Exploring the drawbacks of main nozzle design in air-jet weaving: Current challenges and future directions

Air-jet weaving is the most productive weaving technique. It uses compressed air for weft transportation. The main nozzle plays a crucial role in the efficiency of the process and the quality of the woven product. The basic design of the main nozzle consisting of separate nozzles for different wefts has remained unchanged since its inception. This design has certain drawbacks that affect the performance and efficiency of the process. This study throws light into these drawbacks with the help of numerical simulations. A generic main nozzle with eight nozzles is chosen for the study. The orientation of the nozzles with respect to the weft channel affects the performance of the nozzles. The difference in the performance of the nozzles is analysed to understand the deficits of the nozzle and its impact on the process. The paper also proposes a novel design concept for the main nozzle that can overcome the identified limitations. In addition, an economic analysis is conducted to quantify the potential savings with the proposed nozzle system with a focus on the German market. The authors also suggest future research directions to realise and test the new concept that can improve the efficiency and productivity of air-jet weaving. • The design limitations of the main nozzle are identified. • A new design concept that addresses the limitations is proposed. • Energy cost reduction of over 5 million euros annually in Germany. • CO 2 emission reduction of around 6500 tonnes annually in Germany.