Realization of a Novel Weaving Framework in Looms for Manufacturing of E-Textiles

A novel embedded control-based weaving system for the fabrication of four-layered e-textiles has been realized in this work. The technique used for 3-D woven structure manufacturing has been utilized. In order to integrate all the layers in a 3-D structure binder yarn is used. In this system, the weft yarns are used for binding instead of a dedicated binding yarn. A novel weft insertion unit for simultaneous picking for all the layers including binding has been designed and developed. The machine is operated with a motor selection algorithm for efficient usage of servo motors. The stepwise weaving operation proposed in this research, assures a short circuit-free structure when conductive yarns are used. In addition, provisions have been made for varying the space between warp yarns to accommodate all kinds of yarns. The system performance has been validated by fabricating a four-layered 2.4 GHz radiofrequency (RF) transceiver employing silver conductive yarns. The performance characteristics of the transceiver have also been discussed.