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com

Air-Jet Weaving
Air-Jet Weaving

Air jet weaving is a type of weaving in which filling 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 which is the most common configuration in the market. Yarn is
drawing from a filling supply package by the filling
feeder and each pick is measured for the filling
insertion by means of a stopper. Upon release of
the filling yarn by the stopper, the filling is fed
into the reed tunnel via tandem and main nozzles. The tandem and main nozzle combination
provides the initial acceleration, where the relay nozzles provide the high
air velocity across the weave shed. Profiled reed provides guidance for
the air and separates the filling yarn from the warp. A cutter is used to
cut the yarn when the insertion is completed. Figure on the right shows a
modern air jet weaving machine.

The air jet weaving machine combines high performance with low
manufacturing requirements. It has an extremely high insertion rate. Due
to its exceptional performance, air jet machines are used primarily for the
economical production of standard fabrics, covering a wide range of styles. Meanwhile, more and more niches and
special fabric segments are covered; heavy cotton fabrics such as denim, terry fabrics, glass fabrics, etc.

Air jet filling insertion is the simplest way of inserting the filling yarn which probably explains why air jet weaving
machines are one of the most popular machines in the world today. The major components of the insertion system are
the tandem and main nozzles, ABS brake system, and relay nozzles which are relatively simple in design. The insertion
medium mass to be accelerated is very small, relative to the shuttle, rapier or projectile machines, which allows high
running speeds. Unlike rapier or projectile insertion systems, there are not many mechanically moving parts to control
and insert the filling yarn. The advantages of air jet weaving machines are:

• high productivity
• high filling insertion rates
• simple operation and reduced hazard because of few moving parts
• low noise and vibration levels
• low spare parts requirement

• reliability and minimum maintenance

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 decelerates and then will be beaten into the fabric. Thereafter, the
air is turned off and the pick is cut to complete the cycle. A typical

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timing diagram of main and relay nozzles is shown. The timed groups of relay nozzles blow air on the tip of the yarn
across the machine width. As a result, the yarn is pulled by the air at the tip (rather than pushed from behind)
throughout the insertion, minimizing the possibility of buckling which may cause weaving machine stops, This also
assures the lowest possible air consumption.

Yarn Feeders

The condition of the yarn feed into the nozzle exerts a great
influence on the movement of the yarn through the shed. Because of
the high yarn velocity during insertion, it is not possible to unwind
yarn intermittently from the filling package. Therefore, yarn storage
and feed systems are used between the nozzle and they yarn
package. There have been two main systems to store the yarn
behind the nozzle before insertion; loop storage and drum storage.
In loop storage, which has become obsolete, air was used to form a
loop and keep the yarn straight without getting entangled. This
storage system is simple in construction, however, it does not
provide positive control on the yarn. The length of the loop depends
on the diameter and speed of the measuring drum and may change
due to slippage between the measuring drum and the feeding roller.
The principle of drum storage is based on the storage of a sufficient
yarn length (more than one pick) on a highly polished metal
cylindrical body. Drum storage and yarn package may or may not
be arranged in a straight line. A stopper pin or hook controlled by a
timing control unit releases the required number of wraps of filling
yarn to form each pick. Today, drum storage is
the only yarn storage system in air jet
machines.

Insertion Configurations:

Three different systems have been used

mainly on commercial air jet weaving
machines:

1. Single nozzle, diffusor guides and

suction on the other side
2. Multiple nozzles with guides
3. Multiple nozzles with profiled reed

Figure show schematics of these three yarn

insertion systems. In System 1, a single nozzle
is used to insert the yarn. Diffusor lamellae
(thin distributing plates) are placed across the
entire width to guide the air stream which is
injected into the shed. The disadvantage of
this system is the weaving width limitation
due to lack of additional nozzles to keep the
air (and yarn) velocity high enough across the
habric width. Therefore, weaving machines
with this configuration are limited in width. In

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System 2, in addition to the main nozzle, auxiliary nozzles are used. They are arranged across the warp width at certain
intervals and inject air sequentially and in groups in the direction of yarn movement. The main nozzle consumes only a
small fraction of the compressed air used in air-jet weaving machines as compared to relay nozzles. System 3 has the
lamellae built in the reed and auxiliary nozzles across the warp. In this system the entrance and exit of the lamellae in
and out of the shed are eliminated. Thus abrasion on the warp ends is reduced and misplacement of the warp ends
between lamellae, which may cause fabric defects, is prevented. With the profiled reed, the restriction on warp density
is also less severe than the case of the confusor guide system. Although all the three systems have been used on air-jet
weaving machines, System 3, multiple nozzles with profiled reed, is the standard in the market today. Auxiliary
nozzles are placed across the machine width on the lay. A relay nozzle can have a single hole or multiple holes
arranged in the direction of yarn flight. A multi-hole relay nozzle is also called a shower nozzle.

Air Flow

The transporting medium, air has a complicated motion during the insertion. The air flow in air-jet insertion is unsteady,
turbulent and can be either compressible or incompressible depending on the velocity. It is unsteady, because, in today’s modern
weaving machines, the air is turned on and off several hundred times per minute, which does not allow a steady flow to form, in
addition to this, the guide channels arc partly open and the walls arc not very smooth which also contributes to the formation of
turbulence. It is generally accepted that, for air velocities above 100 m/s, the compressibility should be taken into account. In air jet
weaving systems, it is possible to have air velocities above and below 100 m/s during one insertion cycle, depending on the position
and time along the insertion length. In addition to all these, the velocity near the nozzle exit can be close to the speed of sound,
making it possible for shock waves to occur inside the nozzle.

Performance of Yarns in Air-jet insertion

Air-jet weaving machines are ideal for cost effective production of bulk fabrics with a wide range of styles. Air-jet machines can
handle both spun yarns and continuous filament yarns. Textured yarns are especially suitable for air-jet weaving due to high
propelling force. However, monofilament yarns are not suitable for airjet weaving because of low friction between air and yarn
which is due to smooth surface of the monofilament yarn. A wide range of fabrics from gauze fabrics to dense, heavy cotton fabrics,
from patterned dress fabrics to ribbon fabrics can be woven on airjet weaving machines.

Since the force required to move the yarn mass is provided exclusively by air friction against the yarn surface, it is largely dependent
on the yarn structure, the yarn and fibre surface, and relative motion of air and yarn. The propulsive force is largely independent of
the fiber material. Minute disturbances in the flow field can also lead to undesirable deviation of the yarn tip that result in faults or
machine stops. The air consumption of the main jet depends on the yarn type and denier. Spun yarns and coarse yarns (with a certain
hairiness) have higher air resistance coefficients than find and smooth materials. This explains why monofilament yarns cannot be
inserted with air-jet. The factors that essentially determine whether a yarn is suitable for pneumatic are its count, structure and twist.

Effect of Yarn Structure

High twist, large denier, long staple high fibril cohesion increase the standability of spun yarns to air-jet, giving longer yarn breaking
time. More air is needed to weave continuous filament fabrics than spun fabrics due to less frictional force between yarn surface and
air flow. Yarn velocity in the insertion channel increases with the number of filaments due to the larger yarn surface that is in contact
with the air.

Yarns having a larger diameter require increased air pressure for filling insertion. This is because the mass of the yarn increases in
proportion with the square of the yarn diameter, whereas the yarn surface area increases linearly with the diameter.

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