When a carpet order is created, the dents that are not used in paths are divided among Rest zones or Free zones as explained here: Calculation of rest- and free zones.


The allocation of the rest and free zones is done by the parameters in the Configure step of the Carpet order (under Production orders in the SCHEDULING section).


Remaining number of dents = number of machine dents - number of dents of the paths.


These dents are first assigned to the free zones Left of the first path (14 in the example below), Right of the last path (7 in the example below) and In between all the paths (1 in the example below).


If there are still unassigned dents, these will be automatically assigned to the rest zone (which can be put Left, Right, Symmetrical or User-defined.



If the number of remaining dents is very small, it might not be efficient to create a rest zone containing pole yarns. You can always reassign rest and free zones after verifying your carpet order, but it is also possible to set a minimum width for the rest zone, to avoid weaving pole rest zones.


To divide the remaining dents automatically over the free zones instead of creating a rest zone with rest pattern, set the value of Minimum width in the custom settings of a production order.



What value should I set?


You should set the the Minimum width of the Rest zone. If the remaining number of dents (= width of the machine - width of the paths - width of the desired free zones) is smaller than this width, the remaining dents will be divided among the Free zones. If the remaining number of dents is larger than this value, a rest zone will be created with the pattern selected as rest zone. 


To consider:

  • If a rest zone is created because the remaining number of dents is larger than the minimum width of a rest zone and the free zone next to the rest zone is 0 dents, this free zone will be set to 1 dent, so it is possible to cut between the pole yarns of the rest zone and the start of the carpet.
  • If you always want to add one dent to the free zone that is next to a rest zone but you don't want to divide the dents automatically (and the free zone is set to 0 dents), you set this value to 1.


Rules followed to divide the dents

  • If the rest zone has more dents than is set, as described above, if the free zone next to it is 0 dents, it will be set to 1:



This results in:

  • If the remaining number of dents is less or equal than the minimum, and you only have one path, the dents for rest will be equally added to free zone left and free zone right.
  • If the remaining number of dents is less or equal than the minimum, and you have one in between zone, the dents from the rest zone will be added to the in between free zone.
  • If the remaining number of dents is less or equal than the minimum and you have multiple paths, the dents will be divided over the in between free zones.


If it cannot be divided evenly over the free zones, one dent will be added to the free zones in following order:

  • If the widest path is situated on the left, a dent will be added to the free zone on the right of the widest path.
  • If the widest path is situated on the right, a dent will be added to the free zone on the left of the widest path.
  • If the widest path is in an other place, a dent will be added next to the widest path. Dents will always be added in between widest paths.
  • When the first dent is added, this procedure is repeated for the remaining number of dents.


Carpet order verify step


When a carpet order is verified, a suggestion to put the rest and free zones is made. See also Carpet order verification & confirmation.