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Title:
A CIRCULAR LOOM AND A METHOD FOR PRODUCING REGULATED WEFT PATTERN FABRIC, AND A WOVEN FABRIC WITH REGULATED WEFT PATTERN
Document Type and Number:
WIPO Patent Application WO/2022/101726
Kind Code:
A1
Abstract:
: The invention discloses a circular loom and a method for producing regulated weft pattern fabric where the weave density of weft yarn may be varied. It also discloses a fabric that has congestion zones (28) at predetermined locations. The main motor (1) drives the main drive (2) and a haul-off motor (15) drives a fabric haul-off drive (14). The rotational speeds of both motors (1, 15) are controlled via a main electronic control unit (34). Key weaving parameters are fed to a human machine interface (35). An incher unit (7) is provided at multiple locations along periphery of an E-ring stand (20) to facilitate the operation of the loom. The speed of the haul off motor (15) is decreased with respect to the main motor (1) such the at same interval of time more weft yarn /tape (32) will enter into the weaving pattern to form a cramming effect or congestion zone (28).

Inventors:
LOHIA GAURAV (IN)
Application Number:
PCT/IB2021/059909
Publication Date:
May 19, 2022
Filing Date:
October 27, 2021
Export Citation:
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Assignee:
LOHIA CORP LTD (IN)
International Classes:
D03D37/00
Foreign References:
US5787938A1998-08-04
JPS6359444A1988-03-15
EP0396408A11990-11-07
Attorney, Agent or Firm:
TASE, Vijay (IN)
Download PDF:
Claims:
Claim: 1. A circular loom for producing regulated weft pattern fabric characterized in that said loom comprises: - A basic frame (25) mounted on an extension base frame (24); - a main motor (1) that drives the main drive (2) which in turn rotates the main shaft (3) which is mounted on the base plate (31); - A cam (21) driven by said main shaft (3), said cam (21) being mounted on a circular cam plate (30) fitted onto said main shaft (3); - a jockey lever (9) connected to a swinging lever (10) which swings about a point, wherein at its one end, said swinging lever (10) has pair of cam rollers (11) which follow cam control curve, and at its other end, said swinging lever (10) is connected with a heald belt (12); - upper and lower pulleys mounted on upper and lower pulley blocks (4, 4A) on which said heald belts (12) are supported, wherein said heald belt (12) has an inner belt and an outer belt connected together to form a close loop such that they move vertically in opposite directions and, thus, form a fully open shed; - a circular reed ring (8) provided on the upper side of the circular base plate (31), on which a plurality of shuttles (18) travel; - creels mounted on two opposite sides of said loom through which warp tape/yarn (26) are delivered, said warp tape/yarn (26) drawn through the E-ring stand (20) via a compensation unit (5) that has compensator wires (6) passing through said heald belt (12) and further through said reed ring (8); - a fabric haul-off system (37) comprising a take-up roller (13), a haul off motor (15) and a haul-off drive (14), wherein warp/tape yarn arriving from said reed ring (8) is taken up by said take-up roller (13) through a weaving ring (17) supported by weaving ring supporter (19); wherein said main motor (1) and said haul off motor (15) are independently controlled through a main electronic control unit (34). 2. The circular loom as claimed in claim 1, wherein said swinging lever (10) to which the cam roller (11) is attached is connected to the heald belt (12) by a pin member, a vertical movement is given to the heald belt (12) by the swinging to and fro movement of the swinging lever (10). 3. The circular loom as claimed in claim 1, wherein both motors (1, 15) are controlled through a main electronic control unit (34) to which control parameters are fed through a human machine interface (HMI - 35), said HMI being mounted on said main electronic control unit (34). 4. The circular loom as claimed in claims 1 to 3, wherein said cam plate (30) has a control cam curve with respect to said heald belts (12) to form a fully open shed by passing the warps through the eyes of the corresponding heald wires, respectively, and wherein rotation of said cam plate produces a plain weave. 5. The circular loom as claimed in claim 1, wherein the rotational speed of the cam (21) which is driven by the main motor (1) is different from the rotational speed of the take up roller (13). 6. The circular loom as claimed in claims 1 to 5, wherein the predetermined speed of the haul off motor (15) is synchronized or near to same with the speed of the main motor (1). 7. The circular loom as claimed in claims 3 to 6, wherein said control parameters consist of a length of plain weave, cramming length, and cramming density. 8. The circular loom as claimed in claims 3 to 7, wherein an incher control unit (7) comprising of control buttons for start of the loom, and emergency stop of the loom, and an incher button provides input signal to the main control unit (34).

9. The circular loom as claimed in claim 8, wherein said incher control unit (7) is provided at multiple locations along the periphery of the E-ring stand (20). 10. The circular loom as claimed in claims 1 to 9, wherein a first encoder (38) is attached to said main motor to measure the rotational speed of said main motor (1), and a second encoder (39) is attached to said haul-off motor (15) to measure the rotational speed of said haul-off motor (15). 11. The circular loom as claimed in claims 3-10, wherein said main control unit (34) is capable of communicating with said HMI (35), said incher control unit (7), said motors (1, 15), and said motors (1, 15) are capable of communicating with each other. 12. The circular loom as claimed in claims 8 to 11, wherein said incher button facilitates bobbin replacement, wherein by pressing the incher button, the shuttle (18) moves for a moment in circular fashion such that its place is taken by the proceeding shuttle (18). 13. A method for producing regulated weft pattern fabric on a circular loom as claimed in claims 1 to 12, characterized in that said method comprises the steps of: a) setting up said circular loom in its stop condition; b) feeding predetermined values for the parameters of bag length, cramming length and cram density into the human machine interface (MHI – 35); c) communicating the parametric values of step (b) to the main control unit (34); d) starting the circular loom by pressing the start button on the incher unit (7); e) rotating the cam (21) using a signal sent by the main control unit (34) to the main motor (1); f) sensing the rotational speed of the cam (21) using the first encoder (38) and sending it back to the main control unit (34); g) sending a signal to the haul-off motor (15) from main control unit (34) to rotate and drive the take up roller (13) at calculated speed as per the parameters fed into the HMI (35); h) sending rotational speed of the haul-off motor (15) sensed by the second encoder (39) to the main control unit (34) ; i) forming a closed loop feedback system among the main motor (1), haul off motor (15) and main control unit (34). j) adjusting the rotational speeds of main motor (1) and the haul off motor (15) to respective predetermined values; 14. The method as claimed in claim 13, wherein in step j, the rotational speed of the haul off motor (15) is decreased with respect to that of the main motor (1). 15. A woven fabric with regulated weft pattern made using the circular loom as claimed in claims 1 to 12 and by a method as claimed in claims 13 and 14, characterized in that said fabric has congestion zones (28) identified by a greater weave density of weft yarns in said congestion zones (28) than the other areas of the fabric. 16. The woven fabric as claimed in claim 15, wherein said congestion zones (28) are formed at predetermined locations in fabric (29).

Description:
A CIRCULAR LOOM AND A METHOD FOR PRODUCING REGULATED WEFT PATTERN FABRIC, AND A WOVEN FABRIC WITH REGULATED WEFT PATTERN Field of Invention: This invention relates to a circular loom and its method for producing regulated weft pattern fabric. In particular, the present invention relates to a circular loom, a method to weave a fabric where the weave density of weft yarn may be varied and a fabric produced by the method using the said loom that has congestion zones at predetermined locations. Background of Invention: Circular looms have been known for many years for weaving a tubular fabric. Even though the structures of the shed forming mechanism and weft tape insertion mechanism are more complicated, the applicable fabric structure is limited to a plain weave structure. Furthermore, the densities of the warps and wefts constituting a woven fabric are coarser than in a woven fabric made by the conventional weaving loom. Practically, the usage of tubular fabric made from circular looms are mainly the bags made from woven fabric of a plain weave structure utilizing tapes of synthetic resins, such as polypropylene, polyethylene resins or synthetic resin strands, such as multifilament yarns or cords of synthetic resins, as warps and wefts have been broadly used for transportation and storage of granules, such as grains, sugar fertilizers and synthetic resin pellets. This is because these bags are strong and light in weight. For manufacturing these bags, a single fabric of a plain weave structure or a tubular fabric of a plain weave structure is produced by known circular looms, and then, this fabric is cut into pieces of fabric and the pieces of fabric are sewed to form the bags. Warps and wefts used for formation of these bags are much thicker and therefore, the weave densities of these warps and wefts are very coarse. Accordingly, utilization of a circular loom for producing these bags has been taken into consideration. Furthermore, a tubular fabric of a more uniform texture can be made by a circular loom and in case of a circular loom, since shuttles (18) are moved in one direction, the weaving speed can be increased. Therefore, various attempts have been made to utilize circular looms more prominently in packaging sector. In these circular looms, many warps are guided to a plurality of shed forming mechanisms arranged along an annular shuttle guide member and shuttles (18) travel in one direction along this annular shuttle guide member, prior to arrival of the shuttles (18), sheds are sequentially formed by the shed forming mechanisms and the shuttles (18) travel and pass through these sheds. Then, the sheds are closed, and prior to arrival of subsequent shuttles (18), the positions of the shed-forming warps are reversed, and sheds are sequentially formed. The shuttles (18) are then inserted and passed through these sheds to form a plain weave structure. A so-formed tubular fabric of a plain weave structure is then taken out from the circular loom. A key limitation of circular looms is that they typically produce a plain weave structure with pre-determined warp and weft density, which limits the type of fabric produced. Further, as there is pre-dominantly coarser density of weft yarn/tape, the seam strength of tubular fabric is lower. Further, there are issues with the fraying of weft yarn/tapes ends when cut pieces are made for bag making. Hence, there is need to address these issues and make better quality tubular fabric both in the strength and looks. Objects Of Invention: Main objective of this invention is to provide a circular loom and its method for producing regulated weft pattern fabric. Another object of the present invention is to reinforce the seaming area or fabric seam strength. Yet another object of the present invention is to provide a fabric where the weave density of weft yarn may be varied and that has congestion zones at predetermined locations. Further objective of this invention is to provide fabric structure such that there is reduction in fraying of weft tape on fabric cutting. Another objective of this invention is to provide a method to produce a fabric with variable mesh density at different locations. Yet another objective is to provide a different look to tubular fabric. Summary of Invention: The invention describes a circular loom and a method for producing regulated weft pattern fabric so that the weave density of weft yarn may be varied. The circular loom (36) of the present invention consists of the basic frame of the machine, which has an extension base frame (24) on which base frame (25) is mounted. On the base frame (25), various main functional elements of circular loom are mounted. The main functional elements are namely the main motor (1) which drives the main drive (2) which rotates the main shaft (3) which is mounted on the base plate (31). The main shaft (3) drives the cam plate (30) which is mounted on the circular cam plate (30) fitted with main shaft (3). The jockey lever (9) is connected to the swinging lever (10) which swings about a point. At its one end, the swinging lever (9) has pair of cam rollers (11) which follow cam control curve. At its other end, the swinging lever (10) is connected with the heald belt (12). Heald belts (12) are supported by upper and lower pulleys mounted on upper and lower pulley blocks (4, 4A). The heald belt (12) has inner belt and outer belt connected together to form a close loop such that they move vertically in opposite directions and, thus, form a fully open shed. Since the swinging lever (10) to which the cam rollers (11) are attached is connected to the heald belt (12) by a pin member, a vertical movement is given to the heald belt (12) by the swinging to and fro movement of the swinging lever (10). The warp tape/yarn (26) are delivered by the creels (not shown) mounted on both sides of loom. The warp tape/yarn (26) coming from creels are drawn through the E-ring stand (20) via a compensation unit (5) that has compensator wires (6) passing through the heald belt (12) and further through the reed ring (8) onto the take-up roller (13) of the fabric haul-off system through weaving ring (17) supported by weaving ring supporter (19). The warp tape/yarn (26) thus are drawn through the suitable warp draw roller into the shedding mechanism and then onto the weaving ring (17) wherein the formed fabric (29) is drawn upward through the fabric haul-off system. The fabric haul-off system (37) comprises a haul off motor (15) and a haul-off drive (14) and also the take-up roller (13) mounted on the take- up frame (23). The haul-off drive (14) may comprise of set of pulleys or gears which are driven by belts, these belts are connected to the haul off motor (15). The width of the hauled-off fabric is maintained using a spreader (16). Both the warp draw-roller (33) and fabric take-up roller (13) have independent drive motor and reduction gear box system. Further, the main drive motor (1) and haul off motor (15) is independently controlled through the frequency inverter drive control system. The working of both motors (1, 15) is controlled through a main electronic control unit (34) like programmable logic control unit (PLC). This PLC unit is programmed, and pre-determined control parameter are fed through human machine interface unit (HMI) (35) mounted on the main control unit (34) of machine. Further, the loom of the present invention (1) comprises of an incher unit (7) at more than one location along the periphery of the E-ring stand (20) to facilitates switching on/off the inventive loom (1) as shown in figure 1A. The incher unit (7) is a control box which comprises an indication light to indicate the state of the loom – loom operational or stopped, an incher button to facilitate shuttle manipulation, a start button and an emergency stop button to stop the loom. In a characterizing element of the circular loom (36), for a predetermined duration, the fabric haul-off system (37) drives the fabric (29) with the set pre- determined speed that is achieved by a fine control rotation of the haul off motor (15) and depend upon the rate of production which is regulated through the HMI (35) automatically. At this duration the rotational speed of the cam plate (30) which is driven by the main motor (1) is different from the rotational speed of the haul off motor (15).In such a condition, the weft density can be increased many folds than the nominal weft density in the given fabric (29) at that duration. The portion of fabric (29) formed at that duration is termed as congestion zone with congested weave (28). On the other hand, when the predetermined speed of the haul off motor (15) is synchronized or near to same with the speed of the main motor (1) a normal weave (27) pattern is obtained. The combination of the said process will obtain a woven fabric (29) as shown in figure 2. Due to the differential in speed, more weft tape/yarn (32) are crammed into the same space, thereby cramming the weft tapes to form congestion zones (28) (see Figure 2). This allows forming of a ‘congestion effect’ or periodic cramming in fabric (29). This effect can be used in periodic order to create a periodic pattern (see Figure 3) of weft tape/yarn (32) congestion zones or strips of the fabric (29) in a direction perpendicular to the length of the fabric (29), in a simple way and at predetermined distances. The congestion zones (28) are placed at predetermined locations in fabric (29) and can be used as reinforcing element for bag length start point and end point. The present invention also discloses a method to weave a fabric where the pattern may be regulated. During normal weave pattern (27), the speed of main motor (1) and the haul off motor (15) is synchronized or near to same so that the weaving pattern is uniform. However, in order to provide congestion zone with congested weave (28) the speed of the haul off motor (15) is decreased with respect to the main motor (1) such that at same interval of time, more weft yarn /tape (32) will enter into the weaving pattern to form a cramming effect or congestion zone (28). Finally, the present invention discloses a woven fabric, the characterizing feature of which is that said fabric has congestion zones (28) identified by a greater weave density of weft yarns in said congestion zones (28) than the other areas of the fabric. Brief Description of Figures Figure 1 shows a circular loom with the weft cramming assembly of the invention Figure 1A shows the perspective view of the inventive circular loom Figure 1B shows the flow diagram of process of periodic cramming Figure 2 shows the fabric with crammed weft Figure 3 shows the fabric with repeat pattern of crammed weft List of Parts: 1. Main motor 11. Cam roller 2. Main drive 12. Heddle belt (or heald belt) 3. Main shaft 13. Take-up roller 4. Upper pulley block 14. Haul-off drive 4A. Lower pulley block 35 15. Haul-off motor 5. Compensation unit 16. Spreader 6. Compensator wire 17. Weaving ring 7. Incher control unit 18. Shuttle 8. Reed ring 19. Weaving ring support 9. Jockey lever 40 20. E-ring stand 10. Swinging lever 21. Control Cam curve 22. Inlet column 31. Base plate 23. Take-up frame 32. Weft tape/yarn 24. Extension frame 33. Warp draw roller 25. Base frame 34. Electronic control unit 26. Warp tapes 15 35. HMI 27. Normal weave 36. Inventive circular loom 28. Congestion zones with 37. Fabric haul off system congested weave 38. First encoder 29. Fabric 39. Second encoder 30. Cam plate 20 Description of Invention: The circular loom (36) of the present invention is shown in Figure 1. It consists of the basic frame of the machine, which has an extension frame (24) on which base frame (25) is mounted. On the base frame (25) various main functional elements of circular loom are mounted. The main functional elements are namely, the main motor (1) which drives the main drive (2) which rotates the main shaft (3) which is mounted on the base plate (31). The main shaft (3) drives the control cam curve (21) which is mounted on the circular cam plate (30) fitted with main shaft (3). The jockey lever (9) is connected to the swinging lever (10) which swings about a point. At its one end, the swinging lever (9) has pair of cam rollers (11) which follow cam control curve. At its other end, the swinging lever (10) is connected with the heald belt (12). Heald belts (12) are supported by upper and lower pulleys mounted on upper and lower pulley blocks (4, 4A). The heald belt (12) has inner belt and outer belt connected together to form a close loop such that they move vertically in opposite directions and, thus, form a fully open shed. Since the swinging lever (10) to which the cam rollers (11) are attached is connected to the heald belt (12) by a pin member, a vertical movement is given to the heald belt (12) by the swinging to and fro movement of the swinging lever (10). A vertical movement of one of the heald belt (12) reversed to the vertical movement of the heald belt (12) is given to the adjacent heald belt (12). The same number of heald wires are held by each of the heald belt (12), which are fixedly arranged lengthwise in a space between the confronting horizontal planes of the upper and lower pulley blocks (4,4A). Further, the cam plate (30) is machined such that a control cam curve (21) is constructed on it. This control cam curve (21) has an irregular profile such that any object which moves over it follow a specified coordinate. The control curve (21) further supports a pair or the cam rollers (11) for each swinging lever (10), such that these cam rollers (11) follow the profile of the control cam curve (21). The shape of the control cam curve (21) is constructed in such a way that it provides a swinging action to the swinging lever (10). Further, the shape of the control cam curve (21) is designed with respect to movement of the heald belts (12), so that a fully open shed is formed when the warps tape/yarn (26) are passed through the eyes of the corresponding heald wires, respectively, a shed forming a plain weave (27) structure can be produced by rotation of the cam plate (30). Since a plurality of pairs of the above- mentioned paired heald belt (12) is annularly arranged along the periphery of the cam plate (30) adjacently to one another, these heald belt (12) can create successive sheds of identical shape with rotation of the control cam mechanism. Further on the upper side of the circular base plate (31), there is circular reed or the reed ring (8) forming endless track for the shuttle (18) for its rotational movement. Accordingly, if a plurality of shuttles (18), for example, six shuttles, is propelled by the respective shuttle propelling mechanisms held by the supporting member, synchronously with formation of these sheds, a tubular fabric portion of a plain weave structure can be formed by insertion of weft tape/yarn (32) by shuttles (18) into the wrap tape/yarn (26) shed formed. The warp tape/yarn (26) are delivered by the creels (not shown) mounted on both sides of the loom. The warp tape/yarn (26) coming from creels are drawn through the E-ring stand (20) via a compensation unit (5) that has compensator wires (6) passing through the heald belt (12) and further through the reed ring (8) onto the take-up roller (13) of the fabric haul-off system through weaving ring (17) supported by weaving ring supporter (19). The warp tape/yarn (26) thus are drawn through the suitable warp draw roller into the shedding mechanism and then onto the weaving ring (17) wherein the formed fabric (29) is drawn upward through the fabric haul-off system(37). The fabric haul-off system (37) comprises a haul off motor (15) and a haul-off drive (14) and also the take-up roller (13) mounted on the take-up frame (23). The haul-off drive (14) may comprise of set of pulleys or gears which are driven by belts, these belts are connected to the haul off motor (15). The width of the hauled-off fabric is maintained using a spreader (16). Both the warp draw- roller (33) and fabric take-up roller (13) have independent drive motor and reduction gear box system. Further, the main drive motor (1) and haul off motor (15) is independently controlled through the frequency inverter drive control system. The working of both motors (1, 15) is controlled through a main electronic control unit (34) like programmable logic control unit (PLC). This PLC unit is programmed, and pre-determined control parameter are fed through human machine interface unit (HMI) (35) mounted on the main control unit (34) of machine. This allows independent control for accelerating or decelerating of the haul off motor (15) with respect to the speed of rotation of the cam plate (30) as per the requirement for even fabric (29) formation. However, the speed of rotation of the cam plate (30) is governed by the main motor (1). Now as per the circular loom (36)of the present invention for a predetermined duration, the fabric haul-off system (37) drives the fabric (29) with the set pre- determined speed , this predetermined speed is achieved by a fine control rotation of the haul off motor (15) and depend upon the rate of production which is regulated through the HMI (35) automatically. At this duration the rotational speed of the cam plate (30) which is driven by the main motor (1) is different from the rotational speed of the haul off motor (15).In such a condition, the weft density can be increased many folds than the nominal weft density in the given fabric (29) at that duration. The portion of fabric (29) formed at that duration is termed as congestion zone with congested weave (28). On the other hand, when the predetermined speed of the haul off motor (15) is synchronized or near to same with the speed of the main motor (1) a normal weave (27) pattern is obtained. The combination of the said process will obtain a woven fabric (29) as shown in figure 2. As an example, if six shuttle inventive loom (1) is running at 720 ppm, the rpm at which the main motor (1) is driving the cam plate (30) is 120 rpm. The weft density is 40 tapes/10cm and tape width is 2.5mm, the production rate of 2.9 meters /min is achieved. So, the speed of the haul off motor (15) is automatically set to a value known as predetermine value such that it pulls the fabric (29) vertically upwards at the rate of 2.9 meters /min. Figure 1A shows a perspective view of the inventive circular loom (1) wherein direction of movement of the following is defined: ● Cam plate (30) moves in the clockwise or counter clockwise direction, the drive is provided by the main motor (1) located on the base plate (31). The same movement is provided to the shuttle (18) which carriers weft yarn/tape (32). ● The fabric (29) which is being woven, moved in the vertically upwards direction. The movement of the fabric (29) is governed by the take-up roller (13). ● Warp yarn /tape (26) is drawn by the warp draw roller (33) and guided into the heald belt (12), direction of movement is shown by broken arrow such that its passes through the reed ring (8) and then to the weaving ring (17) for weaving. The circular loom (1) of the present invention further comprises of a main electronic control unit (34) The control unit (34) is programmed, and pre- determined control parameter are fed through human machine interface unit (HMI) (35) mounted on the main control unit (34) of machine. The various parameters are feed through the HMI such as: ● Bag length which is defined in centimeters and is termed as the length of the fabric (29) required with the plain /normal weave (27) ● Cramming length which is defined in centimeters and termed as the length of fabric (29) required with congested weave (28) ● Cram density which is defined in percentage and termed as how dense the weft tape/yarn (32) is present at the cramming length. The above said parameter are feed into the HMI (35) to obtain a periodic camming or congestion weave (28) pattern along with the normal weave (27). Further, loom (1) of the present invention comprises of an incher unit (7) at more than one location along the periphery of the E-ring stand (20) to facilitates switching on/off the inventive loom (1) as shown in figure 1A. The incher unit (7) is a control box which comprises of following buttons or indications as shown in figure 1B: ● Indication light – changes from green, yellow and red depending upon the process such as green light indicates that the machine is running, yellow light indicates that the bobbin change over in shuttle (18) is happening or inching process is performing and red light indicates that the machine is stopped. ● Incher button – as the bobbin in the shuttle (18) is exhausted, the operator manually changes the bobbin. A loom (1) having pularity of shuttles arranged in the circumference of the reed ring (8), needs to be replaced at a single time, so incher button provides operator an easy way such that operator does not have to move circumferentially for each bobbin replacement. By pressing the incher button, the shuttle (18) moves for a moment in circular fashion such that its place is taken by the proceeding shuttle, in this process operator does not have to move anywhere but to stand at a particular location. While pressing the incher button one by one operator can easily change all the bobbins. ● Start button – To start the machine ● Emergency stop button – To stop the machine Figure 1B shows the flow diagram of the process of periodic cramming wherein incher control unit (7) is present which provides an input signal to the main control unit (34) to start the machine or even provide signal during emergency stop. The input parameters are feed into the HMI (35). The HMI (35) sends the signals to the main control unit (34) which in turn send the signals to the main motor (1). Subsequently, the rotational speed of the main motor (1) is measured by the first encoder (38) which is affixed to the main motor (1). The first encoder (1) can be chosen from a group of detecting devices such as proxy, magnetic encoders, optical detectors such that it calculates the pulse or rotational movement of the motor (1) and send the feedback to the main control unit (34). Now based on the feedback received from the main motor (1), the main control unit (34) sends communication signal to the haul off motor (15) to adjust its rotational speed forming a close loop. The second encoder (39) which is affixed to the haul off motor (15) measures the rotational speed of it and provides a feedback to the main control unit (34). Based on feedback of first encoder (38) and second encoder (39), the speed of the haul off motor (15) is regulated to produce a fabric (29) as shown in figures 2 and 3. Due to differential in speed of the main motor (1) and haul off motor (15) a congestion zone with congested weave (28) is obtained which is known a weft cramming. If the periodic cramming is required at particular instant or for period of time/length of the fabric (29) , the speed of the haul off motor (15) is decreased but the speed of the main motor (1) or the speed of the cam plate (30) or the speed of the shuttle (18) remains normal as all the three speed as defined are almost same as the parts are connected to each other. Due to the differential in speed more weft tape/yarn (32) are crammed into the same space, thereby cramming the weft tapes to form congestion zones (28) as shown in the congested weave in Figure 2. This allows forming of a ‘congestion effect’ or periodic cramming in fabric (29). This effect can be used in periodic order to create a periodic pattern (see Figure 3) of weft tape/yarn (32) congestion zones or strips of the fabric (29) in a direction perpendicular to the length of the fabric (29), in a simple way and at predetermined distances. The congestion zones (28) are placed at predetermined locations in fabric (29) and can be used as reinforcing element for bag length start point and end point. During the production of sacks, the bag length cutting can be precisely made within the congestion zones (28). The advantage of the congestion zones (28) formed by higher weft density is that it gives higher seam strength to the stitch done at that location during bag bottom formation. Further, the higher weft density at top edge of bag helps to avoid the fraying of weft ends as there’s a greater possibility of heat fusing these ends upon cutting of fabric (29). It also allows increased the top seam strength. From the foregoing discussion, it is evident that the circular loom of the invention has a number of embodiments. In its preferred embodiment, the circular loom for producing regulated weft pattern fabric comprises: - a basic frame (25) mounted on an extension base frame (24); - a main motor (1) that drives the main drive (2) which in turn rotates the main shaft (3) which is mounted on the base plate (31); - A cam (21) driven by said main shaft (3), said cam (21) being mounted on a circular cam plate (30) fitted onto said main shaft (3); - a jockey lever (9) connected to a swinging lever (10) which swings about a point, wherein at its one end, said swinging lever (10) has pair of cam rollers (11) which follow cam control curve, and at its other end, said swinging lever (10) is connected with a heald belt (12); - upper and lower pulleys mounted on upper and lower pulley blocks (4, 4A) on which said heald belts (12) are supported, wherein said heald belt (12) has an inner belt and an outer belt connected together to form a close loop such that they move vertically in opposite directions and, thus, form a fully open shed; - a circular reed ring (8) provided on the upper side of the circular base plate (31), on which a plurality of shuttles (18) travel; - creels mounted on two opposite sides of said loom through which warp tape/yarn (26) are delivered, said warp tape/yarn (26) drawn through the E-ring stand (20) via a compensation unit (5) that has compensator wires (6) passing through said heald belt (12) and further through said reed ring (8); and - a fabric haul-off system (37) comprising a take-up roller (13), a haul off motor (15) and a haul-off drive (14), wherein warp/tape yarn arriving from said reed ring (8) is taken up by said take-up roller (13) through a weaving ring (17) supported by weaving ring supporter (19). In the aforementioned preferred embodiment, the main motor (1) and said haul off motor (15) are independently controlled through a main electronic control unit (34). In another embodiment of the circular loom the swinging lever (10) to which the cam roller (11) is attached is connected to the heald belt (12) by a pin member, a vertical movement is given to the heald belt (12) by the swinging to and fro movement of the swinging lever (10). In yet another embodiment of the circular loom both motors (1, 15) are controlled through a main electronic control unit (34) to which control parameters are fed through a human machine interface (HMI - 35), said HMI being mounted on said main electronic control unit (34). In still another embodiment of the circular loom the cam plate (30) has a control cam curve with respect to said heald belts (12) to form a fully open shed by passing the warps through the eyes of the corresponding heald wires, respectively, and wherein rotation of said cam plate produces a plain weave. In a further embodiment of the circular loom the rotational speed of the cam (21) which is driven by the main motor (1) is different from the rotational speed of the take up roller (13). In another embodiment of the circular loom the predetermined speed of the haul off motor (15) is synchronized or near to same with the speed of the main motor (1). In yet another embodiment of the circular loom the control parameters consist of a length of plain weave, cramming length, and cramming density. In yet further embodiment of the circular loom an incher control unit (7) comprising of control buttons for start of the loom, and emergency stop of the loom, and an incher button provides input signal to the main control unit (34). In a still further embodiment of the circular loom the incher control unit (7) is provided at multiple locations along the periphery of the E-ring stand (20). In another embodiment of the circular loom a first encoder (38) is attached to said main motor to measure the rotational speed of said main motor (1), and a second encoder (39) is attached to said haul-off motor (15) to measure the rotational speed of said haul-off motor (15). In yet another embodiment of the circular loom the main control unit (34) is capable of communicating with said HMI (35), said incher control unit (7), said motors (1, 15), and said motors (1, 15) are capable of communicating with each other. In a further embodiment of the circular loom the incher button facilitates easy bobbin replacement, wherein by pressing the incher button, the shuttle (18) moves for a moment in circular fashion such that its place is taken by the proceeding shuttle (18). Another preferred embodiment of the invention discloses a method for producing regulated weft pattern fabric on a circular loom. The fabric has a composite weave. The method comprises the steps of: a) setting up said circular loom in its stop condition; b) feeding predetermined values for the parameters of bag length, cramming length and cram density into the human machine interface (MHI – 35); c) communicating the parametric values of step (b) to the main control unit (34); d) starting the circular loom by pressing the start button on the incher unit (7); e) rotating the cam (21) using a signal sent by the main control unit (34) to the main motor (1); f) sensing the rotational speed of the cam (21) using the first encoder (38) and sending it back to the main control unit (34); g) sending a signal to the haul-off motor (15) from main control unit (34) to rotate and drive the take up roller (13) at calculated speed as per the parameters fed into the HMI (35); h) sending rotational speed of the haul-off motor (15) sensed by the second encoder (39) to the main control unit (34) ; i) forming a closed loop feedback system among the main motor (1), haul off motor (15) and main control unit (34). j) adjusting the rotational speeds of main motor (1) and the haul off motor (15) to respective predetermined values; In another embodiment of the method, in step j, the rotational speed of the haul off motor (15) is decreased with respect to that of the main motor (1). In yet another preferred embodiment of the invention, a woven fabric made using the circular loom of the invention and by a method described here is disclosed. The fabric has a composite weave. It has congestion zones (28) identified by a greater weave density of weft yarns in said congestion zones (28) than the other areas of the fabric. In another embodiment of the fabric, the congestion zones (28) are formed at predetermined locations in fabric (29). While the above description contains much specificity, these should not be construed as limitation in the scope of the invention, but rather as an exemplification of the preferred embodiments thereof. It must be realized that modifications and variations are possible based on the disclosure given above without departing from the spirit and scope of the invention. Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their legal equivalents.