Air jet weft

insertion
Pre-winder

 Known as Weft storage device or feeders or

accumulators
 Positioned b/w the weft package & insertion device
 Improve quality of fabric
 Accumulate pre-determined length of yarn before
insertion of pick
 High unwinding speed in air jet is required about 2000
m/min. (warping = 800-1200 m/min.)
Functions of pre-winder

 To supply filling yarn at constant & proper speed

 Used to reduce the tension variation
 Weft yarn is drawn from the package & wound on
measuring drum/band by yarn guide tube
 Pick length depends upon the fabric width & adjusted
by measuring band & coils
Functions of pre-winder

 Package unwinding speed can be increased by increasing

package angle
 To prepare weft before actual weft insertion due to high
weft insertion speed during picking
Functions of pre-winder

 The stopper pin control the release of weft yarn electro

magnetically at desired angle
 Sensor control the number of coils to be unwind. As the
required no. of coils are drawn from the drum the
stopper pin blocks the excessive coils.
 The measuring band further help to adjust the pick
more accurately
Types of Accumulators

1. Pneumatic weft accumulators or loop storage device

2. Drum pre-winders
1.Loop pre-winders

 Old type of weft storage device

 Yarn was taken in continuous manner & at constant
speed
 Yarn is blown in pipe or tube in loop form by means of
additional nozzle
 The length of yarn inserted is that delivered by roller
b/w two consecutive clamp or stopper action
Loop pre-winder
 Disadvantages of loop pre-winder
 All types of yarn can not be woven
 High twist yarn (lively yarns) can entangle with each
other
 Space required is too high
2. Drum pre-winder
 Developed more recently
 Yarn reserve is built by no. of windings or coils on drum
 Drum dia. & no of windings define pick length
Drum pre-winders

 Two types of adjustments at the fabric change

I. Changing the dia. of drum by series of fingers
II. Changing the no. of coils
 Stopper or clamp is replaced by electromagnetic pin
 The electromagnetic pin opens & closes to release
required no. of windings
 Modern drum is equipped with a sensor to make yarn
reserve at every time
Drum pre-winder

 Modern drum is equipped with a sensor to make yarn

reserve at every time
 Can adjust the yarn speed automatically according to
yarn consumption
 Stop motion sensor & pneumatic threading is also
present
 Balloon limiters are used for coarse yarn
Drum pre-winder
 Balloon limiters reduces the balloon forces which will
lead to reduction in energy consumption
 Yarn coils are separated in drum storage
 A device separate the winding or coils on drum to avoid
overlap (fingers)
 Friction on fingers of drum produce higher opposing
force during withdrawal of yarn
 The rough surface of drum is better for automatic pick
repairing
Comparison B/w drum & loop
feeders
Drum storage Loop storage
Arrival time of filling is more Arrival time of weft is not
constant constant
Suitable for high weft Suitable for low weft
insertion rate insertion rate
Better control of yarn Poor control of yarn
Shorter insertion time Longer insertion time
High initial acceleration Low initial acceleration
Yarn storage method
Parameters affecting the
unwinding tension
 Angle of package
 Crossing angle of yarn
 Winding density
 Size & surface properties of package
 Wax application to yarn
 Package diameter
 Relative humidity in yarn package
Types of pre-winder(w.r.t working)
Pre-winder
Pre-winder
Winding sensor & magnetic Pin
Toyoda Pre-winder
Band adjustment
Winding sensor & magnetic Pin
Pre-winder settings
Pick length & no. of winding setting
Pre-winder selection factor
Pre-winder allignment
Balloon Breaker
Bobbin break detector
Yarn Break (ABS or PFT)

 PFT = Programmable filling detector

 ABS = Automatic break system
 Yarn break is present at the entrance side of the
tandem nozzle
 Slows down the inserted weft to prevent sudden action
of magnetic pin
Yarn Break ABS or PFT
Yarn Break
Tension with & with out break
Air jet insertion

 Weft yarn is inserted into the warp shed with the help
of compressed air.
 Figure shows a schematic of air jet weaving utilizing a
multiple nozzle system and profiled reed.
Air jet insertion

Def: The process of drawing the filling yarn from the supply
package & inserting this yarn into the shed using a jet
of air is called air jet weaving.
Main nozzle

 It accelerate the yarn up to the required velocity

 There are two types of main nozzles
i. Fixed main nozzle: It bring the filling yarn up to the
speed & offer it to the moveable main nozzle
ii. Moveable main nozzle: it presents the filling yarn up to
the tunnel or profile of reed. It is fitted on sley.
Main nozzle

 It consists of body & injector

 The size of the injector depends upon the count of
filling yarn & its diameter is 2-3 mm.
Main nozzle
Rely nozzles
 These are also known as sub nozzles
 These are arranged through out the entire length of
reed
 Assist the main nozzle in blowing the pick through guide
channel or profile
 The sub nozzles are divided into groups & each group
works after certain time of interval
Relay Nozzles

 Each group works in such a way that second group starts

when the first is in operation
 Sub nozzles are fitted on the sley at certain angle
 Relay nozzles have varying pitch (the distance b/w two
consecutive nozzles is called pitch
Relay nozzles
 Three types of pitch
i. Normal pitch = 70-80 mm
ii. Short pitch = 30-40 mm
iii. Fixed pitch = 10-20 mm
Injection air timing of sub
nozzles
Solenoid valve

 It is connected to relay nozzle on one side & the other

to the air tank
 Regulates amount of air by electromagnet function
 The main nozzle has its own solenoid valve
 The relay nozzles are connected to solenoid in group of
2-5.
Relay nozzles & solenoid
valve
Cutters

 Two types of cutters one on picking side & other on

receiving side
 Picking side cutter is known as weft cutter & receiving
side the leno cutter
 Weft cutter cuts the filling leaving 5-10 mm thread on
selvedge
 The leno cutter separates the waste on leno waste on
receiving side
Cutters

 The cutter are sharpened after certain time with the

help of grinding wheel
 Type of cutter depends upon the yarn type
 The following parameters are important for cutters
 Cutting position
 Cutting degree
 Cutter condition
Weft sensors

 Also known as weft feeler or filling detector

 There are two sensors on receiving side known as FD1 &
FD2
 The distance b/w them is 120-130 mm
 1st sensor detect the presence of filling yarn
 2nd sensor has reverse function, it stops the machine if
filling approaches on it
Working of weft feeler

 Each weft detector consists of a light source that is

usually infra-red
 And a photo sensor which feels the emitted infra-red
light
 In the way between emitter and the receiver will
inserted yarn be available then its presence is to be
verified
Weft feeler
Weft feeler
Adjustment of weft feeler

 Intensity Adjustments

 Time of Detection
Stretch nozzle

 Ensures the stretching of the filling yarn at beat up

 Avoid slackness in the weft on receiving side
 Compensate loss in air pressure of relay nozzle
 Helps weft detectors in filling detection
Stretch nozzle
Profile reed

 Profile reed is used in air jet insertion

 Profile creates a path for the traveling of filling yarn
 Profile is in such a position that warp yarn should not be
in the way during traveling of weft
 The reed should be clean to avoid blockage
Nozzle insertion system
Air jet insertion cycle
 Figure shows a typical sequence of events during a complete
cycle in air jet filling insertion.
 After the tandem and main nozzles are turned on, yarn is
released from the clamp (stopper).
 When all the coils of the particular pick have been pulled
off the feeder, the stopper closes, the yarn deaccelerates
and then will be beaten into the fabric
Air jet insertion cycle

 Thereafter, the air is turned off and the pick is cut to

complete the cycle.
 The timing diagram of main and relay nozzles is shown.
Air jet weft insertion
Air jet Insertion
Air jet insertion

 Weft yarn is inserted into the warp shed with the help
of compressed air
 Figure shows a schematic of air jet weaving utilizing a
multiple nozzle system and profiled reed.
Effect of Air Velocity on Weft
Insertion
 The amount of propulsive or drag force on element of a
weft depends upon
 Air drag co-efficient
 Air velocity
 Yarn velocity
 Density of air
 Yarn diameter
 Incremental length of yarn
Effect of Air Velocity on Weft
Insertion
 The drag force may be transverse or longitudinal.
Effect of Air Velocity on Weft
Insertion
Effect of Air Velocity on Weft
Insertion
 Cf is also known as air drag coefficient for longitudinal
or traverse flow.
 The component of the resultant force parallel to the
undisturbed initial velocity is referred to as the friction
force (Fi) and the component perpendicular to that
direction is called drag (Fd) as shown in Figure.
Effect of Air Velocity on Weft
Insertion
Effect of Air Velocity on Weft
Insertion
 This force is proportional to the square of
the relative velocity between the air and
yam.
 The propulsive force increases with an
increase in the air velocity and the yarn
diameter.
 This is because with increasing diameter,
the yarn surface area that is in contact
with the air becomes larger.
 The dimensionless coefficient Cf is a
function of Reynolds number.
Effect of Air Velocity on Weft
Insertion
 Reynolds number is a dimensionless number that
characterises fluid flows.
 Re = Vd/v, where
V= speed of fluid flow (m/sec)
d = diameter of tube (m)
v = kinematic viscosity of fluid
Effect of Air Velocity on Weft
Insertion
 Skin friction coefficient of spun yams and thick yarns
(with a certain hairiness) is higher than that for fine and
smooth yarns.
 For untreated cotton yams the Cf is twice that of singed
cotton yams.
 For textured yarns, Cf varies depending on the openness
of the yarn structure.
Effect of Air Velocity on Weft
Insertion
Effect of Air Velocity on Weft
Insertion
Effect of Air Velocity on Weft
Insertion
 Then, yarn acceleration ceases;
friction changes from a moving to a
breaking force.
 The yarn begins to move by inertia and
loses velocity as a result of air
resistance. In other words, air acts as
a brake on the yarn rather than as a
propulsive force.
 This is the main cause of the
divergence of filling yarn from the
centerline of the shed.
Effect of Air Velocity on Weft
Insertion
 Therefore, in an ideal situation on the
machine, yarn velocity should never
exceed the air velocity.
 In this case, the buckling of the yarn tip
can be reduced as a result of the
reduction in the deviation of the yarn
from a straight path.
 To achieve this, relay nozzles (sub-
nozzles, auxiliary nozzles) are used to
maintain high air velocity (as well as high
yarn velocity) across the machine width.
Automatic feed control