Air Jet Weaving Relay Nozzle Control for Yarn Insertion
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Solution Overview
Problem
Air jet weaving machines face inefficiencies in compressed air consumption and timing, leading to weaving faults due to improper timing and air flow rates for weft thread transfer, resulting in increased energy usage and process interruptions.
Innovation Solution
The method involves controlling the air flow rate of relay nozzles in an air jet weaving machine by adjusting the pressure of the air supplied and throttling it between the air tank and the nozzles, allowing for real-time tuning based on the type and properties of the weft thread, thereby optimizing air flow rates across different zones of the shed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the air flow rate of relay nozzles is increased to ensure proper weft thread transfer, then the reliability of yarn insertion is improved, but the compressed air consumption increases
Solution Approach 1:
The patent applies dynamics by making the air flow rate adjustable and adaptable rather than fixed. The system dynamically adjusts air flow rates based on real-time measurements of weft thread arrival time and speed, allowing optimal air consumption for each insertion event while maintaining reliable yarn transfer.
Solution Approach 2:
The patent changes physical parameters of the air jet system, specifically adjusting air flow rates and timing based on measured weft thread behavior. By varying these parameters according to actual performance data, the system achieves reliable insertion while minimizing compressed air consumption.
2Productivity
If the air flow rate is uniformly high across all relay nozzles to ensure weft thread arrival, then the productivity is maintained, but the loss of substance (compressed air) increases
Solution Approach 1:
The patent applies local quality by assigning different air flow rates to different relay nozzles based on their specific positions and functions within the shed. Instead of uniform high air flow across all nozzles, each nozzle receives customized air supply optimized for its local requirements, reducing overall compressed air consumption while maintaining productivity.
Solution Approach 2:
The patent uses partial action by providing compressed air only to the specific relay nozzles that require it for effective weft thread transfer, rather than activating all nozzles at full capacity. The system selectively applies air support based on measured performance needs.
3Manufacturing precision
If the timing of relay nozzles is adjusted to optimize weft thread transfer, then the manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
The patent implements feedback by measuring the actual arrival time and speed of weft threads and using this information to adjust the timing and air flow rates of relay nozzles. This closed-loop control system improves manufacturing precision while keeping the control logic relatively simple and systematic.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces compressed air consumption by at least 10% while maintaining acceptable weaving interruptions, ensuring precise air flow adjustments to enhance the weft thread transfer process.
Implementation Method 1
the weft thread to be inserted, i.e. the weft yarn or the weft, is inserted in the shed at the insertion side by means of a jet of air, provided from a main jet nozzle
Implementation Method 2
Relay nozzles can be provided with compressed air, in order to assist the yarn, more particularly the yarn tip, to fly to the opposite side of the shed
Implementation Method 3
At the end of the shed, opposite to the insertion side, optionally a stretch nozzle is provided, which may be provided with compressed air when the yarn tip arrives at this opposite side. The stretch nozzle causes the yarn to remain straight in the shed before and during the actual beating-up of the inserted yarn
Data Source
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AI summary
The present invention provides a method and an apparatus for controlling transportation of a weft (8A, 8B, 8C) through a shed (1) of an air jet weaving machine. The shed (1) comprises, in transport direction of the weft, subsequently at least a first zone (zone 1) and a second zone (zone 2). The method comprises controlling the air flow rates of relay nozzles (4[i]) in the zones so as to accelerate the weft (8A, 8B, 8C) through the first zone (zone 1) of the shed, and so as to transport the weft (8A, 8B, 8C) through the second zone (zone 2) of the shed. The shed may furthermore comprise, in transport direction of the weft, subsequent to the first zone and the second zone, a third zone (zone 3). The method in these embodiments comprises controlling the air flow rates of the relay nozzles so as to allow the weft to stretch in the third zone of the shed. The apparatus comprises corresponding apparatus parts.