2008

I n the past, air-jet weaving was often denounced as an energy waster because of
the needed air pressure and therefore air consumption. Limitations related to the weftinsertion technology also reduced performance and flexibility, and often, the insertion
of the weft was not accurate.
More fast and accurate looms are developed
Dornier GmbH are equipped with the redesigned, patented ServoControl® pressurecontrol system with semi-automatic filling threading in the pilot and main nozzles of
the mobile tandem nozzle group. This system allows faster and more flexible
adaptation of the air-jet weaving machines to future demands.
The new positive weft clamp (PWC) allows all air-jet weaving machines to run without
any holding pressure.
Belgium-based Picanol's OMNIplus 800 standard air-jet weaving machine is equipped
with the highly energy-efficient Sumo motor and with highly effective main nozzles,
relay nozzles and valves.
The combination of the Sumo motor with the direct drive of the main shaft and
shedding motion results in power savings of more than 10 percent in comparison with
conventional clutch and brake configurations. In addition, the energy cost for air
conditioning is reduced as the Sumo motor dissipates less heat in the weaving mill.
The speed of the motor is controlled electronically, without a frequency converter, thus
reducing power consumption and permitting greater flexibility. The very short drive
train is simple and compact, and the machine is up to full speed right from the very
first pick.

Economical Air-Jet Weaving
Newest air-jet weaving technologies improve performance and flexibility
while reducing air and energy consumption.
Jürg Rupp, Executive Editor

I n the past, air-jet weaving was often denounced as an energy waster because of
the needed air pressure and therefore air consumption. Limitations related to the weftinsertion technology also reduced performance and flexibility, and often, the insertion
of the weft was not accurate. Those days are gone with the latest developments of the
major weaving machinery manufacturers. Modern weaving machines are fast and
flexible, and operate with a considerable reduction in energy.

Some Recent Offerings

This system allows faster and more flexible adaptation of the air-jet weaving machines to future demands. patented real-time . versatility and flexibility. The speed of the motor is controlled electronically. yarn-friendly insertion of up to four weft colors or types of yarn. fancy slubs. This extends the spectrum of weft yarns suitable for insertion. The combination of the Sumo motor with the direct drive of the main shaft and shedding motion results in power savings of more than 10 percent in comparison with conventional clutch and brake configurations.000 meters per minute is combined with extensive automation. such as those used for apparel and home textiles. can now be processed on air-jet weaving machines with high productivity and reliable quality. relay nozzles and valves. is designed to produce a wide range of fabrics. and ergonomic design are further features of the machine. The new positive weft clamp (PWC) allows all air-jet weaving machines to run without any holding pressure. Belgium-based Picanol's OMNIplus 800 standard air-jet weaving machine is equipped with the highly energy-efficient Sumo motor and with highly effective main nozzles. According to the company.'s Active Weft Control System allows further reduction of compressed air consumption by the new L5500 air-jet weaving machine. All air-jet weaving machines from Germany-based Lindauer Dornier GmbH are equipped with the redesigned.The new L5500 air-jet weaving machine made by Switzerland-based Sultex Ltd. thus reducing power consumption and permitting greater flexibility. A high weft-insertion rate of more than 2. fabric patterns with large repeats. The very short drive train is simple and compact. and the machine is up to full speed right from the very first pick. For the first time. the energy cost for air conditioning is reduced as the Sumo motor dissipates less heat in the weaving mill. the compressed air consumption is further reduced. In addition.to mediumweight technical textiles. Sultex Ltd. without a frequency converter. user-friendliness. A maximum working width of 400 centimeters also allows cost-efficient production of light. including elastane. Less Air Consumption Is Key Thanks to the new Sultex Active Weft Control System (AWC). patented ServoControl® pressure-control system with semi-automatic filling threading in the pilot and main nozzles of the mobile tandem nozzle group. softtwisted yarns and others.

Picanol's unique Adaptive Relay Valve Drive (ARVD) system automatically adapts the relay nozzle settings to the behavior of the weft yarn during the insertion. The compact device can easily be positioned using a clip anywhere on the reed without damaging the reed dents. the supply pressure for the nozzles can be dropped up to 1 bar. the Slim Throughlight Sensor (STS). even on dark weft colors and fine threads down to 20 denier. depending on the style program. With the Air Gripper System (AGS). resulting in reduced air consumption. As a result.monitoring of the weft yarn makes predictive control of the relay nozzles possible. The air lines between valve and relay nozzle have been made as short as possible. The main and tandem nozzles ensure gentle acceleration of the weft yarn with minimal air consumption. The position of both the fixed and the movable main nozzles is easily adjusted. according to Picanol. the weaving machine adjusts every weft insertion for minimal air consumption. The patented RTC (Real Time Controller) from Sultex is an active control system that influences the current weft insertion rate. With the new generation of main nozzles. The new Diamond-Like Coating (DLC) on the relay nozzles significantly extends their lifetime when using abrasive yarns. The air consumption of Dornier air-jet weaving machines can be reduced by up to 28 percent thanks to newly developed relay nozzles. results show an average reduction of 10 percent. Short reaction and blow times make economical compressed air consumption possible. the relay nozzles do not need to be used as much to keep the weft yarn stretched. The OMNIplus 800's new air supply system and more efficient main nozzles allow improved performance. special stretching nozzles and an optional TandemPlus main nozzle. spandex yarns in the weft also are woven faultlessly. The result is an absolute minimization of the air consumption. thus further reducing air consumption. Picanol reports. The air pressure and timing can be adjusted electronically and separately for fixed and movable main nozzles. Depending on the weft yarn and machine width. The relay nozzles also are optimized. . The shape of the nozzles and the position of the holes give an increased pitot value and enable maximum use to be made of the available insertion time. is based on the principle of light rays. It provides the highest functional and quality reliability. Picanol's pneumatic catching device (PCD) catches the weft yarn once it has reached the right-hand side of the fabric. optimizing the nozzle blow times. Dornier's new weft stop sensor. according to Picanol. Regardless of the weft being woven. air consumption can be reduced by 10 to 40 percent. the air consumption of the machines can be reduced by up to 20 percent. a stretching function also is integrated. making use of the advanced integrated electronic controls. When using PCD.

Higher Productivity Automatic pick repair effectively reduces the operator's workload and leads to shorter downtimes. leading to an appreciable reduction in operating and maintenance costs. maximizing efficiency for increased production and higher machine allocation per weaver. Another consequence is that the sides of the . special stretching nozzles and an optional TandemPlus main nozzle. the extended weft insertion time has a positive effect on the running characteristics. The air consumption on the Dornier air-jet weaving machines can be reduced by up to 28 percent thanks to newly developed relay nozzles. it becomes harder to maintain the required air humidity at the weaving machine level. Removing Heat Fast-running machines generate more heat than their slower predecessors. The run-up with empty picks to prevent starting marks reduces wear on the machine components. As the weave room temperature rises. the sley drive by complementary cams optimizes sley dwell. eliminates costly power consumption peaks. In particular with delicate. freely programmable starting mark preventer helps ensure faultless fabric quality. According to Sultex. The results are consistently high fabric quality and low energy consumption. The direct servo motor drive eliminates the need to replace wear-prone drive belts and clutch and brake linings. and avoids short-term power supply overloads. low-tensile-strength wefts. The resulting consequences are particularly important in regions with hot climates.Picanol's standard OMNIplus 800 air-jet weaving machine is equipped with the energy-efficient Sumo motor and highly effective nozzles. Sultex reports the L5500's chronologically controlled.

according to Stäubli. the new format is highly economical. With the expanded number of hooks. especially silk and upholstery fabrics. in an application with 18. a new air-conditioning installation can be kept small and energy-efficient. Such a combination needed two drive mechanisms and two transmissions to the weaving machine. the LX 3202 can be used with even wider weaving machines. 432 hooks reduces energy consumption by almost 50 percent. or an existing installation could still be compatible with high-speed weaving. According Stäubli. For operator-friendly programming and controlling. the new LX 3202 with 18. the new Stäubli LX 3202 jacquard machine with 18. a first machine with 10.432 hooks are already installed and are said to meet the high expectations of the users. M6 modules are used for individually lifting harness threads. every jacquard machine is equipped with a JC6 controller. With Picanol's OptiMax machine's water-cooling option.warp tend to dry out because of heat radiation from mechanisms in the machine frames. The first LX 3202 machines with 18. As far as energy consumption is concerned.432 hooks. As with other Stäubli jacquard machines. Switzerland-based Stäubli AG's LX 3202 high-performance jacquard machine now is available in a monoblock version with 18.432 hooks format reduces energy consumption by almost 50 percent. Compared to a twin machine with the same total number of hooks. offering weavers increased output and freedom in creating patterns. the coupling of two machines was necessary . Calculations confirmed that drive energy almost doubled at equivalent speed and harness type. half of the thermal load produced by the weaving machine is extracted from inside the machine.432 hooks.for example. . including a color touch-screen and appropriate interface options for data transfer and networking.192 hooks. Previously. In this way.240 and a second with 8. Low-Energy Jacquard Machine Shedding and jacquard machines are also playing an important role in the energy balance. Compared to a twin machine with the same total number of hooks. the machine's large format is ideal for high-performance applications in the production of flat fabrics with high thread densities. Modern jacquard machines use less energy and have higher production outputs than earlier models.