A PRESENTATION ON

MODERN AIRJET & RAPIER LOOM

Md. Azmir LatifMSc. in Textile Engineer

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

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

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

Basic Motion

• Shedding Mechanism

• Picking Mechanism

• Beat up Mechanism

• Take up Mechanism

• Let off Mechanism

shedding mechanism

Shedding mechanism

Possible Shedding Mechanism:

– Cam Shedding

– Dobby Shedding

– Jacquard

– ELSY [for selvedge & Waste Collection (False Selvedge)]

– Leno (for selvedge binding)

Cam Shedding

Main Parts

– Bevel gear

– Repeat gear

– Cam shaft

– Cam

– Bowl

– Wheel lever

– Short lever

– Long lever

– Harness frame

Main Parts of Cam Shedding

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

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

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

Heald Wire

Brand : Grob Horgen

Origin : Switzerland

Cam Shedding Mechanism

• According to pattern cams are added andadjusted 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

ELSY

• Stands for Electronic Leno Selvedge System

• Don’t need any extra healdframe 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

Mechanical Leno

• Selvedge Type: Leno type

• A simple hook mechanism

• Needs to incorporate with ELSY to produce binding weave in the fabric edge.

picking mechanism

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

Main Parts of Picking

• Creel: • Filling detector:

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

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

Main Parts of Picking

• Gripper & Receiver heads

– Carry the weft yarn

• Suction heads

– Prevents bouncing back of inserted yarn

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

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

Rapier Track

To prevent rapier slippage a rapier track is made withhooks

This hooks do:– The minimization of the gripper sole wear.

– The break of the gripper.

– The reduction of the filling stops

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

Rapier Drive Mechanism

View from top

Drive lever

Toothed segmentLink to toothed segment

Beat up mechanism

Beat up mechanism

• Cam beat up

• No of Cam: Two on each side

• Beat up angle: 0o

Main Partso Sumo motor (Main Motor)o Motor gear & Drive wheel gearo Beat up camo Sleyo Reed

Main Parts of Beat Up

Beat up Arrangement

Bowl

Cam Gear

Gear train from main Motor

Main Parts of Beat Up

Reed• Attached with sley

• Push the newly inserted thread to fell

• Plain reed is used in rapier

Beat Up Mechanism

• main motor rotates thedrive shaft

• This rotation isconverted toreciprocating motion insley

• The reed is fixed withsley

• As a result, it pushes thenewly inserted pick tothe fell

Let off mechanism

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

Main Parts of Let Off

ELO Motor

Let off wheel

Beam collar

take up mechanism

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

Take up mechanism

Rollers

ETU Motor

Batcher

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)

others motion

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)

Others Auxiliary Motion

• Weft stop Motion (By FD)

• Catch cord breakage

• Batcher stop

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

Picanol Omni Plus (Airjet Loom)

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

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

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

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

Shedding mechanism

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

Shedding GeometryShed angle

Shedding GeometryConversion Table of Shedding angle

Here “α” between 22° to 26° used for filament yarn

28° to 34° angle used for spun yarn weaving.

Shedding GeometryShed Height

The optimal height setting depends on a number of factors:

The article type

The weave

The machine speed (rpm).

Shedding Geometry

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.

picking mechanism

Picking

Weft passage

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-

winder.

Weft passage

• Type: Can plus 2231

• Manufacturer: Picanol

Prewinder

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.

NozzlesFixed main nozzle

Movable main nozzle

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.

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.

Air Supply accessories

• Buffer tank for relay nozzle

– Left Buffer Tank

– Right Buffer Tank

Main nozzle modules and valve

Air Supply accessoriesRelay valve

Each valve controls 1 or 2 (Maximum

three) relay Nozzles.

Pressure regulator

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.

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

beat up mechanism

Beat up

• Same as rapier. Only difference is here profile reed is used.

Profile Reed

To facilitate air passage, in this reed a groove is made by curving on dent wire.

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

others motion

Same as rapier.

Same as rapier.

Same as rapier.

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

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.

Weft stop motion

Others stop motion

• Bobbin breakage

• Leno breakage

• Catch cord breakage

• Batcher stop

• Machine brake