Picanol introduces the OMNIjet airjet weaving machine. The OMNIjet has been specifically designed to focus on adding value. The machine is based on Picanol’s OMNIplus 800 technology, with full electronic monitoring and control, Sumo main motor and microprocessor-controlled filling insertion. The OMNIjet machine is exceptionally user-friendly and enables the weaver to produce high-quality fabrics at high speeds while keeping the weaving cost low.

The OMNIjet meets the investors’ objective of maximizing their return on investment. The machine helps weaving mills win in the market by offering high-quality fabrics at the lowest possible cost.

The main features of the OMNIjet are:

·          Optimized insertion preparation for two or four colors or yarn types

·          Accurate, user-friendly setting of all main machine functions using the LCD display and push buttons

·          Reed width of 150, 190 or 230 cm (59”, 74.8” or 90.5”)

·          High-performance filling insertion for weaving more with less air

·          Low-built, ergonomic construction

·          Electronic Take-Up and Electronic Let-Off

·          Sumo main motor with direct machine drive, for highest speeds at lowest power consumptions

·          Fast warp gaiting and cloth doffing, no tools required

·          Rotary selvedge units

·          Easing motion

Sumo main motor

Picanol introduced the Sumo main motor in 1999 on its Gamma rapier machine. It drives the weaving machine directly, without clutch or brake. The Sumo motor soon proved to have the highest performance of any weaving machine drive train on the market and its success led Picanol to use it as the standard motor on all its weaving machines. Machine speed is set and controlled electronically, which makes it easy to obtain the highest industrial speed in function of the quality of the yarn, the number of frames, and the fabric construction.

A high-performance prewinder

The OMNIjet machine is equipped with the OMNIjet WD (Wobbling Disc) prewinder, which is uniquely designed for airjet weaving and has a wide application range. The major parameters are automatically set and the piezo bobbin break sensor prevents fabric defects and offers direct start-up possibilities at bobbin run out. The prewinder is simple to handle and maintain, and can easily be threaded through a pneumatic system.

State-of-the-art nozzles

The fixed and movable main nozzles have a high traction force, resulting in fast insertion rates with low air consumption. They can be set individually in flow or blow duration. Threading up is very easy.

A stretching nozzle at the right-hand side can keep the filling tip fully extended until it is caught by the closing shed, thus preventing the formation of loops.

Optimized sley movement

The sley movement has been optimized for maximum insertion time, thus reducing the number of weft stops.

Digitally controlled valves and cutter

The electromagnetic valves ensure perfect control of the airflow in the shed. The opening and closing times are monitored by the OMNIjet’s microprocessor. The microprocessor also controls the filling cutter and makes it possible to set the cutting times separately for each filling channel – a great advantage over mechanical systems.

Optical filling detector

The optical filling detector, mounted in front of the reed, stops the machine whenever the filling fails to reach the right-hand side of the machine. A second detector may be used to check whether the pick is broken in the shed or blown apart.

Autospeed

Thanks to the integration of the electronic insertion controls with the SUMO-drive, OMNIjet is the only machine in its class featuring Autospeed. This enables the machine speed to be automatically maximized to the conditions of the filling yarn resulting in an overall production increase.

An ergonomic machine

The slight slope of the OMNIjet machine guarantees easy access for the operator. The push buttons are always within easy reach and provide control of all the important machine functions. Access to the filling area is easy, as well as the access to adjust shed opening and harness height.

All the advantages of digitization

The electronic OMNIjet terminal monitors and controls all the main machine functions. Its big LCD screen enables the operator to set the weaving parameters in a very user-friendly way.

The settings are accurate and the result of slight adjustments can be checked immediately in the fabric. When a stop occurs, the LCD screen advises the operator which action to take.

The system can display diagnostic data and stop causes, so avoiding search time for stop detection. It also displays all the main data in shifts, giving the opportunity to maximize efficiency.

Speed changes made easy

The Sumo motor has a wide speed range, which is very useful for starting up new styles. On the OMNIjet, the foreman sets the machine speed on the keyboard even while the machine is running. This in contrast to conventional drive systems, which always involve changing pulleys and belts, or require the use of an intermediate frequency converter in order to change speed.

Automatic recalculation of insertion parameters

When the speed of the main motor changes, the microprocessor automatically recalculates the electronic insertion parameters – another example of how OMNIjet makes life easier for the machine operator. The parameters can easily be viewed on the microprocessor display.

Save and transfer settings in no time

All electronic settings can be easily reproduced or transferred from other OMNIjet machines, either by means of electronic memory cards or through a network connection: patterns, warp tension, pick density etc..

Efficient stop motions

The OMNIjet machine has an electric warp stop motion with up to 6 bars with a 30 mm (1.2”) pitch. A dropper location lever helps the operator to locate the warp break quickly.

The filling stop motion consists of an optical filling detector mounted in front of the reed (no cutting of the reed).

Central lubrication

The Electronic Take-Up (ETU), the Electronic Let-Off (ELO) and the sley are fed with oil under pressure from a central forced lubrication system controlled by the microprocessor. A microfine oil filter removes all impurities and extends the lifetime of the parts and the oil.

Robust mechanics

The OMNIjet machine is built around two cast iron side frames connected by very sturdy cross-members. This rigid structure and the perfect balancing of the mechanical parts eliminate all vibration, enabling the machine to produce high-quality fabrics at high industrial speeds continuously. The crank-driven sley motion with long stroke, the extra reinforced central 4-bar-linkage drive and the balanced sley guarantee stable beat-up, thus optimizing cloth quality.

Yarn-friendly insertion

The OMNIjet WD prewinder, the main nozzles with cylindrical inserts, the optimized sley movement, the electro-magnetic valves, the electrical filling cutter and waste cutter – they all contribute to the high fabric quality that can easily be obtained with the OMNIjet machine.

Sumo increases the fabric quality

The speed of the Sumo motor is electronically controlled and set, which makes it much easier to adapt the machine speed for optimizing the fabric quality. Additionally, the Sumo motor has a very powerful, stable, and controllable start torque – a guarantee for the best fabric quality. Starting marks can be avoided because the stop and start parameters are under complete control.

Electronic Let-Off (ELO) and Take-Up (ETU)

Electronic Let-Off and Electronic Take-Up motions are standard on OMNIjet, another feature contributing to high fabric quality. They ensure a balanced warp tension during weaving, which helps minimize warp and weft stops.

The Electronic Let-Off motion is driven by an independent servomotor. Tension control is carried out by means of an electronic sensor. The system operates very accurately from full to empty beam, an essential requirement for continuous quality.

Also the Electronic Take-Up motion is driven by an independent servomotor. Pick densities can be set from 6 to 72 picks per cm (15 to 183 picks per inch). The required pick density is electronically set so that no pick wheels are required. The accuracy of the settings makes it easy to adjust the pick density of the fabric for optimum fabric weight and minimum yarn consumption. The settings are also easy to reproduce on other machines.

Both let-off and take-up have a continuous control system (not on/off) to fully assure the cloth requirements. The electronic link between let-off and take-up is an additional tool for the weaver to manage stop/start fabric marks.

Based on experience built up over many decades

Picanol’s thorough knowledge of weaving technology and of the global textile market have enabled it to develop and produce an airjet weaving machine that provides the perfect balance between price and performance. The machine offers all main features of the Picanol technology such as full electronic monitoring and microprocessor-controlled filling insertion. As a result, the OMNIjet weaving machine is certain to meet the investors’ objective of maximizing their return on investment.

Modular concept

In designing the OMNIjet machine, a lot of attention was paid to minimum initial investment cost. The modular concept is a built-in flexibility that allows adaptations. As an example: deciding for an crank motion today still leaves the possibility to modify the machine to a cam- or dobby-motion in the future.

Consuming less air

The OMNIjet machine consumes less air than its competitors. Highly effective main nozzles, yarn friendly relay nozzles, valves directly mounted on the air-tank, optimum sley motion, … they all contribute to a reduced pressure drop in the air distribution system.

Adaptive Relay Valve Drive (ARVD)

The unique ARVD-system is a further development that automatically adapts the relay nozzle timings throughout the insertion, making use of the advanced integrated electronic controls. This results in an absolute minimization of the air consumption.

Consuming less energy

The combination of the highly energy efficient Sumo motor with the direct drive of main shaft and shedding motion results in power savings of more than 10% in comparison with conventional clutch and brake configurations. Moreover, the energy cost for air conditioning is also reduced as the Sumo motor dissipates less heat in the weaving mill.

Minimum maintenance with fewer spare parts

The Sumo system requires no extra downtime of the machine and no workload of the staff for mechanical checking and maintenance, as is required by conventional clutch/brake systems. With the Sumo direct-drive, on the contrary, there is no clutch, no brake coils, no flywheel, and no separate motor for slow motion movements ... The absence of all these parts means that both their maintenance and spare parts consumption are eliminated: this is the “savings by design” philosophy.

For more information, please contact Erwin Devloo, Ter Waarde 50, 8900 Ieper, Belgium, tel. + 32 57 222 090, edv@picanol.be.