weaving-airjet air consumption

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

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.


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.



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.


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


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.


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.


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



Fig. a modern AIR JET weaving machine.

Filling feeding system


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


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,


Use of weft accumulators, which reduces average tension on weft during insertion of weft, equalizes yarn tension caused


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.


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.



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.


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.


Preventing Air Leakages


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


Improving Volumetric Efficiency of Air Compressors


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.


Cost Reduction Opportunities


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.


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


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.


Compressor Controls


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.


Distribution Lines


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


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.


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.


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


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


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


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.


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



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


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.


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


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.


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


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.


It should avoid the damaged or error portion of the

surface so such condition of deposition is micro fiber can drop the


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


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.


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.


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



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


Reduction of air consumption


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.



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


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


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


life time up to 5 times and avoids wear and yarn cuts. DLC coating

is therefore specially recommended for abrasive warp yarns.


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


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.


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


all of the air consumption in the air jet loom because of their

number. Tsudakoma invented a new sub-nozzle. The part around


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.



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


5. Weft insertion ra


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



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



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


Air consum 41.5


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




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


A sum 40 m


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



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



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



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.


e obs d ex fillings


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.



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


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


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


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



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



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 .



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



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



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



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



54



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


2.8 4.02.9

Air consumption: 72-73.5 rpm



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



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



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



58

n these settings,


O


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



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



60

On these settings,



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


decided to do all the settings on a single loom and observed

that, there is significant reduction in the consumption of

compressed air.


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



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


m


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



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.



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.



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


Use", Melliand Textilberichte (Eng. Ed.), September, 1980.


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



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.

15. Ishida,MSF 16. Jeong, S. Y., Kim, K. H., Choi, J. H., and Lee, C. KDesign of the Main Nozzle with Different Acceleration Tand Diameter in an Air-Jet Loom, Int. J. PrecM 17. Picanol NV, "The Air Index, a New Reference for Yarn Evaluation", Picanol News, October, 8-11 (2001). 1 19. www.lindauer-dornier.com (date of access: 2 221.09.2007) 2industries.com/textile/products/weaving_jat710 (daaccess: 21.09 22. www.tsudako(date of access: 21.09.2007) 2


Publishing Company, Inc., U.S.A., 2001. 2

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

weaving-airjet air consumption

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