showing an interlacement of the wrap and weft threads with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the inventions are shown. While the following description details the preferred embodiments of the present invention, it is not limited in its application to the details of construction and arrangement of the parts illustrated in the accompanying drawings.
With reference to the figures, numerical designation has been given for each element to facilitate the reader's understanding of the present invention, and particularly with reference to the embodiments of the present invention illustrated in the figures; various preferred embodiments of the present invention are set forth below. The enclosed description and drawings are merely illustrative of preferred embodiments and represent several different ways of configuring the present invention. Although specific components, materials, configurations and uses of the present invention are illustrated and set forth in this disclosure, it should be understood that a number of variations to the components and to the configuration of those components described herein and in the accompanying figures can be made without changing the scope and function of the invention set forth herein.
Fig.1 is a traditional schematic of a loom is shown; highlighting general arrangement of 4 sheds 10, 12, 14 and 16 which are formed simultaneously. With

state of the art devices for shed formation and pick insertion, it is not at all difficult to form 4 sheds 10, 12, 14 and 16 at a time and insert a pick 18, 20, 22 and 24 in each of these 4 sheds 10, 12, 14 and 16 simultaneously. But the difficult part of the job is beating up of all these 4 picks i.e., pick 18, 20, 22 and 24 to the fell of the cloth. The figure clearly elucidates that except the pick 18, all the other picks cannot be beaten up to the fell of the cloth 26 because of the presence of the heald wires 28 in front of them.
Fig. 2 is a general arrangement showing concept of double pick inserting loom with an embodiment of the present invention, wherein, two wrap beams 30 and 32 are incorporated to supply the two sets of warp ends forming the two sheds one behind the other, and pick 44 and 42 are inserted in front of reed 40, a sley 38 is used for beat up to form the fell of cloth 46. Further, whip rolls 34 and 36 are used for maintaining tension in the warp yarn. Such an arrangement will surely increase the production capacity of the loom two fold if it is possible to have a shedding device, which does not obstruct the subsequent beat-up operation as both the sheds are necessarily formed in front of the reed 40. This is contrary to the conventional method of shedding, in which, the sheds are formed behind the sley 38 or reed 40.
Fig. 3 shows a general arrangement showing arrangements of wrap threads 54 and 56 in the formation of front shed. One of the important arrangements in the formation of the front sheds is that, the set of warp threads 56 forming one layer of the sheds is kept straight and the other set of warp threads 54 forming the other layer of the shed is made to follow a zigzag path. Here, warp thread 54 pulled from warp beam 48 is formed in zigzag form using a whip roll 52 to keep lesser tension during shedding. While, warp thread 56 pulled from warp beam 50 is kept straight. This made possible insertion of pick 58 and 60 before beat-up operation to form plain weave cloth 62.
Fig. 4 is a general arrangement of double pick inserting loom is shown along with a front shedding plate 70. Here, warp thread 66 is formed in zigzag form using a

tension compensator 64 to keep lesser tension during shedding. While, warp thread 68 is kept straight. The shedding plate 70 is acted upon by constant upward force acting on the ends of the plate which are behind the reed 76. Alternately a constant downward force may be applied on the shedding plate just in front of the reed 76 so that the depth of shed formed will be sufficient for inserting the picks 78 and 80 without difficulty. As the shedding plate70 is pivoted, the sloping surface of the race board will move the shed forming ends of the plates upwards as the sley 74 moves forward for beat up. Due to this upward movement of the shedding plate, the picks 78 and 80 can be beaten up to the fell of the cloth 82 without any obstruction to form plain weave cloth 84. When the sley 74 moves back, the shed will automatically open due to the upward force acting on the outer end of the shed plate 70 (or the downward pressing force acting on the plates in front of the reed). The sley 74 is driven to and fro by a crank arm 72 by means of such as, but not limited to like hydraulic cylinders, pneumatic cylinders, motor, cams etc. It is required that instead of using thin wires with round cross section in the reed, plates with proper width must be used for construction of the reed 78. Then only the shedding plate 70 will not miss their respective reed gaps when the sley 74 starts moving back after beat-up.
Fig. 5A is showing a general arrangement of reed 88 used in a traditional loom. Here, it is shown with the employment of thin circular cross-section wire reed 88, there exists a chance that the shedding plate 86 may miss its respective reed gap while forming the plain weave cloth 90.
Fig. 5B is showing a general arrangement of reed 88 within an embodiment of the present invention. Here, it is shown with the employment of proper width plate type reed 88, the shedding plate 86 cannot miss the reed gap while forming the plain weave cloth 90.
Fig. 6A, 6B and 6C is showing a sequence of weft insertion. In a general arrangement there are two sets of rapier drives, rapier housing 102 with a double

rapier head 104 and rapier housing 106 with a double rapier head 108. A set of warp threads 94 are inserted through reed. Further, there is a weft supply package 100 is provided along with a weft tube 96 in which a measured length of weft thread 98 is placed and the two ends of this weft thread are to be picked by the two rapier heads104. Fig. 6A is showing general arrangement before picking. Here, the ends of weft thread 98 are picked up by the double rapier head 104 this illustrate that the rapier head 104 is acting as “giver” rapier. Fig. 6B is arrangement during picking of weft thread 98 into warp threads 94. Double Rapier head 104 picks the ends of the weft thread 98 from the weft tube 96 and it carries the weft to the double rapier head 108, which is acting as “taker” rapier. The two ends of the length of weft thread 94 are kept ready to be presented to the two left rapier heads104 of the weft insertion system. Fig. 6C is showing weaving after beat-up of weft thread 98 after the insertion of weft thread 94 in to warp threads 94, the reed beats up the picks inserted to the fell of the cloth and cycle is ready for inserting next weft thread 110 into warp threads 94 to carry out the weaving. A firm selvedge is formed on the left side of the cloth and the cut ends of the weft thread 98 are protruding from the body of the cloth on the right side. Similarly, the sequences of operations may be repeated from the right side of the loom, which means that the weft is supplied from the right side of the loom and a firm selvedge is formed on the right side of the cloth and the cut ends of the weft thread are protruding from the body of the cloth on the left side. In this way, firm selvedges are formed on either sides of the fabric as the loom continues to weave if the weft yarn is inserted into the shed alternating from either end of the loom in sequence.
Fig. 7 is showing an interlacement of the wrap and weft threads with firm selvedge on both sides. It is shown when the picks are inserted from both sides of the loom in order to weave a plain cloth.
The foregoing description of embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of

the invention. The embodiments were chosen and described in order to explain the principals of the invention and its practical application to enable one skilled in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated.

CLAIMS We claim,
1. A double yarn picks insertion loom for weaving textile fabric, comprising:
at least one warp sub-assembly providing plurality of double row warp
threads 94;
at least one weft supply package100 for supplying single weft threads at a
time, stored in plurality of weft tubes 96;
at least one double picking 98 supply head having means to pick the weft
from weft supply package 100 from plurality of weft tubes 96 to be inserted
into the warp;
sley 74 and a crank arm 72 to beat up inserted weft into the warp to weave
the cloth; and
a reed 76 for pushing the weft yarn securely into place, separating
the warp threads, holding them in their positions and keeping them
untangled;
wherein;
at least one shedding assembly having plurality of shedding plates 70 are
installed before the reed 76 associated with weft supply package 100 for
creating one zigzag warp thread 94 with said shedding plates 70 having
sloping surface to allow an up-down movement for raising and lowering of
warp yarns 94 by employing a harnesses to make an opening and having
such thickness so as to freely move in the gap between the reed having
sufficient strength so as to control the warp threads up and down;
the supply heads having two head/tips 104 and 108 holding two ends of the single weft threads at a time from the weft tubes 96 for filling one head into the zigzag warp thread and the other end to other warp thread 94.
2. The loom as claimed in claim 1, wherein said sley 74 is arranged
horizontally along the width of a loom which rocking continuously to and
fro.

3. The loom as claimed in claim 1, wherein said sley 74 is driven to and fro by a crank arm 72 by means of such as, but not limited to like hydraulic cylinders, pneumatic cylinders, motor, cams etc.
4. The loom as claimed in claim 1, wherein the loom is designed to produce a plain weave fabric on two warp and two weft threads.
5. The loom as claimed in claim 1, wherein at least one warp insertion mechanism employs warp yarn, warp spool, warp supply package;
6. The loom as claimed in claim 1, wherein said reed 76 consists of a frame with lots of vertical slits using suitable thickness plates, which resembles a comb.
7. A method for double yarn picks insertion, the method comprising steps of: providing plurality of warps and wefts 98;
inserting single wefts 98 into the warps via a double rapier head carrying a both the ends of the weft yarn across plurality of warps or inserting, either from right to left or left to right;
beating up the picks via a reed to create a fell;
a firm selvedge is formed on the left side of the cloth and the cut ends of the weft thread are protruding;
wherein,
two ends of the weft 98 are presented to the two rapier heads carrying system of the weft insertion system acting as a ‘giver’ rapier heads 102;
the ‘giver’ rapier heads 102 further pass the length of weft 98 to two rapier heads 106 on acting as a ‘Taker’ rapier heads;

the double pick 98 is inserted into the two front sheds by the weft insertion system;
providing a weft for inserting a double pick; and
two sheds, formed one behind the other, for inserting a pick in each of these sheds simultaneously.
8. The method for double yarn picks insertion as claimed in claim 6, wherein rapier weft insertion system according to claim 5, wherein the method allows formation of firm selvedges at both sides of the fabric without the use of any special selvedge forming devices.
9. The method for double yarn picks insertion as claimed in claim 6,wherein employing less time and reduced manpower for producing plain weave thus become cost effective and with high production capacity and energy saving.
10. The method for double yarn picks insertion as claimed in claim 6, wherein the method removes any obstruction while the picks are beaten to create the fell of the cloth.