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Air jet and Rapier loom

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Modern looms still weave by repeating in sequence the operations of shedding, picking, and beating. In weaving technology, modern looms means shuttle less loom. Air jet and Rapier both are performed automatically with high production and commonly used in Bangladesh.

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Air jet and Rapier loom

  1. 1. A PRESENTATION ON MODERN AIRJET & RAPIER LOOM Md. Azmir Latif MSc. in Textile Engineer
  2. 2. A MODERN RAPIER LOOM Keyword: General specification, yarn passages, basic motions, shedding, picking, beat up, let off, take up, warp stop motion, others auxiliary motion
  3. 3. Picanol Gammax (Rapier) General Specification Name : Picanol GamMax Type : Rapier Weaving Machine Rapier Type : Double flexible rapier Shedding Mechanism : Positive cam shedding Cam arrangeme nt : Outside cam arrangement Cam Manufactur er : Staubly
  4. 4. Yarn Passage • Warp passage: – Beam (Flanged beams) – Backrest roller (Double backrest roller) – Warp breakage detector (Electrical drop wire mechanism) – Heald frame – Reed – Fell of the cloth • Fabric Passage: – Temple Mechanism – Spreader – Take up roller – Front Rest – Guide roller – Batcher • Weft Passage: – Creel – Prewinder – Filling detector – Finger Selector – Filling Cutter – Wastage Cutter – Gripper Head – Receiver Head – Wastage Cutter – Suction Head
  5. 5. Basic Motion • Shedding Mechanism • Picking Mechanism • Beat up Mechanism • Take up Mechanism • Let off Mechanism
  6. 6. shedding mechanism
  7. 7. Shedding mechanism Possible Shedding Mechanism: – Cam Shedding – Dobby Shedding – Jacquard – ELSY [for selvedge & Waste Collection (False Selvedge)] – Leno (for selvedge binding)
  8. 8. Cam Shedding Main Parts – Bevel gear – Repeat gear – Cam shaft – Cam – Bowl – Wheel lever – Short lever – Long lever – Harness frame
  9. 9. Main Parts of Cam Shedding
  10. 10. Cam • used to convert the rotary motion of shaft to reciprocating motion • entire cam arrangement is placed on an oil bath • Cams are supported by guard cam for safety Various Types of Cam
  11. 11. Wheel lever, Short lever & Long Lever • Convey the reciprocating motion • drive the heddle frame • two sets of link carrying the drive bracket are pivoted on each side of long lever • brackets allow easy mounting and dismounting of harness frame
  12. 12. Harness Frame Features: – Glued heddle rod – Lightweight Aluminium profile – R-flex corner connection system – Integrated heald dumper – Stainless steel corner reinforcement. Brand : GTP Mode l : XLF extra Light 152
  13. 13. Heald Wire Brand : Grob Horgen Origin : Switzerland
  14. 14. Cam Shedding Mechanism • According to pattern cams are added and adjusted to their respective position • As the camshaft rotates cams also rotate • When the bowl is pressed, the wheel lever swing upward • Via long lever, harness frame is pushed upward to its upper position • Again after cam nose has passed the bowl, the harness is pulled to its bottom position • It is a positive shedding mechanism
  15. 15. ELSY • Stands for Electronic Leno Selvedge System • Don’t need any extra heald frame to make selvedge. • Laws of motion can be changed without hampering the fabric quality. • Shed crossing can be set as required. • Selvedge weave can be inputted differently. • Used for selvedge and false selvedge. • Selvedge Type: Fringed
  16. 16. Mechanical Leno • Selvedge Type: Leno type • A simple hook mechanism • Needs to incorporate with ELSY to produce binding weave in the fabric edge.
  17. 17. picking mechanism
  18. 18. Picking Mechanism General features – Flexible rapier – Double (2 rapiers) – Sprocket type wheel drive – 2 heads (gripper & receiver) – Side housing, fixed (unmovable) • Main parts • Creel • Prewinder • Filling detector • Filling Presenter • Filling Cutter • Gripper • Receiver • Suction head • Wastage cutters
  19. 19. Main Parts of Picking • Creel: • Filling detector:
  20. 20. Main Parts of Picking Prewinder: – Type: Luna X2 – Pre wind yarn on drum from package – Supply the required length of yarn at required tension for weft insertion
  21. 21. Main Parts of Picking • Filling Presenter: – lower the appropriate filling yarn so that it can be taken by gripper head • Filling Cutter & Wastage Cutters – Filling Cutter Cuts the inserted weft yarn after beat up – Wastage Cutter Cuts the excess length of weft yarn outside the fabric edge
  22. 22. Main Parts of Picking • Gripper & Receiver heads – Carry the weft yarn • Suction heads – Prevents bouncing back of inserted yarn
  23. 23. Mechanism of Picking • Yarn presenter is lowered to present the thread • The gripper head catches the yarn • Both the gripper and receiver proceed towards the middle of shed • The yarn is then transferred from gripper head to receiver head • The receiver head then drags the yarn through the rest of the shed • Finally the filling cutter cuts the thread Gripper head is carrying the weft Weft is transferring from gripper to receiver Weft is transferred Receiver is carrying the weft
  24. 24. Hook Opener • The gripper opener: Opens the gripper clamp to facilitate lint removal • The receiver opener: Opens the receiver. Its position is critical so that it opens the hook at the exact time of weaving cycle
  25. 25. Rapier Track To prevent rapier slippage a rapier track is made with hooks This hooks do: – The minimization of the gripper sole wear. – The break of the gripper. – The reduction of the filling stops
  26. 26. Rapier Drive Mechanism Rapier driving arrangement consists of: • Main shaft • Rocker arm • Oscillating link • Drive lever • Adjustable link • Conical Toothed segment • Rapier driving pinion • Rapier wheel
  27. 27. Rapier Drive Mechanism View from top Drive lever Toothed segmentLink to toothed segment
  28. 28. Beat up mechanism
  29. 29. Beat up mechanism • Cam beat up • No of Cam: Two on each side • Beat up angle: 0o Main Parts o Sumo motor (Main Motor) o Motor gear & Drive wheel gear o Beat up cam o Sley o Reed
  30. 30. Main Parts of Beat Up Beat up Arrangement Bowl Cam Gear Gear train from main Motor
  31. 31. Main Parts of Beat Up Reed • Attached with sley • Push the newly inserted thread to fell • Plain reed is used in rapier
  32. 32. Beat Up Mechanism • main motor rotates the drive shaft • This rotation is converted to reciprocating motion in sley • The reed is fixed with sley • As a result, it pushes the newly inserted pick to the fell
  33. 33. Let off mechanism
  34. 34. Let off Mechanism • Servo motor aided let off. • Speed of let off motor gradually increases with the decrease of beam diameter. • Main Parts – ELO Motor – Reduction wheel – Gear box – Let off wheel
  35. 35. Main Parts of Let Off ELO Motor Let off wheel Beam collar
  36. 36. take up mechanism
  37. 37. Take up Mechanism • Servo motor aided take up • Batcher mechanism • Main Parts – ETU Motor – Gear train – Take up roller – Spreader – Double pressure roller – Guide roller – Batcher
  38. 38. Take up mechanism Rollers ETU Motor Batcher
  39. 39. Wastage winder • Used to wind up wastage and excess warp. • One gets drive from let off gear (for warp). • The other one from take up wheel (wastage) Wastage winder (wastage take up) Wastage winder (Excess warp take up)
  40. 40. others motion
  41. 41. Warp Stop Motion • Electrical drop wire mechanism. • If a warp is severed drop wire falls on contact bar and complete the circuit which stops the machine. • Main parts: – Drop wire. – Contact bar. – Guide bar. – Main circuit (Circuit box)
  42. 42. Others Auxiliary Motion • Weft stop Motion (By FD) • Catch cord breakage • Batcher stop
  43. 43. A MODERN AIRJET LOOM Keyword: General features, main parts, motions, shedding, picking, beat up, let off, take up, warp stop motion, weft stop motion, others stop motion
  44. 44. Picanol Omni Plus (Airjet Loom)
  45. 45. Picanol Omni Plus (Airjet Loom) Name : Picanol Omni Plus Type : Airjet Weaving Machine Machine Weight : 1900 Kg Maximum Speed : 850 RPM Attachments :  E- Leno  AIC (Adaptive Incretion Control)  PFT (Programmable filling tensioner) Sand Roller Circumference : 534 mm Shedding Mechanism : Positive cam shedding Cam arrangement : Outside cam arrangement Cam Manufacturer : Staubly
  46. 46. Main Parts • Bobbin break sensor • Pre-winder (weft Feeder) • Balloon Breaker • PFT • Main nozzle (Fixed & Movable) • Relay nozzle • Weft cutter • Waste cutter • Filling detector • Pressure control regulator • Cam with cam box. • Lever and Puller. • Reed. • Easing arm • Back rest • Take up roller • Cloth roller • Catch Cord • Disk type tensioner • Drop wire and Dropper bar. • Leno selvedge attachment (e- Leno) • Temple • ELSY (Electric Leno Selvedge System) • Batcher • Waste winder
  47. 47. Main Parts • Electrical boards • MCB • AIB • TRIAX-2 • WEB X • DDMP • LDEC • FDCB • PB • Various motors • Sumo Motor • Hydraulic Motor • Cutter Motor • ELCA Motor • ELSY Motor • PFT Motor • ETU Motor • ELO Motor • E-leno Motor
  48. 48. Motions • Primary motions – Shedding – Picking – Beat Up • Secondary motions – Let off – Take up • Tertiary Motion – Auto Warp stop Motion – Auto Weft stop Motion – Batcher motion – Brake motion
  49. 49. Shedding mechanism
  50. 50. Shedding • Possible Shedding Mechanism: – Cam Shedding – Dobby Shedding – Jacquard – ELSY [for selvedge & Waste Collection (False Selvedge)] – E-Leno (for selvedge binding) • Cam Shedding: – Same as rapier. • Shedding Parameters Shed Angle : 22° to 34° Heald Frame Height : 72-87 mm Back Rest Depth : 1-6 Drop Wire Bar Height : -7 to +5 Back Rest Height : -8 to +19
  51. 51. Shedding Geometry Shed angle
  52. 52. Shedding Geometry Conversion Table of Shedding angle  Here “α” between 22° to 26° used for filament yarn  28° to 34° angle used for spun yarn weaving.
  53. 53. Shedding Geometry Shed Height The optimal height setting depends on a number of factors:  The article type  The weave  The machine speed (rpm).
  54. 54. Shedding Geometry
  55. 55. E-Leno • Produce leno selvedge for edge binding. • Two leno box, one for each side. • Drive by a single motor (Omni plus) or separate motor (Omni plus 800). • Each box support two leno bobbin, these two bobbins are rotated in a circular path to produce a one up one down leno selvedge.
  56. 56. picking mechanism
  57. 57. Picking Weft passage
  58. 58. Weft passage Creel : Supports the cone. Disc- Tensioner : Add a tension on yarn which is being unwounded by pre-winder. Bobbin break sensor : Detects yarn breakage between creel & Pre- winder. Incorporated with pre-winder. Balloon- Breaker : Prevent large balloon formation which leads to yarn breakage. Incorporated with pre-
  59. 59. Weft passage • Type: Can plus 2231 • Manufacturer: Picanol Prewinder
  60. 60. Prewinder • The pre-winder contains the following components: – The motor and control unit – The drum with 7 independently adjustable fingers – The magnetic winding blocking unit for controlling the filling length – The yarn-supply sensor – The positioning sensor – The winding sensor – The bobbin break sensor – PFT used to stretch the floating filling inside the shed.
  61. 61. Nozzles Fixed main nozzle Movable main nozzle
  62. 62. Nozzles • Relay nozzle – Total No of relay nozzles 28. – Divided into 2 groups. – Left (Contain 14 nozzles). – Right (Contain rest of the nozzles). – Contains 1 to 17 opening (holes) for air supply.
  63. 63. Nozzles • Relay nozzles should be set as high as possible to clear the relay nozzle openings earlier when entering the shed, and keeping them clear longer when leaving the shed. • The more the relay nozzle is turned towards the reed, the higher the yarn flight in the insertion channel. • The height of the relay nozzle is critical, if it is low, the flight of the filling will be low, if the height is very high it will leave nozzle mark on fabric.
  64. 64. Air Supply accessories • Buffer tank for relay nozzle – Left Buffer Tank – Right Buffer Tank Main nozzle modules and valve
  65. 65. Air Supply accessories Relay valve  Each valve controls 1 or 2 (Maximum three) relay Nozzles. Pressure regulator
  66. 66. Filling Cutter • Filling cutter cut the yarn after each filling and start a new filling insertion cycle • Generally, at 10° position the cutter cut the yarn.
  67. 67. Requirement of air supply for picking • Main line pressure – 7 to 9 Bar Required • Main valve pressure – Up to 6 Bar • Auxiliary valve pressure – 5 to 6 Bar (Fixed) • Left relay valve pressure – Up to 5.5 Bar (Depends on weft yarn Count & M/C RPM) • Right Relay valve pressure – Up to 0.5 Bar more than left relay valve pressure
  68. 68. beat up mechanism
  69. 69. Beat up • Same as rapier. Only difference is here profile reed is used.
  70. 70. Profile Reed  To facilitate air passage, in this reed a groove is made by curving on dent wire.
  71. 71. Profile Reed • Commonly used reed count: • 590 DM • 652 DM • 739 DM • 985 DM • 869 DM • 787 DM • 1190 DM • 1085 DM • 931 DM • DM: DENTS PER METER
  72. 72. others motion
  73. 73. Same as rapier. Same as rapier. Same as rapier.
  74. 74. Weft stop motion Device used : Filling detector No of FD : 2 (FD1 & FD2) Mechani sm : Laser based Stop signal : If the thread does not reach FD1 If the thread reach FD2
  75. 75. Weft stop motion • Mechanism – FD is constructed with a light emitting diode and photo electric sensor. – The filling yarn interrupt the continuity of light and photo electric sensor convert it into an electronic signal.
  76. 76. Weft stop motion
  77. 77. Others stop motion • Bobbin breakage • Leno breakage • Catch cord breakage • Batcher stop • Machine brake

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