Drum and take-up unit selection¶
Reference — Calculation: from the carrier loading to product length and weight, plus the drum suggestion from the drum master data and the suitable take-up units
Purpose¶
This calculation leads in one step from the carrier loading to the take-up unit. From bobbin, material, fineness, ply count, number of carriers and braiding angle, product length and weight are obtained as in the other calculations, and with the product diameter the space required. From this, the page suggests drums from your drum master data and names the take-up units that can carry the drum dimensions, product diameter and weight — from your Machine Fleet or from the Herzog catalogue. If the product does not fit onto one drum, the page splits it across several.
New as of version 2.1.0
The calculation is located under Calculations > Product. Prerequisites are drums in the master data and — for the Machine Fleet source — created take-up units.
Inputs¶
The inputs are divided into four sections.
Braid¶
| Field | Unit / selection | Meaning |
|---|---|---|
| Carrier bobbin: | – | Bobbin from the bobbin master data. Its bobbin volume determines how much yarn fits on one bobbin. |
| Material: | – | Material from the master data; takes over density and fineness. |
| Fineness: | tex, dtex, den, Nr_metric, Nr_english | Fineness of one thread. |
| Density: | g/cm³ | Density of the material (three decimal places). |
| Ply count: | pcs | Threads per carrier; preset to 1. |
| Bobbin filling grade: | % | Share of the bobbin volume that the yarn fills; preset to 70 %. Together with fineness, density and ply count, this gives the yarn length per bobbin, as in Material length on bobbin. |
| Number of carriers: | pcs | Number of carriers. |
| Braiding angle: | ° | Braiding angle of the braid. |
| Product diameter: | mm | Counts for the space on the drum, for checking the take-up units and — with a core — for their diameter. Length and weight of the cover come from material, fineness and braiding angle. |
Core¶
Only for products with a core, such as a core-cover rope. The details under Braid then apply to the cover; the core only counts towards the weight, the length is supplied by the cover bobbins.
| Field | Unit | Meaning |
|---|---|---|
| Core share: | % | Share of the core in the cross-section of the product, as in Core-cover product. Leave empty if the product has no core. |
| Material: | – | Material of the core; takes over the density. |
| Density: | g/cm³ | Density of the core. Mandatory as soon as a share is entered. |
| Filling grade: | % | Filling grade of the core as in Core-cover product; preset to 65 %. Mandatory as soon as a share is entered. |
Drum¶
| Field | Unit | Meaning |
|---|---|---|
| Filling grade on the drum: | % | Share of the drum volume that the braid fills. The round braid leaves cavities; 70 to 80 % is usual. Preset to 75 %. |
| Flange clearance: | mm | Distance of the top layer below the flange edge. At 0 mm (default) the calculation goes up to the flange edge, as with the volume figures of the Herzog drums. |
Take-up units¶
| Field | Selection | Meaning |
|---|---|---|
| Take-up units from: | Machine Fleet (default) or Herzog catalogue | Where the take-up units for the check come from: your created take-up units or all take-up unit models from the Herzog catalogue. |
| Split: | Equal portions, Full drums + remainder, Remainder on a smaller drum | How the product is distributed if it does not fit onto one drum (see below). |
Mandatory details
Carrier bobbin, fineness, density, ply count (at least 1), bobbin filling grade, number of carriers, braiding angle, product diameter and filling grade on the drum must be filled in; with a core share, also the density and filling grade of the core. Missing values are marked red.
Result¶
| Value | Unit | Meaning |
|---|---|---|
| Product length: | m | Product length that a full bobbin set delivers (highlighted in blue). |
| Drums: | – | The drum suggestion, e.g. "3 × Wooden drum …, 23.6 m each + 1 × …, 11.6 m each". For a reel take-up unit it reads "Reel of the …". |
| Take-up unit: | – | The first suitable take-up unit per part, with "(+… more)" if there are several. |
| Space required on the drum: | l | Space taken up by the product length at the full product diameter. |
| Product weight: | kg | Weight of the entire product length. |
| Weight per meter: | g/m | Weight per meter, including the core. |
| of which core: | g/m | Share of the core in the weight per meter (only with a core). |
| Total weight per drum: | – | Product plus empty weight of the drum, per part of the suggestion. If the empty weight is missing, it reads "… kg + empty weight"; for a reel "… kg without reel". |
| Check: | – | All checks passed. or Cannot be checked: … with the missing details (see below). |
Table "Drums and reels"¶
To the right of the inputs, the page lists all drums from the master data and the reels of the reel take-up units, sorted by size:
| Column | Meaning |
|---|---|
| Drum / reel | Name of the drum (with article number in brackets, if maintained) or Reel of the …. |
| Capacity | Product length that fits onto one drum. |
| Count | Drums of this type for the whole product. |
| Suitable take-up units | Up to three take-up units, followed by (+…); all are listed in the tooltip. |
| Note | Why a drum does not work or what is missing (see below). |
The suggestion is highlighted in blue; drums that do not fit any take-up unit are gray.
Operation¶
The common structure of all calculation pages is described in How calculation pages are structured. The page reads the drums from the master data anew with every calculation — changes in the drum editor take effect immediately.
The suggestion¶
From the setup to the suggestion, the page proceeds in these steps:
flowchart TD
B[Carrier setup<br>bobbin, material, fineness, ply count] --> P[Product length<br>and product weight]
P --> K[Capacity of each drum,<br>limited by the load capacity]
K --> E{Does everything fit<br>on one drum?}
E -- yes --> S[Smallest suitable drum]
E -- no --> A[Split across<br>several drums]
S --> W[Check take-up units]
A --> W
W --> V[Suggestion: drums<br>and suitable take-up units]If the whole product fits onto one drum, the page suggests the smallest suitable drum. Otherwise it splits according to the selected Split:
| Split | Result |
|---|---|
| Equal portions | The drum type with the fewest drums (if tied, the smaller one); the product is distributed evenly across all of them. |
| Full drums + remainder | The same drum type; all drums except the last are wound full, the remainder goes onto another drum of the same type. |
| Remainder on a smaller drum | Full drums of one type, the remainder onto the smallest drum that can take it. The solution with the fewest drums is chosen; if tied, the one with the smaller total volume. |
The capacity of a drum follows from its bobbin volume in the master data, the Filling grade on the drum and the Flange clearance. For a reel, the reel volume of the take-up unit counts; there is no flange clearance there. If the load capacity of a take-up unit limits the length per drum, the page calculates with the shorter length.
What is checked¶
For each take-up unit, the page compares drum outer diameter, drum width, product diameter and the weight of product and empty drum with its limits — the details are described under Take-up units. Reel take-up units do not take a drum; for them only product diameter and load capacity count.
Not checkable instead of silently suitable
If a detail is missing, the calculation says not checkable instead of reporting a drum as suitable. Possible reasons: Take-up unit drum diameter missing, Take-up unit traverse width missing, Take-up unit load capacity missing, Drum empty weight missing, Weight per meter missing. Take-up units with missing details remain in the suggestion, but are listed after those that definitely fit.
The following appear in the Note column of the table:
| Note | Meaning |
|---|---|
| No take-up unit accepts this drum | The drum dimensions do not fit any take-up unit. |
| Does not fit | A reel cannot hold the product. |
| Product diameter fits no take-up unit | The drum fits, the product is too thin or too thick. |
| Too heavy for every take-up unit | Dimensions and product fit, the weight does not. |
| Load capacity: at most … m per drum | The load capacity limits the length on this drum. |
| Empty weight missing | The drum has no empty weight in the master data. |
Messages without a suggestion¶
| Message under Check | Remedy |
|---|---|
| No take-up unit has been created in the Machine Fleet. Choose the Herzog catalogue as the source. | Create take-up units or select Take-up units from: Herzog catalogue. |
| There are no drums yet. Add them under Master data → Drums with "From Herzog catalogue …". | Create drums in the master data or take them over from the catalogue. As of version 2.1.0, new workspace folders start without drums. |
| The product does not fit into the winding space of any drum. | Create a larger drum or check the product diameter. |
| No drum fits any of the take-up units. See the notes in the table. | The Note column gives the reason for each drum. |
Calculation¶
The exact calculation formula is not part of this documentation.