Objective: To study the consumption of air in air jet weaving machines
Specific Objective: Reduction in the consumption of air on existing machines
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.
This paper was presented at Veermata Jijabai Technological Institute (VJTI), Mumbai in the VASTRA 2010 with a live demo on the ‘The Study of Air Consumption on Airjet Weaving Machine’ in a two day event held on Feb 19th & 20th, 2010
The authors are associated with DKTE, Ichalkaranji