Air jet looms are used in the industry to produce high-quality clothing fabrics, mainly for denim fabrics. Indian companies produce millions of meters of fabric each year, and the export potential is still weak. The main reasons for poor export are fabric quality incompatibility with cost-effective world-class manufacturing of weaving, subjective decisions in the four-point fabric inspection system, delivery urgency due to low output, and retention of skilled labor in specific industries. Based on workshop experience, we can avoid the above failures by maintaining a regular follow-up system.
We will discuss the setting of Tsudakoma weaving machine in the supporting example, while the implementation in other weaving machines (such as Toyota air-jet loom, Picanol air-jet loom, etc.) can be carried out with the help of the machine manufacturer’s manual. Some changes.
The warping and sizing of beams need to fully prevent and track technical parameters. The correct selection of sizing ingredients and the use of the same ingredients in sufficient amounts under the specified temperature, humidity and concentration are very important for making beams. In order to determine the size cost-effectively, attention must be paid to steam and air leakage during maintenance planning.
Knotting or knotting at the beam edge: Knotting and tying are important processes to prevent warp breakage, which have a significant impact on the efficiency and quality of the fabric.
The maintenance list (the frequency can be maintained for six months/a year) depends on the RPM of the loom and the tracking of the results.
If any loom works inefficiently, produces poor-quality fabrics, or breaks down beyond expectations, preventive maintenance is required until these problems are resolved.
Weaving defects and troubleshooting
1. Check the cable and its position.
2. Air pressure of all nozzles.
3. The height of the heald frame crosses the scaffold.
4. Check the time and position of the stretching nozzle.
5. Stretch the dent of the reed on the opposite side of the nozzle.
6. Check the H1 contact condition for any damage.
7. Check the side of the heald frame.
1. Check the angle and height of the sub-nozzle.
2. Check the extension of the tip of the sub-nozzle.
3. The sub-nozzles should be parallel.
1. Check the working condition of H1 and H2 feeler gauges.
2. Check the antenna timing in the i-board.
3. Check the sensitivity of H1 and H2 feeler gauges.
4. Clean the H1 and H2 contacts.
5. Check the condition of tightening belt, gear and beam pinion.
1. Check whether the two ends are parallel.
2. Remove the tangles at the ends of the warp yarns.
3. Check that the sticky end of the cloth edge should not enter the main body.
2. Check the correct RH cutter setting.
3. Check the continuous operation of the batching winder.
1. Check the beam gear and beam drive pinion.
2. Check the beam metal bushing, the condition of the fixture and the bearing.
3. Check the ELO timing, check the degree of freedom of the tension rod and the position of the shock absorber.
4. Check the condition of the tightening device and tightening belt.
5. Check the pressure roller spring tension.
6. The loom should not be shut down for a long time.
1. Check whether all the serrated bars are in bad contact at the fixture.
2. The serrated bar should be cleaned thoroughly/polished with Brasso.
3. Regularly check the sensitivity of the dropper.
4. The electrical connection at the cable with the clamp should be checked regularly.
5. Remove the fluff from the serrated bar/drip pin.
6. Make sure that there is a hanging pin attached to the end of each warp.
7. Check whether the WSM bar is running frequently, if the fault occurs again.
1. Check the position of the stop motion separator.
3. Check the condition of the healds.
4. Check whether there are any cuts on the sand roller.
5. Check the flatness of the temple cover.
6. Check whether the temple ring is free.
7. Check the position and condition of the bottom guide rod.
Tears or holes in temples
1. Check if the temple cover is facing to the temple support.
2. Make sure that the temple support is firmly installed on the temple pole.
3. Check the height of the heald frame and the shed crossing time.
5. Check the bottom guide setting.
6. Check the pressure roller spring tension.
With the help of microprocessor-based control, we can use air-jet looms to achieve higher efficiency and higher productivity. This means that the weaving team can analyze the following details in time to prevent losses in the gray stage:
3). Work stoppage due to mechanical reasons
4). Idling stop based on hourly damage rate
5). Weaver's time to participate in the loom
6). Alert for due maintenance/lubrication plan
7). Production evaluation is based on the efficiency of the loom, the number of weaving meters, weft insertion, and the total running time of the loom.
8). The length of the film is controlled by the alarm signal.
9). Graphical analysis and control of production costs, various defects during the operation of the loom, etc.
10). The knitting can be changed without any mechanical changes.
11). The speed of the loom can be changed without replacing the motor pulley.
12). PPI can be changed from the microprocessor.
If the probe head is loose during weaving, it will be recognized on the display. In this way, the loom can be taken care of before a particular component breaks. It has been observed that one of the more advantages of this device is that if the reed screw remains slightly loose, the feeler gauge will vibrate when installed on the reed, so timely inspection of the loom can avoid further damage.
By maintaining effective maintenance plans and troubleshooting methods based on changing needs and market trends, most fabrics can be woven on air-jet looms with zero-defect fabrics. The performance of the air-jet loom will not deteriorate due to long-term use, as long as it is regularly maintained and lubricated properly. The manufacturer has a large number of air-jet looms with microprocessor-based controls. The only limiting factor is that everyone must focus on the results to play their role.
We thank Dr. AK Sharma, Director of ATIRA, and Mr. KK Misra, CEO of ATIRA.
1. India Textile Exhibition 2015, Jay Narayan Vyas
2. Air-jet loom operation and maintenance manual
3. T sudakoma.co.jp
4. Picanol
5. Toyota-industries.com
Pradeep Kulshrestha is an experienced technical expert in the field of textile operations management, with more than 30 years of experience in nine well-known companies in India and abroad. He is currently the department head of the ATIRA Incubation Center (Center of Excellence), dedicated to the continuous development of technical textiles and composite materials.
Dharmendra Goswami is an experienced weaving expert in the field of modern looms with ten years of experience. He serves as a business development officer at the ATIRA Incubation Center.
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