Volkmann CarpetCabler

Direct-Cabling Machine

Why are carpet yarns directly cabled on Volkmann cabling machines ?

Cabling is a mechanical yarn upgrading process which precedes carpet production. Cabled yarns are ideal for ensuring the formation of a high-quality pile during the manufacture of rugs and carpets.

In the direct cabling process, two yarns are twisted around each other in a single operation without the individual strands themselves being twisted.
This ensures better cohesion, and associated with this, a better degree of fiber support. The pile is both upright and stable once it has been incorporated in the backing fabric or nonwoven matting.

In contrast to the Two-for-One twisting process, the yarn balloon contains only one yarn with a correspondingly low level of air resistance. Energy consumption levels are thus also considerably smaller. Because only one yarn is drawn from the pot, double-length feed packages can be processed in one loading. This ensures long operating times and the manufacture of substantial knot-free lengths of cabled yarn.

Yarn path with direct-cabling.

In a direct-cabling machine, one feed-package is loaded into the protection pot.
The yarn end is unwound and tensioned by a yarn-brake located above the package in the pot.
The second feed-package is loaded into a creel, unwound, and tensioned slightly before it enters the lower hollow shaft of the spindle.
This yarn end wraps around the storage disc and forms a balloon around the pot package.
At the balloon apex, both yarns meet and wrap around each other, which thus dissolves the false twist in the balloon yarn.
At the meeting point, both yarns must have the same tension in order to form a balanced composite yarn with no residual torque and equal lengths of component yarns.

In practice, the precise setting of the tension is determined by experiment.
Whenever the spindle speed is altered, the pot-yarn tension must be adjusted to compensate for a consequent increase or decrease in balloon tension.
The most accurate test for balanced conditions is to measure the lengths of both ends after unplying and detwisting.