weaving-airjet air consumption
TRANSCRIPT
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Study of AIR CONSUMPTION n AIR JET weaving machines.
D.K.T.E's, karanji.
1
o
Textile & Engineering Institute, Ichal
Study of Air Consumption on Air Jet
Weaving Machine
By:
Arif K Naikwade &
Nilesh Zambare
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Study of AIR CONSUMPTION on AIR JET weaving machines.
OBJECTIVE: To study the consumption of air in air jet weaving machines. SPECIFIC OBJECTIVE: Reduction in the consumption of air on existing machines.
By:
ARIF K NAIKWADE
&
NILESH ZAMBARE
2D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
ABSTRACT As it is well known, power consumption due to compressed air is
the main disadvantage of Air jet loom when compared to rapier
and projectile looms. This is making air jet less preferable where
energy cost is the problem, despite their high production speeds.
Studies which have been taken to reduce them, included
manufacturing of different parts i.e. researches have been taken
place on the manufacturing levels. But, we decided to reduce the
consumption of air which may be due to some wrong settings,
ignorance, etc. without any investment which can give profits to
the mill by reducing the consumption of air. A decrease of air
consumption by 18% was accomplished in a weaving mill by just
changing the process parameters consisting mainly the blowing
time of nozzles. By improving work practices i.e. by implementing
KAIZEN we could save the compressed air.
3D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
Introduction to AIRJET
For the weft insertion mechanisms of air jet looms, the
profile reeds with sub-nozzle systems are the most advantageous in
terms of improving high speed weaving and wider cloth width. Not
only the airflow from the main nozzle and sub-nozzles but also the
airflow in the weft passage is closely related to the flying state of
the yarn at the time of weft insertion in this system. In order to
manufacture high quality textiles with air jet looms, it is necessary
to establish optimum weaving conditions. These conditions include
the supply air pressure and air injection timing for the main nozzle
and sub-nozzles according to the kind of well yarn. Energy saving
is the most important of the technical subjects related to air jet
looms today. Research about the improvement in performance of
main nozzles and sub-nozzles, which plays an important role for
weft insertion, has been performed by various researchers.
4D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
Although some effort has been made to improve the
efficiency of compressed air usage, the effort has not been
uniform. There is still a critical need to understand the energy loss
or consumption in filtration, distribution and machine usage in the
textile industry. Due to technical barriers, reducing energy
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Study of AIR CONSUMPTION on AIR JET weaving machines.
consumption by compressed air systems has been viewed as a
complicated task.
Intensive efforts have been made by researchers and air-jet
loom makers to overcome this problem and achieve a dramatic
reduction in air consumption without any decrease in loom
performance and fabric quality, but due to faulty mill practices and
ignored settings, air consumed by looms is on higher side. So, our
project aims to reduce the air consumption significantly, by
optimizing some loom parameters. These parameters, includes
mainly the relay nozzles because they consume 80% of the
compressed air produced.
TERMS Air Index value A term designated to quantify the velocity of
yarn in air as well as the deviation in velocity when tested on a
diagnostic testing machine known as the Air Index Tester.
5D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
Arrival Time The amount of time required for the pick to travel
the width of the fabric being manufactured during weaving,
expressed either in terms of degrees of shed rotation or units of
time.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
Count A numerical designation of yarn size indicating the
relationship of length to weight, defined as the amount of 840-yard
skeins required to weigh one pound.
Filling Stop A temporary shut down of a weaving machine due
to an error in filling yarn insertion.
Pick the length of yarn required to be woven into a particular
width of fabric.
Spun Yarn A cotton-based yarn consisting of staple fibers
usually bound together by twist.
Yarn Hairiness A quantitative method of describing the surface
roughness of cotton based spun yarn by counting the amount of
broken fibers that protrude from the surface of the yarn, giving it a
fuzzy appearance.
Yarn Package a large spool of yarn.
Brief Description of Air Jet
Looms
6D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
Fig. a modern AIR JET weaving machine.
Filling feeding system
7D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
The air jet loom feeds the filling as in Figure 1. The filling length
is measured according to the width of the fabric by 1 rotation of
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Study of AIR CONSUMPTION on AIR JET weaving machines.
the loom. It is accelerated by the main nozzle at a specific timing,
and is inserted into the air guide o the reed. Groups of sub-nozzles
are located across the whole width. Each group jets compressed air
in a specific order to feed the filling tip to the right end of the
fabric. The compressed air is supplied from the compressor, its
pressure is adjusted by the regulators for the main nozzle and the
sub-nozzles, and it is stored in the proper tank. The control system
of the loom opens and closes the electro-magnetic valve, and sends
the compressed air to the nozzles.
Cost Effectiveness of Shuttle less Looms
Shuttle less looms have numerous advantages over shuttle looms.
Some of these are:
Increase in loom productivity, Increase in weaver productivity, Improvement in the quality of fabric, Longer lengths and wider widths fabrics can be produced, As many as 16 colours of yarn in the weft can be used
without sacrificing the speed of the machine,
Increase in versatility,
8D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
Use of weft accumulators, which reduces average tension on weft during insertion of weft, equalizes yarn tension caused
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Study of AIR CONSUMPTION on AIR JET weaving machines.
by the diminishing diameter of weft supply package, avoids
snarls in the weft and gives fewer weft breakages,
Reduces cost of production due to higher productivity and better value realization due to improved fabric quality.
9D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
Comparative labour costs (excluding fringe benefits) for inserting
10,000 picks are worked out and are given in Table-2. The
assumptions made for arriving at the labour costs are also give in
this table.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
10D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
Comparative power consumption figures for different types of
shuttle less looms and the shuttle loom (for 190 cm width looms)
are worked out (i.e. estimated) and are given in Table-3.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
Figures in Table-3 are only for loom drive and do not include power requirement for humidification, lighting, etc.
Optimisation of Compressed Air Cost
Compressed air cost can be minimised broadly in two ways. One,
by minimising wasteful consumption of compressed air i.e. by
preventing compressed air leakages and secondly by improving the
efficiency of compressors. Ways and means for both these aspects
are discussed.
11D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
Preventing Air Leakages
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Study of AIR CONSUMPTION on AIR JET weaving machines.
Leakages usually occur in small openings; but the
cumulative effect is great. Some tips for preventing the air leakage
are given herewith.
Standardise on good hose clamps; Inspect steam packing of valves in the system periodically,
repack when necessary.
Replace/repair leaky shut-off valves. Install condensate separators with automatic traps to
eliminate the need for operators, opening the manual valve to
clear water, thereby wasting air.
Use good quality air hoses to avoid breaks and leaks.
Dont blow away your money!
Leaks may cost you significant amounts of money and CFM each year.
A 1/16 leak may cost $523, 6.49 CFM A 1/8 leak may cost $2,095, 26 CFM A 1/4 leak may cost $8,382, 104 CFM
12D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
Improving Volumetric Efficiency of Air Compressors
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Study of AIR CONSUMPTION on AIR JET weaving machines.
Volumetric efficiency of an air compressor has a
significant bearing on the operational cost of air compressors. Low
volumetric efficiency results in higher per unit cost of compressed
air. The main contributing factors for low efficiency are:
Clogged air inlet filters. Obstruction at the inlet valve. Piston ring leakage. Hot inlet air. Inter cooler working inefficiently. Increase in impeller-diffuser clearance in case of centrifugal
compressors.
It is therefore, necessary to check the volumetric efficiency
periodically and if it falls below stipulated value the compressor
should be checked and attended.
13D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
Cost Reduction Opportunities
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Study of AIR CONSUMPTION on AIR JET weaving machines.
Cost reduction opportunities that were explored include re-
use of plant air, compressor motor selection, optimizing
compressor control schemes, recovering the heat of compression,
ensuring that the distribution lines are properly configured and free
of leaks, and determining the minimum pressure and flow
requirements at the end use.
Air Intake Typically, the air being compressed is taken from outside
the plant, from air at ambient temperature and relative humidity.
This creates wide varieties of conditions that the compressor has to
be adjusted to meet. During the summer months, the compressor is
under the greatest load. The volumetric flow rate of the inlet must
be higher (around 10%) to provide the same SCFM (standard cubic
feet per minute) during the summer months as in the winter.
14D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
After air is used at its point of operation, it is added to the
air already in the plant. This additional volume of air must leave
the plant somehow, i.e. open doors, cracks in door and window
frames, etc. This air that is being leaked from the plant would have
much lower moisture content than the outside air. The air inside
the plant will also have a higher density in the summer months due
to a lower temperature. The implementation of a system that
recovers the conditioned plant air may prove to be useful in
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Study of AIR CONSUMPTION on AIR JET weaving machines.
reducing air compression costs. The potential energy savings from
reusing this already dry air could be significant when the
conditions outside the plant are extremely hot and humid. Certain
geographic locations would benefit more than others from this
reuse which has extremely hot and humid summer months. The
installation cost of such a system can be very high for an existing
plant, but this option should be considered when a new plant is
designed.
Compressor Motor Efficiency Improvements in motor design have led to increased energy
efficiency in motor operation. New motors that are suitable for
textile manufacturing plants operate at an efficiency of 95%,
comparing to motors designed 15 years ago at 90% or less. Over
time, the efficiency of the motors may be reduced. It is not
uncommon for the efficiency to drop several percentage points
after 10 years of operation. High efficiency new motors should be
considered when a replacement or major maintenance is needed on
the motors.
15D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
Compressor Controls
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Study of AIR CONSUMPTION on AIR JET weaving machines.
Centrifugal compressors typically use inlet guide vanes to
control the airflow through the compressor. This throttling is
beneficial in that the efficiency is not reduced significantly with
this method of control. The typical throttle range is down to around
80% of maximum airflow capacity. The highest efficiency is
reached when the compressor is operating at 100% capacity. If air
is not being used on the demand side as fast as it is being
produced, the pressure will rise in the air receiver. A compressor
(or multiple compressors) must be throttled to prevent this. All of
the compressors should be operating at full capacity except for the
one(s) being throttled. If the total compressor output is still greater
than the demand after the compressor(s) has been throttled to their
limit, air must be exhausted from the system through the blow-off
valve. An appropriate control scheme can reduce or eliminate this
wasteful blow-off. A precise compressor control scheme with little
pressure variation is desired. The compressor does not need to
produce air at a higher pressure than the minimum pressure
required for proper plant operation. The typical pressure output by
a compressor tends to fluctuate somewhat throughout the day. A
good control scheme would minimize these fluctuations.
16D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
Distribution Lines
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Study of AIR CONSUMPTION on AIR JET weaving machines.
The distribution system represents a great source for energy
savings. There are pressure drops associated with the flow through
all equipment in the line, even in the piping itself. The pressure
drop from the point of use and from the output of the compressor
should be as low as possible. Equipment should be properly sized
to give a minimum pressure drop. End use equipment should be
evaluated so that it is using the lowest possible pressure and flow.
The ultrasonic detector is able to focus the sensor at a specific
point, making it suitable for detecting leaks while machinery is in
operation. Escaping air produces the highest noise levels at a
frequency around 40 kHz, well beyond the human audible
frequency range. The device measures the loudness level at this
frequency. Estimates of the amount of air can be obtained from the
dB reading.
End Use
17D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
Compressed air savings at the end use leads to a direct
reduction in the amount of compressed air needed for operation. A
general rule of thumb is that 1 SCFM of air costs approximately
$65 per year in a large manufacturing plant. Savings at end use can
be achieved by either reducing the airflow through the equipment,
or by lowering the pressure at the point of use. Lowering the
pressure at end use will also have a natural flow reduction effect.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
The flow and pressure reduction must occur without impacting
performance. Manufacturing plants should continually monitor
production equipment to make sure the minimum pressure and
airflow are being used.
Physical properties and characteristics of yarn
Several physical properties and characteristics
of yarn are thought to have an effect on yarn velocity in air jet
weaving applications. The yarn characteristic thought to have the
most effect on yarn velocity (and therefore, Air Index value) is the
yarn hairiness, which is a quantitative means of describing the
surface roughness of a cotton-based spun yarn. Yarn hairiness is a
means of counting the broken fibers that protrude from the surface
of a spun yarn, giving the yarn a fuzzy appearance. It is
hypothesized that yarns with higher hairiness values will result in
higher Air Index values, due to an increase in surface area of the
yarn for the air to push on; i.e., an increased aerodynamic drag.
18D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
Other physical characteristics of yarn will be investigated
in this report to determine whether or not they have an influence on
Air Index value, especially yarn count. The count of a spun yarn is
a numerical designation of yarn size that relates the length of the
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Study of AIR CONSUMPTION on AIR JET weaving machines.
yarn to its weight, as well as describing its diameter. The higher
the yarn count, the smaller the diameter and density of the yarn is,
so it is thought that higher yarn counts will result in higher Air
Index values. This is due to the increased surface area-to-mass
ratio as yarn count is increased.
Figure: Schematic of Air-Jet Weaving Machine and Process
19D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
Fig. shows a schematic of a typical air-jet weaving
machine with the primary machine components labeled. As
previously mentioned, air-jet weaving is a process that uses
compressed air to drive filling yarn perpendicular to and through a
warp. The warp is a set of longitudinal yarn threads on a large
spool that runs parallel to the selvage (fabric edge) and is
interwoven with the filling. The filling yarn is supplied to the pre
winder, which wraps the yarn until the correct pick length has been
detected. The pick is the length of yarn required to be woven into a
particular width of fabric. The pick is then supplied to the
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Study of AIR CONSUMPTION on AIR JET weaving machines.
Programmable Filling Tensioner (PFT) which stretches the pick so
that there is enough tension for the pick to travel through the air
nozzles. A fixed air nozzle at the end of the PFT uses compressed
air at high pressures to move the pick to the movable main nozzle,
which then sends the pick in air across the reed. The reed is a
comb-like device that separates warp ends to provide a tunnel
(known as the shed) for the pick to travel through and also beats
each succeeding filling thread against that already woven. The
filling detector at the end of the machine senses the arrival of the
pick, which is cut by two electric cutters at opposite ends of the
woven fabric, and the process is repeated.
The movable main nozzle provides the major force
on the yarn during the pick insertion process. To assist in moving
the pick through the shed, a set of relay nozzles are incorporated
across the shed and are sequentially activated to prevent pick
buckling and maintain velocity. The overall forces that the pick
experiences during insertion is the sum of the forces applied from
the fixed, moving, and relay nozzles minus friction forces from the
reed insertion channel and pre winder.
20D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
In order to successfully weave fabric via air-jet weaving, some of
the components of the air-jet weaving machine must constantly
rotate at high rotational velocities. Beginning with the movable
main nozzle, the entire shed rotates at rotational velocities of up to
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Study of AIR CONSUMPTION on AIR JET weaving machines.
21D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
1000 RPM. Filling insertion usually begins somewhere between 70
and 90 degrees of rotation, and the pick arrives at the filling
detector anywhere between 200 and 300 degrees, depending on the
user-programmed specifications. The amount of time it takes the
pick to travel from the pre winder to the filling detector is defined
as the arrival time and is also specified in degrees of rotation.
However, if the rotational velocity (often expressed in RPM) the
machine is operating at is known, the arrival time can be easily
converted to a time unit, usually milliseconds. Typical air-jet
weaving machines have two filling insertion channels that alternate
consecutively as to which channel is providing the pick to be
woven. The arrival time, and therefore the speed at which the pick
travels through the shed, is primarily governed by the air efficiency
of the filling yarn. Therefore, the arrival time is used by weavers as
a means of indicating how well the yarn is matched up to the
amount of air being applied to send the pick through the shed.
However, pick insertion is a process in which many errors can
occur. A filling stop is a temporary weaving machine shut down
that occurs when there is an error in the process of the pick
traveling from end to end in the shed during weaving. There are
many causes of filling stops in air jet weaving, and the
microprocessor of the weaving machine detects and records filling
errors, temporarily shutting down the machine until a weaver
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Study of AIR CONSUMPTION on AIR JET weaving machines.
corrects the mishap and restarts the machine. Filling stops result in
monetary losses for the weaver and affect the efficiency of the
fabric manufacturing process.
22D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
The complete filling insertion process is complex and
difficult to simulate. Studies have been performed to simulate
insertion and understand yarn behavior in air during weaving, but
the results of these tests often differ from the actual insertion
procedure on the weaving machine. The Air Index tester can be
used to measure the ability of a particular yarn to be woven in air-
jet weaving applications. The Air Index provides a means of
checking the regularity of a particular yarn style in air-jet weaving,
which can be used as a way of benchmarking different yarn
suppliers. In addition, it can also be used to provide an additional
criterion for choosing weaving machine settings, permitting the
possibility of reduced air consumption requirements in
manufacturing a particular style of cloth. As previously mentioned,
the two yarn properties thought to have the most influence on Air
Index are yarn count and hairiness. The hairiness of a yarn is a
quantitative way to describe the surface roughness of a cotton-
based spun yarn. The most common method of measuring yarn
hairiness is the Zweigle yarn Hairiness Tester, which
microscopically counts the number of protruding fiber ends over
twelve different length groups. These lengths range from 1 to 25
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Study of AIR CONSUMPTION on AIR JET weaving machines.
mm, and the results are presented in the form of a histogram and as
a numerical representation of frequency distribution. The Shirley
Hairiness Meter, on the other hand, provides a means of measuring
the absolute hairiness of a yarn by counting the frequency of hairs
at any specified length between 1 and 10 mm.
Yarn types can be classified by a number of ways. For
cotton-based spun yarns, the yarn is generally classified by its
count, with the measured count value rounded to the nearest whole
number. Most yarn suppliers manufacture spun yarns in a manner
to achieve a count very close to the whole number count value
being produced. Synthetic yarns (filaments) are often classified by
their denier, which is a unit of measure for the linear mass density
of fibers. Denier is defined as the mass of a fiber strand in grams
per 9000 meters. The denier system is used in the United States to
number synthetic filaments, with higher deniers corresponding to
heavier filaments. It is common practice to number synthetic
filaments based on the denier system by a set of three numbers,
each corresponding to a different quantity.
23D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
This relationship is beneficial to the manufacturer for two
main reasons. First, it allows the weaver to determine which
manufacturer of a particular yarn style is going to be more
economic to use in air jet weaving. Since higher Air Index values
result in quicker arrival times, packages of yarn with higher Air
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Study of AIR CONSUMPTION on AIR JET weaving machines.
Index values will require less air consumption to travel from one
end of the weaving machine to the other during manufacturing.
This presents the opportunity for a monetary savings in energy cost
since less air is required to weave that particular style, and energy
costs are a big contributor to the overall manufacturing cost in a
weaving plant. In addition to energy cost reduction opportunities,
the relationship between Air Index value and arrival time could be
used to help determine optimal weaving machine settings for that
particular yarn style. Although the exact relationships between Air
Index value and arrival time are not known for every style of yarn
in air jet weaving applications, the possibility exists that Air Index
values could be used to determine expected arrival times at a given
air pressure for all styles.
Measure steps to reduce air consumption
Ultra sonic cleaning
Cleaning of main nozzle, relay nozzle, air filter, hose
pipes etc. ultra sonic cleaning is important to maintaining the
efficiency of weaving.
24D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
It should avoid the damaged or error portion of the
surface so such condition of deposition is micro fiber can drop the
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Study of AIR CONSUMPTION on AIR JET weaving machines.
pressure of air blowing through it so these can be avoided due to
these cleaning.
Opening & closing timing of nozzle Correction made delayed opening loss pressure through
valve enhance the efficiency of machine. Early opening will reduce
the air consumption. Improper opening & closing timing of valves
lead to undue stress on yarn thereby leading to break.
After proper adjustment the no. of end breaks can be
reduced. The air consumption can be reduced up to 5 to 6%.
Pressure on the nozzle
25D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
Pressure on
nozzle has more impact on
the m/c performance.
Improper pressure
adjustment will causes the
weft stop during working so quality & productivity can be
minimized. To avoid the problem, proper setting of pressure can be
required. These can be adjusted according to count, rpm, width of
m/c. Proper combination between main & relay nozzle will reduce
the air consumption.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
Setting of nozzle 1- Distance between two nozzles - Improper setting between to
relay nozzle will cause to variation in air pressure and will cause
m/c performance to be in decreasing the air consumption will be
unnecessary increases.
2- Nozzle height Proper height setting of relay nozzle will
causes reduction in air pressure during weft insertion & air
consumption can be reduced. Proper setting of the nozzle height
will provide the uniform displacement of yarn during insertion.
26
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
3- Nozzle angle- For uniform weft
insertion of yarn during insertion
proper nozzle angle will reduce air
consumption. Pressure required for
insertion can be reduced.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
Multi hole versus single hole The multi hole relay nozzles guarantee a very stable
blowing angle at different pressure levels. This is recommended
for style changes that require different relay nozzle pressure
settings. The single-hole nozzles need to be adjusted by hand
whereas multi-hole nozzles keep their blowing angle stable and do
not need any adjustment or fine tuning. Due to the pre-given
horizontal and vertical jetting angles, the multi-hole nozzle
requires less space between the warp yarns, which prevents nozzle
marks in your fabric.
The multi hole pattern allows also a more efficient air
stream, thus delivering a better performance over single hole
nozzles, giving up to 15% higher yarn speed for the same air
consumption. Single-hole nozzles are recommended in case of a
dusty environment or low air quality.
27
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
28
The perfect nozzle for any air
with the introduction of eaving system. Today,
ng
D-t
jet loom Over 40 years ago, Te Strake Textile revolutionized weaving
its unique air jet w
Te Strake Textile is worldwide recognized as the trendsetter and
innovator in air insertion technology. With their complete range of
relay nozzles, Te Strake Textile delivers the perfect relay nozzle
for your needs, no matter which loom type you are using.
Innovation for better weaviperformance
ype relay nozzle
ve experience in air inserBased on their extensi tion technology, Te
another step in air jet weaving with its
hine performance
Strake Textile takes
innovative D-type nozzle. This D-type nozzle incorporates unique
characteristics to outperform any other model in terms of:
Reduced weft stops
Improved mac
Extra stability of nozzle body
Prevention of nozzle marks
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
Reduction of air consumption
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Study of AIR CONSUMPTION on AIR JET weaving machines.
Increased lifetime
29
que body design The new st robust and
stable nozzle c er resistance
head ith the successf ex nozzle head,
the D-type nozzle for better fabric
Uni design makes the D-type nozzle the mo
urrently available, with up to 45% high
to deformation. This stronger nozzle requires an absolute minimum
of adjustments for higher productivity.
New nozzle W ul experience of a round or conv
head has been further optimized
quality. Filamentation, nozzle marks or having your warp yarns
staying on top of the nozzle, belong now to the past.
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
30
Different hole patterns The D-typ 1 7
Different types of nozzles
e nozzle is available with different hole patterns (
16 19 holes) to suit your specific need. The highest performance
is given by the 16 hole nozzle, offering you specific benefits.
C TYPE S TYPE D TYPE B TYPE
Insertion time With the revolutio stream is now
guaranteed.
nary 16-hole pattern, the air
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
perfectly parallel to the warp yarns, thus making maximum use of
the insertion time. As a result, higher weaving speed for increased
productivity or a gentler yarn passage for better fabric quality is
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Study of AIR CONSUMPTION on AIR JET weaving machines.
31
Higher performance he D-type 16 ost savings.
This nozzle c ith less air
T hole nozzle can offer you significant c
an generate the same yarn speed w
consumption in some cases up to 15 20 % depending on the
weaving condition. Either, with the same air consumption, you are
able to increase the yarn speed.
DLC Coating The D-type nozzles ith Diamond-Like
carbon coating which oating. It increases
are exclusively coated w
is superior to any other c
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
life time up to 5 times and avoids wear and yarn cuts. DLC coating
is therefore specially recommended for abrasive warp yarns.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
32
Control of sub-nozzles
Co ona
as in Fig. 02; sub-nozzles are arranged in groups of 4 nozzles. An
lectro-magnetic valve is attached to each group and the sub-
lly, ntrol of sub-nozzles by increased groups conventi
e
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
nozzles of the same group jet simultaneously. Tsudakomas new
arrangement, as in Figure 3, has an electro-magnetic valve with a
smaller inner volume so that it matches to 2 sub-nozzles. The
control of valve is improved, and extra jetting time is reduced.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
33
feeding the filling and reed
Improvement of nozzle for
The main nozzle pulls the filling with compressed air and
guides it to the air guide of the reed as in Figure 4.
A Laval-type nozzle: the interior is wider at one end than
e other. The nozzles pulling force is increased by 30%, and air
zles use almost
th
consumption of the main nozzle is reduced by 10%. (Compared
with the cylindrical nozzle) In addition, the sub-noz
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
all of the air consumption in the air jet loom because of their
number. Tsudakoma invented a new sub-nozzle. The part around
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Study of AIR CONSUMPTION on AIR JET weaving machines.
the jetting outlet of the new sub-nozzle is hollowed (See Figure 5),
and the flow speed is increased by 10%. Because the filling does
not touch the edge of the jetting outlet, damage to the filling is
lowered. For the reed, the air guide of the reed for feeding the
filling is narrowed, and the air flow speed is raised.
34D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
35
ACTION PLAN
Selection of machines working with same fabric qualities.
Study of air consumption on selected machines.
Factors responsible mption.
Air leakages and its effect on air consumption.
Check points
A] Leakages
B] Bends in
2) Settings:-
icking
settings
g time
nozzles
te
for variation in air consu
1) Distance of machine from compressor
pipe
A] Shedding
1. Shedding height
2. Shed angle
B] P
1. Nozzle
2. Opening & closin
3. Distance between the nozzles
4. No of
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
5. Weft insertion ra
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Study of AIR CONSUMPTION on AIR JET weaving machines.
C] Timing
36
ing timing of main nozzle,
y nozzle, stretch nozzle.
D] Machine maintenance
ion of gears, belts, oiling and greasing
Opening & clos
Tandem nozzle, rela
1. Condit
2. Condition of spares i.e. healds, reeds
3. Machine cleaning
E] Worker practices
F] Vibration of machines
G] Air leakages
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
37
Experimental details Firstly, we have studied about two looms i.e. A & B having same sorts but running with different settings. Loom A
80*80 120 (satin weave) 8*88*2
sertion start timing: 90o
Off
Model: TSUDAKOMA ZAX 9100 Professional. Loom speed: 517 rpm
ort particular: S 20In Arrival set: 250o
On 68 260o o
Pin Main 78o 190o
Aux. Main 78o 180o Cutting 350o 34o
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
38
elay nozzle timings (o):
Loom A
R
Valve no. On Off Difference 1. 80 156 76 2. 86 162 76 3. 94 168 74 4. 100 174 74 5. 10 0 74 6 186. 112 186 74 7. 120 194 70 8. 126 200 74 9. 132 206 74 10. 138 212 74 11. 146 220 74 12. 152 223 71 13. 158 232 74 14. 164 240 76 15. 172 246 74 16. 178 254 76 17. 184 260 76 18. 190 266 76 19. 198 270 72 20. 204 274 70 21. 210 276 66 22. 216 278 62 23. 224 280 56 24. 228 282 54 25. 232 284 52
ed: 44 cfm
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
Air consum 41.5
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Study of AIR CONSUMPTION on AIR JET weaving machines.
39
oom B
Model: TSUDAoom speed: 516 rpm ort particular: 80*80 120 (satin weave)
8*88*2 sertion start timing: 88o
Off
L
KOMA ZAX 9100 Professional. LS 20In Arrival set: 250o
On 72 260o o
Pin Main 82o 192o
Aux. Main 82o 182o Cutting 350o 34o
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
40
elay nozzle timings (o):
Loom B
R
Valve no. On Off Difference 1 82 152 70
2 88 158 70 3 94 164 70 4 100 170 70 5 106 6 70 176 112 182 70 7 120 190 70 8 126 196 70 9 132 202 70 10 138 208 70 11 146 216 70 12 152 222 70 13 158 228 70 14 164 234 70 15 172 242 70 16 178 248 70 17 184 254 70 18 190 256 66 19 198 262 64 20 204 266 62 21 210 270 60 22 216 272 56 23 224 278 54 24 228 282 54 25 234 284 50
ir con ed: 43 cf
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
A sum 40 m
-
Study of AIR CONSUMPTION on AIR JET weaving machines.
41
Though, th ualities th oms a ame, due to ifferent settings the requirement of compressed air on these oms showed difference.
Yarn Pressure (kg/cm2 or bar)
Yarn arrival
e q on bo the lo re sdlo
On loom B, we have taken same count of yarn i.e. 80s but of different companies/makes and following studies were taken:
M1 M2 S Avg. Earliest Latest C1 251 248 254 80s
Indo count combed
2.0 2.2 2.5 C2 248 246 248 C1 258 254 260 80
Compact yarn combed
2.3 C2
s 2.2 2.2 255 250 258
C1 258 256 260 80s Compact slip spinning mills
2.2 2.2 2.4
C2 250 248 254
This shows that, even the same count being weaved, the pressure require th m es air r eme
to different makes co niement i.e. e co pr
or sed mpa
equirs.
nt forthem vary due
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
42
ow we observed loom C & D.
uality particular: 60*60 119.2 (2/1 twill weave) 178*58*2
Loom C Loom D
N Q Loom speed: 520 rpm
Insertion timing 86 88
Arrival set 240 238
Loom LoC
om D
C On Off On Off 1 & C2 Pin 72 260 72 260
Main 82 192 82 190 Aux. ain 82 182 82 180 M
Cutting 350 34 350 34 On loom CWe changed the opening timings of relay nozzles and following observations were made: When relay nozzles opens at 82 and closes at 282, the
umption is 52.5-54 cfm.
at 86 and closes at 282, the air consumption is 49-50.5 cfm.
:
air cons And when relay nozzles opens
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
43
) We changed insertion and arrival timings and following bservations were made:
r. no. Insertion Arrival Pressure (kg/cm2 or bar)
Cfm
On loom D: 1o S
M1 M2 S 1. 78 226 1.9 1.9 2.6 47.5-492. 98 225 2.8 2.8 3.2 52-54 3. 88 238 2.2 2.0 3.0 48-49.5
2) We changed the opening timings of relay nozzles and following observations were made:
r. no. Opening Closing CS fm 1. 84 278 50-51.5 2. 86 276 49.5-50.5
3) We changed the nozzle angle by relay nozzle angle gauge of first seven relay nozzles following observations were made: a) Firstly angle was made to 7o
Arrival Pick arrival Pressure Cfm Nozzle angle set time (kg/cm2 or bar)
C1 C2 M1 M2 S Avg. 251 253Ear. 248 248
7 238
Lat. 260 264
2.0
2.1
3.2
49.5-51
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
44
Then we increased some pressure, Nozzle angle
Arrival set
k vtime
Pressure (kg/cm2 or bar)
Cfm Pic arri al
C1 C2 M1 M2 S Avg. 241 243Ear. 238 240
Lat. 246 246
2.2
2.2
3.4
52.5-54.57 238
We observed here more fillings. b) Now, we changed the nozzle angle to 0o Nozzle angle
Arrival set
k vtime
Pressure (kg/cm2 or bar)
Cfm Pic arri al
C1 C2 M1 M2 S Avg. 238 237Ear. 234 236
Lat. 242 240
2.2
3.4
52.5-54.50 238 2.2
Then we decreased some pressure, Nozzle angle
Arrival set
ick ivatime
es e (kg/cm2 or bar)
Cfm P arr l Pr sur
C1 C2 M1 M2 S Avg. 257 257Ear. 254 254
0
238
1.8
1.8
2.8
48-49.5
Lat. 264 260 W erve cessive here.
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
e obs d ex fillings
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Study of AIR CONSUMPTION on AIR JET weaving machines.
45
angle Arrival
set Pick arrival
time Pressure
(kg/cm2 or bar) Cfm
Then with some increase in pressure, Nozzle
C1 C2 M1 M2 S Avg. 244 244Ear. 240 240
Lat. 248 248
.9
2.1
3.2
51.5-53.50 238 1
H o fil were m c) Now, the angle is changed to the 2start of changing the nozzle angles.
Arrival Pick arrival Pressure (kg/cm2 or bar)
Cfm
ere als lings ore.
o again which was at
Nozzle angle set time
C1 C2 M1 M2 S Avg. 241 242Ear. 240 240
2
238
Lat. 244 2462.0 2.1 3.2 51.5-53
At r lay nozz e angle of Though less pressure is required, it gave moderate filling stops. At relay nozzle angle of 00,
ompared to above the pressure required was less, but it Even then by increasing some
e l 70,
Cgave excessive filling stops. pressure the filling stops were unavoidable.
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
At relay nozzle angle of 20, Though some more pressure was required, the loom performance was good.
46
) We changed the opening and closing time of each dividual relay nozzle valve:
Loom D
4inRelay nozzle timings (o):
Valve no. On Off Difference
1. 86 144 58 2. 92 146 54 3. 98 154 56 4. 104 160 56 5. 112 8 56 166. 118 174 56 7. 124 180 56 8. 130 186 56 9. 136 192 56 10. 142 198 56 11. 148 204 56 12. 156 212 56 13. 162 218 56 14. 168 224 56 1
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
5. 174 230 56 16. 180 236 56 17. 186 242 56 18. 192 248 56 19. 200 256 56 20. 206 262 56 21. 212 260 48 22. 218 270 52 23. 224 270 46 24. 230 270 40
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Study of AIR CONSUMPTION on AIR JET weaving machines.
47
By these relay nozzle valve timings, we have succeeded in reducing the 44.5-46 cfm with a good running of loom.
.2 148*55
oom speed: 527 rpm tart timing: 84o
: 234o
On Off
air consumption up to .5
Loom E: Quality particulars: 56cvc*40cvc 123
*2 LInsertion s Arrival set
70o 260o
Pin Main 78o 188o
Aux. Main 78o 178o Cutting 350o 34o
Now, this ti e have pla with the s s of relay nozzles of loom E and following observations were made:
me w yed etting
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
48
elay nozzle timings (o) on loom E:
Mill settings
R
Valve no. On Off Difference 1. 72 146 72 2. 78 150 72 3. 84 156 72 4. 90 164 74 5. 96 168 72 6. 1 72 02 174 7. 108 180 72 8. 114 186 72 9. 120 192 72 1 10. 26 198 72 1 11. 32 204 72 1 12. 38 210 72 13. 144 216 72 14. 152 224 72 15. 158 230 72 16. 164 236 72 17. 170 242 72 18. 176 248 72 19. 182 254 72 20. 188 260 72 21. 194 264 70 22. 200 268 68 23. 206 272 66 24. 210 274 64 25. 214 274 60
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
49
By these timin we fou
Pick arrival timings
gs, nd
Average Earliest Latest C1 233 230 236 C2 233 232 238
Here air consumption was 64.5-66 cfm.
There was some leakage in the pre-winder knob. After removing that leakage, i.e. by replacing it, air consumpt as ed to 4.5 cfm
ion w reduc 63-6 .
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
50
hen we have changed the relay nozzle settings,
Our settings
T
Valve no. On Off Difference 1. 80 144 64 2. 84 148 64 3. 90 154 64 4. 96 160 64 5. 102 166 64 6 1 64 . 08 172 7. 114 178 64 8. 120 184 64 9. 126 190 64 1 10. 32 196 64 1 11. 38 202 64 12. 144 208 64 13. 150 214 64 14. 158 222 64 15. 164 228 64 16. 170 234 64 17. 176 240 64 18. 182 246 64 19. 188 252 64 20. 194 258 64 21. 198 262 64 22. 204 266 62 23. 208 270 62 24. 212 272 60 25. 216 272 56
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
51
By our setting llowin the rvation
Pick arrival timings Pressure (kg/cm2 or bar)
s, fo g was obse :
Average Earliest Latest M1 M2 S C1 236 232 238 C2 236 234 240
2.8 2.8 3.8
Air consumption = 57-58.5 cfm.
Running of loom E with mill and our settings,
Mill settings (shift-1) settings (shift-2)OurEfficiency 86.1% 91.4%
Time hrs 7hr 55min 8Loom speed 525rpm 524rpm Woven cmpx 2.141 2.297 Fillings break 24 20
Down time 19.8 min 14.1 min Total break 49 43 Down time 65.8 min 41 min
Stop sis: C1 C2 C1 C2 analyH1 17 5 10 7 H2 2 - 1 2
Dropper 23 17 Others - 3
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
52
oom F: ort particular: 56cvc*40cvc 123.2 148*55*2
oom speed: 543 rpm sertion start timing: 86o
Arrival set: 240o
On Off
LS LIn
72o 260o Pin Main 82o 188o
82o 178o Aux. Main Cutting 350o 34o
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
53
Relay nozzle valve settings:
Mill settings
Valve no. On Off Difference 1. 80 144 64 2. 80 150 70 3. 86 156 70 4. 92 162 70 5. 98 168 70 6. 1 70 04 174 7. 110 180 70 8. 116 186 70 9. 122 192 70 1 10. 28 198 70 1 11. 34 204 70 1 12. 40 210 70 13. 146 216 70 14. 152 222 70 15. 158 228 70 16. 164 234 70 17. 170 240 70 18. 176 246 70 19. 182 252 70 20. 188 258 70 21. 194 264 70 22. 200 268 68 23. 206 272 66 24. 214 280 66 25. 220 282 62
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
54
Pick arrival timings Pressure (kg/cm2 or bar)
Average Earliest Latest M1 M2 S C1 242 238 244 C2 239 236 244
3.4 3.0 4.8
Air consumption: 75.5-77.5 cfm.
Now, we have reduced some pressure,
k arri ing e e(kg/cm or bar)
Pic val tim s Pr ssur2
Average Earliest Latest M1 M2 S C1 244 240 248 C2 245 240 248
2.8 4.02.9
Air consumption: 72-73.5 rpm
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
55
ow, we have changed the relay nozzle timings, elay nozzle valve timings set by us,
Our settings
NR
Valve no. On Off Difference 1. 88 138 50 2. 88 144 56 3. 94 150 56 4. 100 156 56 5. 106 162 56 6 1 56 . 12 168 7. 118 174 56 8. 124 180 56 9. 130 186 56 1 10. 36 192 56 11. 142 198 56 12. 148 204 56 13. 154 210 56 14. 160 216 56 15. 166 222 56 16. 172 228 56 17. 178 234 56 18. 184 240 56 19. 190 246 56 20. 196 252 56 21. 202 258 56 22. 208 262 54 23. 214 266 52 24. 222 274 52 25. 228 276 48
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
56
k arriv ings Pressure
(kg/cPic al tim
m2 or bar) Average Earliest Latest M1 M2 S
C1 244 240 248 C2 245 240 240
2.7 2.7 4.1
A .5-67.5 c
oom G:
oom speed: 593 rpm ort particular: 40*40 115.6 (plain weave) 106*86
tart timing: 84o Arrival set: 240o
Off
ir consumption: 65 fm.
L
LS Insertion s
On
Pin 260o 66o
Main 78o 188o Aux. Main 78o 178o
Cutting 350o 34o
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
57
elay nozzle timings by mill,
Mill settings
R
Valve no. On Off Difference 1. 78 146 68 2. 78 150 72 3. 84 156 72 4. 92 164 72 5. 70 98 168 6. 104 174 70 7. 112 180 68 8. 118 186 68 9. 124 192 68 1 10. 30 198 68 1 11. 38 204 66 12. 144 210 66 13. 150 216 66 14. 158 224 66 15. 164 230 66 16. 170 236 66 17. 176 242 66 18. 184 248 64 19. 190 254 64 20. 196 260 64 21. 204 264 60 22. 210 268 58 23. 216 272 56 24. 224 274 50
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
58
n these settings,
Pick arrival timings Pressure (kg/cm2 or bar)
O
Average Earliest Latest M1 M2 S C1 246 244 252 C2 246 242 252
2.4 2.4 3.6
Air consumption: 60 Following a th s c b Insertion start timing: 78o Arrival set: 236o
Off
.5-62.5 cfm.
re e setting hanged y us,
On
Pin 58o 260o
Main 70o 160o Aux. Main 70o 170o
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
59
elay nozzle timings:
Our settings
R
Valve no. On Off Difference 1. 74 132 58 2. 76 132 56 3. 80 136 56 4. 86 142 56 5 56 . 92 148 6. 100 156 56 7. 106 162 56 8. 112 168 56 9. 120 176 56 1 10. 26 182 56 1 11. 32 188 56 12. 140 196 56 13. 146 202 56 14. 152 208 56 15. 160 216 56 16. 166 222 56 17. 172 228 56 18. 180 236 56 19. 186 244 58 20. 192 252 60 21. 198 258 60 22. 206 266 60 23. 212 266 54 24. 220 268 48
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
60
On these settings,
Pick arrival timings Pressure (kg/cm2 or bar)
Average Earliest Latest M1 M2 S C1 240 234 244 C2 241 238 246
2.3 2.3 2.9
Air consumption: 50-51 cfm.
Running of loom no 73 with o in
Mill settings (shift-1) se s t- mill and ur sett gs,
Our tting (shif 2)Efficien 92.6% 93.2% cy
Time 8hrs 8hrs Loom speed 93rpm 593rpm 5Woven cmpx 2.632 2.712 Fillings break 27 22 Warp break 7 5 Total break 40 30
Stop sis: C1 C2 C1 C2 analyH1 16 9 12 7 0H2 - 2 - 3
Firstly, we have changed i.e. played with single settings like
ing ngle, o ing and sing tim of
different valves, insertion & ival, etc and got me
duction in the consumption of compressed air. Then we
relay zle timnoz s, a pen clo ing
arr . so
re
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
decided to do all the settings on a single loom and observed
that, there is significant reduction in the consumption of
compressed air.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
61
decrease in the air consumption e of the relay nozzles & main nozzle.
urns on guide.
.
port.
sion, increases the pressure.
Factors affecting increase and
Opening tim Air pressure on relay nozzles & main nozzle. Power fluctuation. Coils on pre-winder. Proper alignment of 270 o. Pin setting- more space is less pressure. Yarn tension- yarn t Nozzle height & angle Waste present on reed sup Filter cleaning. WBS setting. Increase in the yarn ten
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
62
Effect of costing The main aim of our project was to save the
ompressed air required for the air jet weaving which is a
ajor cost ele t 40%. And
by saving this compressed air we can make the profits of our
s t
herefore, 5.5cfm = Rs 2.98
1cfm.
s 5.96/ hr/ loom
52209/ year/ loom
ar/ 128 looms
ar for the shed of 128 looms
sa ing So, this gives additional
rno er o ut investing any
oney. The above calculations are in terms of only
compressed air, the effect of it on fabric cost is as below:
c
m ment in the fabric costing i.e. abou
company by saving power units required. Becau e of his,
fabric conversion cost is also reduced. We have saved about
11cfm in our project. So, its cost calculation is as below.
Saving = 11cfm
1kwh = 5.5cfm
1kwh = Rs 2.98
T
We have saved 1
So, savings = R
= Rs
= Rs 6682828/ ye
Earning of about Rs 67 lakhs/ ye
by v 11cfm/ loom is possible.
tu v f Rs 67lakhs in the company witho
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
m
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Study of AIR CONSUMPTION on AIR JET weaving machines.
Power cost is directly proportional to fabric cost.
Expecting, fabric cost to be Rs X at 61cfm.
Now we have saved 11cfm.
63
The
X-Y @ 50cfm
5.5
5.5 is cfm generated/ kWh
n same. Only power cost
d.
refore fabric cost will be:
Where,
Y = (saved cfm x 2.98) /
2.98 is Rs/ kWh
Other all parameters of cost remai
is deducte
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
64
Conclusion This study showed that the weaving mills could obtain
nsiderable saving in energy cost by just improving the
rk practices and
could reduce air con 8% on a loom by
co
wo by avoiding ignorance in settings. We
sumption by about 1
achieving shortest possible blowing time of various
nozzles, and optimizing this setting by trial and error
method without affecting the performance of loom and
quality of fabric. We have saved about Rs 52 thousand by
saving 11cfm per loom in our project.
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
65
Future scope for the project In a decentralized sector like Ichalkaranji, till now there may
be only 500 Air jet looms but in future they will surely
incre nt ase. But in this sectors owner dont know or they do
think about the cost of air, wasting a lot of compressed air
and money behind that. They dont think about small
leakages & extra opening timings of different types of valves,
extra pressure etc. They think what is it going to cost to
them, and they neglect it. But if we convince them & make
aware about the cost of the compressed air and go
practically & save the compressed air which can give lakhs
of profits to the owner and also less consumption of energy.
By this, fabric cost will also be reduced.
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
66
REFERENCES MADE FOR PROJECT WORK Literature Cited 1. danur, S., "Air-Jet Filling Insertion: Velocity
is,
. Adanur, S., and Mohamed, M. H., Analysis of Air Flow in (1991).
ingle Nozzle Air-Jet Filling Insertion: Corrugated Channel
. Adanur, S., and Turel, T., Effects of Air and Yarn
Single esign
. Krause, H. W., "The Air-Jet Weaving Machine in Practical
AMeasurement and Influence of Yarn Structure", M.S. Thes
North Carolina State University, Raleigh, NC, 1985.
2. Adanur, S., "Air-Jet Dynamic Analysis of Single NozzleAir_Jet Filling Insertion", Ph.D. Thesis, North Carolina State University, Raleigh, NC, 1989. 3Air-Jet Filling Insertion, Text. Res. J., 61(5), 253-258 4. Adanur, S., and Bakhtiyarov, S., Analysis of Air Flow in SModel, Text. Res. J., 66(6), 401-406 (1996). 5Characteristics in Air-Jet Filling Insertion Part II: Yarn Velocity Measurements with a Profiled Reed, Text. Res. J., 74(8), 657-661 (2004). 6. Mohamed, M. H., and Salama, M., Mechanics of aNozzle Air-Jet Filling Insertion System Part I: Nozzle Dand Performance, Text. Res. J., 56(11), 683-690 (1986). 7
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
Use", Melliand Textilberichte (Eng. Ed.), September, 1980.
-
Study of AIR CONSUMPTION on AIR JET weaving machines.
67
ebruary, 1985.
m e,
, NC", 1981.
d Process Technology, University of tuttgart, 1995.
arns
hines", Vol. XXXI, No. 3, The Bombay extile Research Association, September, 2001.
the
ore Articles f Interest
8. Kissling, U., "Experimental and Theoretical Analysis of Weft Insertion by Air-Jet", Melliand Textilberichte (Eng. Ed.),F 9. Ishida, T, "Air-Jet Loom, Present and Future, Part 5: Technical Problems Caused by Air-Jet", JTN, November, 1982. 10. Hasegawa, J., et al., A Study of Weft Insertion Systeon Air-Jet Loom, in "ASME Textile Engineering ConferencRaleigh 11. Poppe, T., "The Influence of Rotor Yarn Properties on Air Consumption in Air Jet Weaving", Master's Thesis, Institute of Textile anS 12. Wahhoud, A., "Investigations into the Behavior of Yin Pneumatic Weft Insertion", Melliand Textilberichte (Eng.Ed.), April, 1983. 13. Tarabadkar, S. A., Sharma, H. M., and Yadav, D. H., "Assessment of Compressed Air Requirement for Spinning and Weaving MacT 14. Ishida, M., and Okajima, A., Flow Characteristics of theMain Nozzle in an Air-Jet Loom Part I: Measuring Flow inMain Nozzle, Text. Res. J., 64(1), 10-20 (1994).Mo
D.K.T.E's, Textile & Engineering Institute, Ichalkaranji.
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Study of AIR CONSUMPTION on AIR JET weaving machines.
68
M., and Okajima, A., Flow Characteristics of the ain Nozzle in an Air-Jet Loom Part II: Measuring High peed Jet Flows from the Main Nozzle and Weft Drag orces, Text. Res. J., 64(2), 88-100 (1994).
., ube
ision Eng. anufact., 6(1), 23-30 (2005).
8. Picanol NV, Picanol News, June, 17-27 (2006).
1.09.2007)
0. www.sultex.com/15500-e.pdf (date of access:
1. www.toyota-te of
.2007)
ma.co.jp/textile/english/product/1000.html
3. Adanur, S., "Handbook of Weaving", Technomic
4. Ajmeri, J. R., and Ajmeri, C. J., Electronic Controls for Efficient Filling Insertion, Pakistan Textile J., June, 2004.
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Measure steps to reduce air consumptionFirstly, we have studied about two looms i.e. A & B having same sorts but running with different settings. Loom AOnOffPin
Loom BOnOffPinOnOffPinOnOffPinOnOffPinOnOffPinREFERENCES MADE FOR PROJECT WORK