Devsan Produces Turkey’s Most Technological Conical Series Warp Preparation Machine
Today, Devsan manufactures fully equipped machines with laser sensor measurement, servo motor and PLC control, including all technological developments. Since 2019, Devsan has started to manufacture direct warping machines required for the warp preparation process. Devsan engineers and service technicians, who also supply the spare parts needed for sectional warpers, direct warping preparation machines and creels, provide 24/7 technical service to their customers.
İlker Kaya, Founding Partner of Devsan, whom we interviewed for the January special issue of Tekstil Teknoloji magazine, stated that their machines used in warp preparation processes have reached high sales volumes in a short time; ‘‘Our machines, which have reached high sales volumes in a short time and are delivered to customers without any problems, are used in warp preparation processes. We use top quality products in motion control, PLC, HMI products in our machines. Communication between devices is net-based and at MB level. In addition, our machines are CE certified and comply with safety standards.’’
İlker Kaya pointed out that although the production of serial warping machines has been started recently, they have received more intense demand from Uşak, Bursa, Denizli, Kahramanmaraş and Gaziantep provinces, and mentioned the remarkable points of their machines as follows: ‘‘The most important points that determine the quality of the serial warping machine are the material and weight of the printing drum, the quality of the accordion comb and the hydraulic system. The printing drum and hard paper material are used in our very light machine. In terms of robustness, it can even withstand pressure above 110 bars. This production technique is also preferred by leading European companies in the sector. Thanks to the lightweight printing drum, unbalanced operation caused by defective beams is minimized. Otherwise, imbalance reduces the lifetime of all mechanical equipment and causes chronic failures.’’
Underlining that they are quite successful in the field of hydraulic unit as an engineer, Kaya expressed; ‘‘With a small oil tank and a simple, understandable circuit, we provide the movements of the machine such as stopping, pressure control, etc. We use high quality valves and equipment in the unit.’’
Devsan, which is one of the noteworthy companies in creel production, continues to develop creels that control the yarn tension automatically by using spring printing logic. In addition, the Parallel/H/rotary creel used in conical warping and serial warping and the trolley/I creel used in serial warping are all produced within Devsan.
‘‘We focus on R&D activities in order to adapt to the world’’
Indicating that they have focused on R&D studies in order to adapt to the world in warp preparation and that they have succeeded in the laser sensor measurement technique in sectional warping machines as a result of their intensive R&D studies in the last 5 years, İlker Kaya explains the process as follows: ‘‘In this process, we spent a long time with warping operators in companies that weave different products. We learned how difficult the algorithm, which seems quite simple in theory, is actually. We have seen that the laser sensor is affected by the colors, the importance of the spot diameter of the selected sensor, the differences that occur when the first band winding is done on the hard surface and the next bands are done on the soft surface, and that these differences also create big differences according to the yarn types. In the machines produced for the process, only advanced mechanical, electronic, material and automation engineering is not enough. For this reason, we are in constant contact with our experienced and valuable textile engineer friends and our valuable professors at Uludağ University Textile Engineering Department. We exchange information.’’
Kaya made the following evaluations considering the changes experienced worldwide and their effects on their companies; ‘‘The increase in our production volume until the 3rd quarter of 2022 has now stabilized with the crisis in the world. As a result of the energy and fuel crisis and the increase in costs, negative effects were reflected in the textile industry as in all sectors. For this reason, textile export sales decreased and we can say that the transition to a period of pause has been made.’’
‘‘We have developed smart lamella units that can read the current yarn count in the creel’’
İlker Kaya underlined that despite the unfavorable effects of these circumstances on Devsan’s orders and sales, they had the opportunity to implement the current R&D projects they had been working on throughout the process and said: ‘‘We started to use regenerative energy generation in our machines by achieving energy saving, braking with servo motor/torque mode operation that turns the drum, and regenerative energy generation in the meantime. We put smart lamella, digitalization and traceability on our agenda. We developed smart lamella units that can read the number of yarns available in the creel. We compared the number of yarn group in the warping machine being worked on with those available. In addition, the cancellation of intermediate yarns in the lamella row in the processes called reported warping has also become much easier. In the old lamella system, such cancellations were performed manually by the operator. This improvement saves a lot of time, reduces operator errors and prevents incorrect warp starts. With Industry 4.0, the concept of creating a digital twin of the machines has entered our lives. This concept is seen as a factor that will completely change the production process of machines. The Scada process helps company planning by obtaining traceability and analysis reports of the data on the machine with the Scada process.’’