The air-jet loom is an advanced weaving technology, known for its extremely high weaving speed and superior production efficiency. To maintain this peak performance capability, the installation and replacement of air-jet loom spare parts must be carried out with absolute technical precision. Unlike rapier looms, air-jet looms rely entirely on a pneumatic system for weft insertion; therefore, the accuracy of every solenoid valve, nozzle, and mechanical detail directly affects fabric quality and machine downtime.
Even a small deviation in the installation process of air-jet loom spare parts can lead to weaving defects, increased operating costs, and significantly reduced component lifespan. This article will present a detailed, professional procedure, from preparation to calibration, helping maintenance engineers perform the installation and replacement of loom spare parts optimally.
1. Preparation Before Installing Air-jet Loom Spare Parts
Thorough preparation is the first and most crucial step to ensure the replacement of air-jet loom spare parts is fast, accurate, and safe. Poor preparation can cause greater errors after installation.
1.1. Ensuring Workplace Safety (LOTO)
Safety is the top priority when working with air-jet loom spare parts:
- Disconnect Main Power: Implement the LOTO (Lockout/Tagout) procedure by disconnecting and locking the power source, and attaching warning signs to ensure the machine cannot start accidentally.
- Release Compressed Air: The air-jet loom operates with high-pressure compressed air. All compressed air must be released from the accumulator and piping system before dismantling any loom spare parts related to pneumatics (such as nozzles, valves).
- Use Protective Equipment: Wear gloves, safety glasses, and safety shoes.
1.2. Preparing Tools and Replacement Components
Adequate preparation of tools and replacement air-jet loom spare parts helps minimize downtime:
- Specialized Tools: Prepare wrenches, Allen keys, a Torque Wrench, Feeler Gauges, and electronic timing measurement devices.
- New Air-jet Loom Spare Parts: Check the part number and condition of the new loom spare parts. Ensure the component is genuine, free from cracks, chips, or deformation.
- Support Materials: Prepare specialized lubricant (e.g., high-temperature grease), Threadlocker adhesive, and clean, lint-free cloths.
1.3. Recording Initial Technical Parameters
Before dismantling air-jet loom spare parts, it is necessary to record the current installation position and parameters:
- Detailed Photography: Take close-up photos of the position and angle of the air-jet loom spare parts to be replaced, especially solenoid valves and adjustment mechanisms.
- Record Timing Values: For time-sensitive parts (like nozzles), record the initial timing values on the machine’s control panel.
2. Installation & Replacement Procedure for Nozzle System Air-jet Loom Spare Parts
The Nozzle System is the heart of the air-jet loom, primarily responsible for weft insertion. The replacement process for these air-jet loom spare parts requires absolute precision.
The nozzle system includes the Main Nozzle and the Relay Nozzles.
2.1. Replacing the Main Nozzle
The main nozzle is the air-jet loom spare parts that provide the initial thrust for the weft yarn:
- Dismantling: Remove the air hoses and electrical wires connected to the solenoid valve. Remove the bolts securing the old nozzle. Thoroughly clean the installation cavity, removing lint and residue.
- Installing the New Nozzle: Install the new main nozzle into position. Use a Torque Wrench to tighten the securing bolts according to the manufacturer’s recommended torque (which is usually a small, precise torque). Insufficient torque will cause air leakage, while excessive torque will damage the threads or deform the loom spare parts.
- Checking Concentricity: Ensure the main nozzle bore is perfectly aligned with the weft yarn path.
2.2. Replacing Relay Nozzles
The relay nozzles are air-jet loom spare parts that maintain the speed and trajectory of the weft yarn across the full fabric width:
- Removal: Remove the relay nozzles along the reed. Check the wear condition of the auxiliary air pipes.
- Installation: Install the new relay nozzles into the groove. The position and inclination angle of each relay nozzle must be precisely according to the machine standard. Inclination deviation will cause the air stream to deviate, resulting in the weft yarn not arriving in time or being blown backward.
- Gasket Material: For certain machine models, new rubber gaskets or cushioning material must be used when installing the loom spare parts to ensure a perfect airtight seal.
2.3. Nozzle Timing Calibration
After installing the air-jet loom spare parts, the air blow timing needs to be calibrated:
- Electronic Setup: Access the machine’s Control Panel. Reset the opening and closing time of the solenoid valves for the main and relay nozzles (usually measured in degrees of crankshaft rotation).
- Stroboscope Check: Use a Stroboscope to check the air flow. Observe whether the air stream is ejected at the set angle. Properly functioning loom spare parts must eject air at the exact moment the weft yarn begins insertion.
3. Replacement Procedure for Mechanical Control System Air-jet Loom Spare Parts
Mechanical air-jet loom spare parts include drive components, the shedding system (Dobby/Jacquard), and the beat-up system. Faults in these parts cause vibration and mechanical deviation.
3.1. Replacing Drive Gears and Bearings
Gears and bearings are air-jet loom spare parts that endure high load and wear:
- Careful Dismantling: When removing gears or bearings, use specialized removal tools (Pulley Puller) to avoid damaging the shaft.
- Installing New Bearings: Install the new bearings (air-jet loom spare parts) into the housing. Only apply gentle pressure; do not use a hammer directly as it can damage the race.
- Backlash Adjustment: After installing new gears, the gap between the teeth (Backlash) must be checked and adjusted according to the manufacturer’s standard. Excessive backlash causes noise and vibration; too little causes binding and machine overheating.
3.2. Replacing the Weft Cutter
The weft cutter is a fast-consuming air-jet loom spare parts, requiring regular replacement to ensure a clean selvedge:
- Dismantling: Remove the old blade. Thoroughly clean the gripping and holding mechanism.
- Gap Adjustment: Install the new blade. Use a Feeler Gauge to check the gap between the fixed blade and the moving blade. This gap must be extremely small (usually less than ). Gap deviation is the main cause of incomplete yarn cutting.
- Checking Movement Mechanism: Ensure the movement mechanism of the cutter (an air-jet loom spare parts) operates smoothly, without jamming or excessive play.
4. Replacement Procedure for Electronic and Sensor Air-jet Loom Spare Parts
Air-jet looms rely on sensors and electronic controllers for high-speed monitoring and response. Electronic air-jet loom spare parts must be handled carefully to avoid ESD (Electrostatic Discharge).
4.1. Replacing the Weft Sensor
The weft sensor (usually optical) is the air-jet loom spare parts that signals a fault when the yarn breaks or is missed:
- Dismantling: Disconnect the cable before removing the old sensor. Clean the mounting area.
- Installation and Positioning: Install the new sensor. The sensor must be positioned precisely to correctly detect the yarn. Use a gauge to check the distance from the sensor to the yarn according to the technical guidelines.
- Sensitivity Calibration: After installing the air-jet loom spare parts, the machine system must be accessed to recalibrate the sensor’s Sensitivity Adjustment to match the type of yarn being woven.
4.2. Replacing Solenoid Valves
Solenoid valves control the timing and pressure of the air blow, making them critical electronic air-jet loom spare parts:
- Resistance Check: Before installing the new valve, check the resistance of the solenoid coil with a VOM meter. The resistance value must be within the allowable range.
- Installation and Thread Locking: Install the new solenoid valve into position. Use specialized Threadlocker to secure the valve, preventing displacement due to vibration.
- Air Tightness Check: After connecting the air hoses, carefully check the connections for any air leaks. Air leakage is a leading cause of reduced pressure and decreased yarn transport efficiency.
5. Reed Installation Procedure – Critical Air-jet Loom Spare Parts
The Reed is the air-jet loom spare parts responsible for beating up the weft yarn and positioning the warp yarns. This component determines the quality of the fabric surface.
The reed installation procedure requires high uniformity and balance.
5.1. Cleaning the Mounting Frame and Gap
- Comprehensive Cleaning: The reed mounting frame must be thoroughly cleaned. Remove all lint and old oil residue.
- Checking the Sley Drive: Check the wear and smoothness of the sley drive guide rails. If the rails are worn unevenly, the reed will beat up the weft crookedly.
5.2. Installing the New Reed
- Balanced Installation: The new reed (air-jet loom spare parts) must be installed into the Reed Frame in a balanced and vertical manner.
- Tension Check: Check the tension of the reed. If it is an adjustable reed type, ensure the tension is uniform across the entire fabric width.
5.3. Beat-up Timing Calibration
- Angle Check: Use an angle gauge to check the timing of the reed beating up the weft yarn into the fabric fell. This timing (usually measured in degrees of main shaft rotation) must be precise according to the machine standard. Beat-up timing deviation will cause density marks on the fabric.
- Air-jet Loom Spare Parts and Air Pressure: Ensure the inlet air pressure of the main nozzle is adjusted appropriately for the weaving speed. Low air pressure can cause the yarn not to be inserted at the correct beat-up timing.
6. Summary of the Procedure and Benefits of Genuine Air-jet Loom Spare Parts
Adhering to a professional installation and replacement procedure for air-jet loom spare parts provides dual benefits: reduced downtime and optimized output product quality.
Genuine air-jet loom spare parts ensure perfect compatibility, minimizing the risk of errors during installation and calibration.
- Minimize Weaving Defects: Precise installation of air-jet loom spare parts ensures correct timing, thereby reducing yarn break rates and weaving defects.
- Optimize Speed: Air-jet loom spare parts installed and calibrated correctly allow the machine to operate at maximum speed while remaining stable.
- Extend Lifespan: Correct installation torque, positioning, and proper lubrication help air-jet loom spare parts avoid premature failure due to mechanical errors.
7. VieTextile – Professional Air-jet Loom Spare Parts Supplier
VieTextile is a trusted partner, supplying a full range of genuine air-jet loom spare parts, along with in-depth technical guidance on installation and maintenance. We are committed to delivering superior stability and performance to your production line.
Investing in high-quality air-jet loom spare parts is a strategic decision that ensures minimized weaving defects and maximized productivity.
- Quality Commitment: We only supply air-jet loom spare parts from clear origins, meeting the strict technical standards of leading global air-jet loom manufacturers (such as Tsudakoma, Toyota, Picanol).
- Comprehensive Solutions: VieTextile supplies everything from consumable air-jet loom spare parts (such as solenoid valves, nozzles) to complex mechanical and electronic components (such as controllers, sensors).
- Technical Support: Our experienced engineering team is ready to provide in-depth consulting on the installation procedures for air-jet loom spare parts, helping your factory troubleshoot quickly and accurately.
8. Frequently Asked Questions (FAQ) About Air-jet Loom Spare Parts
Q1: Which air-jet loom spare parts are most susceptible to failure due to friction? A1: Ceramic thread guides and metal components in direct contact with the yarn, such as the cutter blade and nozzles. These are air-jet loom spare parts that need frequent surface smoothness checks.
Q2: How does an air leak affect weaving efficiency? A2: Air leaks reduce the air pressure propelling the yarn. This results in the weft yarn not reaching the selvedge in time, causing short weft ends, missed weft errors, and forcing the machine to reduce speed.
Q3: Is it necessary to recalibrate the timing after replacing a new solenoid valve? A3: Absolutely necessary. A new solenoid valve is a critical air-jet loom spare parts component that requires electronic and mechanical timing checks to ensure the valve opens and closes at the correct main shaft angle.
Q4: Which machine models does VieTextile supply air-jet loom spare parts for? A4: We supply air-jet loom spare parts for many popular air-jet loom series such as Tsudakoma (ZA, ZAX series), Toyota (JAT series), and Picanol (OMNI, TERRY MAX series).
Q5: Is the use of Threadlocker necessary when installing air-jet loom spare parts? A5: It is very necessary. Air-jet looms operate at high speed and vibration. Threadlocker helps secure the screws of air-jet loom spare parts (especially solenoid valves and sensors) from loosening due to vibration.
Q6: How to check the airtightness of the pneumatic system after replacing air-jet loom spare parts? A6: Use soap solution or specialized leak detection equipment sprayed onto the connections. The appearance of bubbles indicates a leak.
Q7: Does replacing a drive bearing require timing calibration? A7: If the bearing is in the main drive system (such as the camshaft), replacing the air-jet loom spare parts may alter the mechanical clearance (backlash). The entire mechanical timing of the related system needs to be rechecked.
Q8: Does VieTextile offer installation training services for air-jet loom spare parts? A8: Yes. We offer specialized technical training programs on the maintenance and installation procedures for air-jet loom spare parts for our customers’ engineering teams.
To ensure your air-jet loom operates with maximum efficiency and highest stability, mastering and adhering to the air-jet loom spare parts installation procedure is a mandatory requirement. Contact VieTextile for consultation and high-quality component supply.
Contact Information:
- Hotline: 0901 809 309
- Email: info@vietextile.com
- Website: https://vietextile.com
