Dornier D015: Dornier Dornier Weaving Machine Error Code...

Symptoms

The warp beam tension is fluctuating by more than 5% from the setpoint. The fabric shows tension bars and uneven pick density.

Step 1: Measure the actual warp tension using a hand-held tension meter
Compare to the controller reading; if different by more than 5%, recalibrate
Step 2: Inspect the warp beam tension brake for oil contamination
Clean the brake and check the friction material for wear
Step 3: Rotate the warp beam by hand (machine stopped) and feel for binding
Replace the beam axle bearing if rotation is not smooth
Step 4: Check the let-off controller PID settings against the commissioning values
Retune if the parameters have changed or the machine has been modified

Reset: After correction, run at production speed and verify tension stability within 2% of setpoint.

Load cell: Tension type, 0-5000N (Match to loom model and beam width)
Brake lining: Friction material, match to brake type (Replace if contaminated or worn)
Beam bearing: Spherical roller, match to beam axle (Replace if binding or noisy)

Q: What is warp tension?
The longitudinal force applied to the warp yarns during weaving. Correct tension ensures even fabric and prevents yarn breakage. Typical: 20-50 cN per warp end.
Q: What causes tension bars?
Periodic tension variation during let-off. Causes include brake pulsation, bearing binding, and controller tuning issues. Use a tension spectrum analyzer for diagnosis.
Q: How often should I calibrate the tension sensor?
Monthly during production, or after any beam change. Use a calibrated tension meter as reference.