1.

OBJECTIVE:-

The project entitled Study of weft break control in Air jet loom aims at
study of the Air jet loom in brief and the passage of weft through it, recognizing
the different type of weft break occurring at loom, their analysis, finding out the
reason and root cause for occurrence of same.

The object of project is to study weft breakages and control its occurrence
and reduction of the same and therefore enhancing the profit of the
organization.

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2. BRIEF INTRODUCTION TO AIRJETLOOM & PASSAGE OF
WEFT THROUGH IT:-
INTRODUCTION:-
Air jet weaving is a type of weaving in which the weft yarn is inserted into the warp
shed with compressed air. The air-jet weaving machine combines high performance with low
manufacturing requirements. It has an extremely high weft 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 special
fabrics are also covered: heavy cotton fabrics such as denim, terry fabrics, glass fabrics, tire
cord etc.

Salient features of Air jet loom:-

Loom is compact and easy to operate.

Electronic let-off motion is provided.
Productivity of loom is more as compared to the conventional loom.
Cloth roll can be doffed while the machine is running.
Dobby shedding motion is provided.
Leno selvedge is provided to bind the fabric.
Easing motion is provided to compensate for the difference in tension during opening
and closing of the shed.
Colour lamp indication system is used to indicate stop.
A microprocessor is provided which indicates the stop, efficiency, loom speed,
number of picks/minute and angular position of loom etc.

Requirement for Air jet loom:-

Sized warp beam and weft Packages.

Maintained air pressure in the loom shed.
A pre-measuring device for measuring the pick length.
Air nozzle to guide the weft.
Suction device.
Warp and weft stop device.
Temple to grip the fabric.

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PASSAGE OF WEFT IN AIR JET LOOM:-

Three different systems have been used mainly on commercial air-jet weaving
machines:-

1. Single nozzle, confuser guides and suction unit at the exit side
2. Multiple nozzles with guides
3. Multiple nozzles with profiled reed

Although all three systems have been used in commercial looms, the System3 is the
most common and standard configuration in the market.

The air jet looms present in terry towel weaving department, where the project work
has been carried out, are equipped with the third type of configuration i.e. multiple nozzles
with profile reed. So without going into details of first two type, the last type is discussed as
follows.

Passage:-

Weft Tensioner: Additive disk type tensioner is used for weft insertions which maintain
proper tension in the weft yarn.

Weft break sensor: It is an electric sensor which detects any weft break in the region
between weft package and accumulator and automatically stops the loom in case any weft
breaks.

Accumulator: It is a device which fitted between weft package and main nozzle that
unwinds a predetermined length of weft from the package and stores it in the form of no. of
coils on a cylindrical drum. This weft yarn then fed in to insertion device.

Guide and ABS system: This system sharply reduces peak tension that occurs at the end of
filling insertion in order to prevent filling breakage and selvedge looseness. The WBS
precisely controls brake timing and brake stroke according to the yarn release timing detected
by the FDP sensor.

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Stopper Pin: It is an electronically controlled electromagnetic device integrated along with
the accumulator. Its function in releasing the yarn at starts of insertion and stop it at the end
of insertion.

Balloon breaker: it is fitted just after accumulator, its function is to separate the balloon
formation. So as to reduce as ballooning tension as well as minimize the tension fluctuation.
It is generally used for coarser yarn.

Fixed main nozzle: its function is to form the air jet from compressed air with the required
velocity and acceleration characteristics and project it in a proper direction in to air guide
channel.

Relay nozzle or sub nozzle: fitted in series along the sley. It creates an additional air flow in
the direction of air jet. So as to compensate the loss of air velocity.

Catcher Pin: It catch holds the weft after picking at nozzle side so that it can be properly
held for beating.

Profile reed: here the reed is profiled. So as to form a guide channel which guide the air jet
as well as weft during insertion.

Weft detector: it is an optical device fitted at the end of reed at the receiving side. Its
function is to check the arrival of weft at the receiving side .in case of late arrival or miss
pick, then it sense and automatically stopped the loom.

Stretch nozzle: located just beside the weft detector .it supplement the effect of enhanced
stretching action on the weft by the closely spaced relay nozzle at the end of insert ion. So as
to prevent the chance of weft recoiling due to action of stopper.

Selvedge cutter: located at the receiving side. It is an electronically operated mechanical

device which cut the weft yarn extending between fabric and auxiliary selvedge. So as to
separate the auxiliary selvedge which is passed out as a waste.

Weft insertion in Air jet picking:-

Weft insertion by means of air jet consists of

-The air flow from the nozzle.

-The air flow through the shed.
-The weft motion.

The transporting medium has a complicated motion.

Air flow in weft insertion is unsteady, turbulent, and can be either compressible or
incompressible depending on the velocity (for air velocities above 100 m/s, compressibility
should be taken into account).
The main nozzle applies the necessary driving force to initiate the insertion of
predetermined length of weft yarn.
The air jet flying in a free space entrains (becomes mixed) with the environmental air and
loses its velocity on a relatively short distance.
The integrity of the air is preserved by either a confuser or a tunnel (profiled) reed.

4
3. TYPES OF WEFT BREAKAGES WITH REASON AND
ANALYSIS:-

Here in this section the diagram of different type weft breakages along with their cause and
possible steps to rectify them are discussed.

1.

Reason:- i) Obstruction due to fibre tuft

ii) Insufficient amount of air pressure at sub nozzle
2.

Reason:- i) Yarn cut due to thin place in yarn

ii) High Pressure at nozzle
3.

Reason:- i) Presence of fibre tuft in shed

ii) Low air Pressure
iii) Incorrect Drawing-In
4.

Reason:- i) Presence of Fibre tuft

ii) Low Pressure in sub-nozzles
5.

Reason:- i) Improper shed opening timing of selvedge

ii) Insufficient pressure in air nozzle

5
6.

Reason:- i) Blockage in nozzle

ii) Valve problem
7.

Reason:- i) Obstruction in the path of weft due to fibre tuft

ii) Low pressure in sub nozzle
iii) Block sub nozzle
8.

Reason:- i) Presence of fibre tuft in shed

ii) Low Pressure at in sub nozzle
9.

Reason:- i) Problem in Leno heald

ii) Low pressure in sub nozzles
10.

11.

Reason:- i) Excess pressure in the nozzle

ii) May be due to problem in air valve
(Note:- If such problem occurs once or twice than it may be due to excess pressure
but if continues to occur frequently than it may be spinning fault having
many thin places in yarn.

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12.

Reason:- i) Improper drawing in of selvedge

ii) Low pressure of sub nozzle
iii) Presence of fibre tuft in shed
13.

Reason:- i) Presence of tuft or dirt in shed obstructing the passage of yarn

14.

Reason:- i) Presence of tuft or dirt in the shed

ii) Less amount of pressure in air
15.

Reason:- i) Improper shed opening

ii) Low air pressure of sub nozzle
16.

Reason:- i) Low pressure of nozzle

ii) Presence of tuft or fibrous material
17.

Reason:- i) Improper Shed opening

ii) Insufficient pressure at sub nozzle of air

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18.

Reason:- i) Blockage in main nozzle

ii) Problem in valve
19.

Reason:- i) Presence of tuft in shed

ii) Loose Thread
20.

Reason:- i) Insufficient Pressure in air nozzle

21.

Reason:- i) Blockage in main Nozzle

ii) Problem in air valve
22.

Reason:- i) Presence of tuft or dirt in the loom shed

23.

Reason:- i) Improper Drawing-in of warp

ii) Presence of knot at warp thread

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24.

Reason:- i) Knot in warp thread

ii) Presence of tuft or fibrous material
iii) Improper Pressure of air
25.

Reason:- i) Blocked by catcher pin

26.

Reason:- i) Improper arrival timing of weft

27.

Reason:- i) Low pressure in air nozzle

28.

Reason:- i) Knot in Pile thread

29.

Reason:- i) Damaged WBS pin

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30.

Reason:- i) Thin place in yarn

Identifying and avoiding weft stoppages:-

Depending on where they occur these different type of faults can be usually be
divided into following categories

1) Weft loop close to left selvedge

2) Weft loop in the shed mid way along the weaving width.
3) Weft loop on the right in temple region.
4) Snarl in the shed.
5) Snarl in the drawing in area on right.
6) Snarl at the pick tip mainly on the right.

Possible causes of weft loops

I) If occur at left selvedge

- Selvedge draw-in
- Setting of shed
- Setting of main nozzle
- Cutting time and condition of weft cutter
II) If weft loop and snarls mainly occur in the centre and on the right of drawing-in
- Blowtime
- Air pressure of rely nozzle
- Reed and warp preparation
III) If Snarl on far right
- Weft arrival timing
- Air pressure setting

Possible Rectifications:-
I) Bent Pick

1) Check catch cord drawing in and its position

2) Air pressure of all nozzle
3) Heald frame height and shed crossing
4) Check stretch nozzle timing & position
5) Reed dent gap opposite to stretch nozzle
6) H1 feeler head condition to check any damage
7) Binding of leno yarn

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 II) Nozzle mark

1) Check sub nozzle angle and height

2) Check stretch at tip of sub nozzle
3) Sub nozzle should be parallel
4) Check reed dent

III) Jerky/Missing picks

1) Check working of H1 & H2 Feeler

2) Check feeler timing on i-board
3) Check sensitivity of H1 & H2 feeler
4) Clean H1 & H2 feeler head
5) Check take up belt & gears, beam pinion condition

List of Factor that influence weft breaks and loom stoppages in Air jet
weaving:-

1) Pressure of all nozzles

2) Standard air pressure for different type of yarn
3) Distance between nozzles
4) Timing of activation of sub nozzles
5) Hairiness in yarn
6) Thick and thin places in yarn
7) Yarn strength
8) Yarn twist
9) Sensitivity of sensors
10) Cleanliness of sensor
11) Tension maintained in weft passage
12) Proper placing of reed
13) Beating timing
14) Overall timing setting of loom
15) Speed of loom etc.

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4. APPLICATION OF STUDY :-
For the practical application of the study carried out during project, a loom with cmpx
more than 30 and efficiency below 60% is selected and attended for 7 hours(420 minutes),
the detail of this is described as follows.

Date:-17/06/2016

Shed no: 05

Loom no: 153

Model: Zax 9100 Professional Terry

Time: 9.30 AM- 4.30PM (7 hours)

Efficiency : 56.2%

CMPX: 31.9

After attending the loom some of the weft breakages have been observed. It has been
found that fibre tufts are accumulated below the fell of the cloth and randomly obstructing the
passage of weft. By compressed air it is cleaned. Another problem in the loom is that, the
ground beam has many crossing end also at the centre of loom at a particular place a yarn has
knots at random interval. The yarn up to a particular length is cut and piecing with another
thread is done. The crossing of thread is rectified up to the extent possible. All the things are
done by the worker to whom the loom is allotted.

After taking the above mentioned steps it has been observed that the number of weft
break is remarkably reduced as compare to it was since the beginning of the shift. From 8.30
AM to 10.00AM the weft breaks due to the fault were around 6. From 10.08 AM to 11.15AM
no weft breakages occur except one which is due to exhaustion of cone.

The efficiency and CMPX (filling) is checked at random time interval and noted. In
between some stoppages occur due to warp breakages which reduce the efficiency also due
them and warp yarn preparatory faults some weft breaks occur increasing the cmpx.

Observing the loom and up to the recess hour it has been found that the efficiency of
the loom is found to be increased from 56.2% to 69.6% and CMPX is reduced from 31.9 to
19.8. During recess hour the efficiency again went down to 60.7% due to weft breakages but
the main reason behind it found to be late response of the workers to rectify the problem. In
between 1.30PM to 2.15PM loom remains ideal almost 43 minutes. It is because the workers
in the shed of concerned section are not in sufficient number and they are attending the other
loom stoppages. During this period the weft breakage is 5 in number. Then again the loom is
observed seriously and necessary action is taken. In between this period of 2.30PM to
3.26PM the number of weft break is 4 and then it is again reduces remarkably i.e no weft
break for more than a hour from 3.26PM to 4.36 PM. However the time taken for application

12
of study was only up to the end of the shift i.e 4.30PM, still some more time is taken for
observation.

Result:-
After application of information in controlling of weft breakage and taking the
reading of efficiency and cmpx at random interval the following graphs are obtained.

80

70

60

50
Efficiency %

40

30

20

10

0
0 70 74 78 89 105 130 180 182 196 270 298 321 377 387 392 396 405 409 420
Time (in Minutes) Efficiency

35

30

25

20
CMPX

15

10

0
0 70 74 78 89 105 130 180 182 196 270 298 321 377 387 392 396 405 409 420
Time (in Minutes) CMPX

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 From the above two graphs it can be clearly seen that the efficiency of loom is
increased from 56.2% to 69.9% and the CMPX is reduced from 31.9 to 17.4 up to the end of
the shift.

During the complete study and application of the same for the weft break control it
has been observed that the weft break can be controlled by proper observation and
identification of the cause behind weft break and take instant step to prevent further
stoppages for the same weft break reason.

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5.ADVANTAGES OF WEFT BREAK CONTROL AND
SUGGESTIONS:-
Advantages:-

1. Cost Reduction:
When we reduce the yarn breakages the loom, the cost is also reduced. If there are
stoppages at the loom because of any yarn breakages problem than it will be repaired and
some cost will increase in this manners. When we entangled this problem which cause the
loom to stop, the cost automatically goes down.

2. Man Power
After resolving the problem which cause loom to stop man power will also b reduced.
If there is problem of yarn breakage constantly at the loom than a person will be required to
handle this situation, and when we solve this problem than there will be no need of person
constantly at the loom.

3. Effect on Production:
When there is problem of yarn breakage or problem in the mechanical part of loom,
the loom will stop to work. In this way the productivity of loom will be affected and when we
solve these problems production will also be increased.

4. Quality of Fabric:
Yarn breakages on the loom also affect the quality of fabric. When there is constant
breakage of yarn and there is definite knotting for this problem. It will damage the quality of
fabric. When these problems are solved the quality will also be improved.

5. Wastages of Yarn:
Constant yarn breakages on loom due to different problems also cause the wastage of
yarn .This problem will also be solved by reducing the yarn breakages on the loom.

6. Loom Efficiency:
When the yarn breakages occur because the looms to stop are reduced the loom shut
down will also be reduced. This will affect the efficiency of loom and it will increase.

7. Department Efficiency:
When there are some problems in weaving department and suppose 10 looms out of
100 looms are not working, it will affect the department efficiency and it reduced 10%
straight away and when the different problems are solved out the department efficiency will
also increase.

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8. Reduction of Start Mark:
Start Mark is a sign which comes on the surface of the fabric when a loom is restarted
after a shut down. When there is any problem due to which loom gets off again and again it
will leave a Start Mark at the surface of fabric and it effect the fabric very badly. After
solving the problem this effect will also be reduced and a good quality fabric will obtain.

Suggestion:-
Here is some suggestion for further improvement in machineries and training of
workers to control weft break in Air jet loom.

1) Assembly of clearing air pipes below sub nozzles should be fitted so that it will
give air thrust inside shed and the fibrous material and tuft are removed. The
activation of these should not match with air nozzle, such setting should be done.
2) A sensor in accumulator is fitted to sense thin places. It will help to avoid crack
formation.
3) Improvements should be done at sub nozzle air piping and some kind of sensor
should be fitted to detect air pressure in sub nozzle. If it is lowering the sensor
should sense it and automatically clear the piping system for proper flow of air.
4) At a particular pressure different count of yarn will travel with different velocity.
By experiment basis standard air pressure level of different type of yarn should be
prepared.
5) It has been observed that fibres get accumulated below the place of beating i.e
below fell of the cloth. It has to be cleared regularly.
6) Study of different type of filling breaks should be done and diagrams are
developed with proper reason and a manual is prepared and provided to the
workers during training period. It will help new workers in the loom shed to detect
and rectify breakages easily and instantly.

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6.CONCLUSION:-
By this project work the various types of possible weft breakages are studied along
with their reason and necessary steps that have been taken to rectify them. This project also
allows us to learn more about air jet loom practically which will help us to understand this
topic as per curriculum and syllabus in future. This also helped us to learn how practically
problems are handled in an industry which will be useful to us in future when we will join
industry field.

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