The workflow of high-speed jacquard machines (taking mainstream electronic jacquard machines such as Staubli TXL, Bonas, etc.) can be divided into the following continuous stages according to the timeline from "preparation" to "weaving" and then to "stop":
1. Pattern preparation and data distribution (before weaving)
Pattern design and conversion: Designers use CAD pattern design software to draw patterns, and the software converts the patterns into binary or hexadecimal needle data (i.e. the lifting and lowering status of each needle at each latitude) according to the organization rules of warp and weft yarns.
File transfer: The operator opens the pattern file (such as. EP,. JPG format, etc.) in the control system (industrial PC/HMI touch screen) and confirms the process parameters such as "lifting sequence".
. Command Issuance: Click "Send File", and the pattern data will be downloaded to the single board computer or driver module of the jacquard faucet through a bus (such as CAN bus, industrial Ethernet RS485, etc.). The internal memory of the faucet is ready and waiting to be called at any time.2. Start up and synchronization establishment (at the moment of startup)
System power on and self-test: Connect the air source and power supply, start the control computer and servo drive system.
. The jacquard machine performs initialization self-test (checking whether the solenoid valve, sensor, and knife box position are normal), and at the same time, the negative pressure suction system starts to clean the flying flowers.Synchronization between weaving machine and jacquard machine: The weaving machine spindle starts to rotate, and the spindle encoder provides real-time feedback angle signals to the jacquard machine control unit (PLC).
. Based on this, the control unit establishes a synchronous timing of "one weft, one action" - that is, for every revolution of the loom (or every introduction of a weft yarn), the jacquard machine must complete a needle selection and opening action.Set to "Ready" state: When the operation panel is turned to the "Ready" position, the faucet automatically returns to the brown flat position (the wire is in the middle stationary position). At this time, the sensor on the cutter box does not work, making it convenient for the stopping worker to pass through the wire, search for weft, or handle broken ends.
.III. High speed weaving cycle (core workflow)
This is the highest frequency and core stage of the jacquard machine, where each warp (each opening) completes the following steps in a very short time (milliseconds):
Read instructions: When the spindle of the loom reaches the time of inserting a certain warp, the control unit reads the corresponding pattern data from the memory and decomposes it into real-time control instructions (up or not up) for each warp (or each group of solenoid valves/servo motors).
.Needle selection action (electromagnetic/servo drive):
Electromagnetic type (such as Bonas): corresponding to the warp yarn that needs to be lifted, the electromagnetic valve is energized to generate suction force, which attracts the hook and prevents it from descending with the lifting blade;
; The warp yarn that does not require lifting, the solenoid valve is powered off, and the hook descends with the lifting blade.Servo type (such as Staublil): The servo motor precisely drives the needle/hook according to the preset trajectory, determining whether it is hooked or not.
.Knife lifting and opening formation:
The upper and lower knife boxes (or single knife boxes) of the jacquard machine are driven by conjugate cams or servo motors to perform high-speed up and down reciprocating motion (high-speed models can reach 800 times/minute).
.Organization point formation: The selected needle hooks onto the lifting blade. When the lifting blade rises, the corresponding warp yarn is lifted through the pulley system by pulling the through yarn → first yarn → full yarn, forming the upper layer of the shuttle.
.Formation of weft tissue points: unselected warp needles descend with the knife box (or fall back under the action of spring/gravity), and the corresponding warp yarns remain below, forming the lower layer of the shuttle.
.Insertion and beating: At the moment when the shuttle opening is clearly opened, the rapier/jet/water spray and other insertion devices shoot the weft yarn into the shuttle opening.
. Subsequently, the weft mechanism tightens the weft yarn, and the upper and lower layers of the warp yarn are exchanged or reset, completing a weaving cycle. The fabric moves forward by a certain weft density distance.Retraction: After the knife is lifted and the opening is completed, the heald wire quickly returns to the brown flat position under the action of the elastic heald device (spring, rubber bundle or air pressure), preparing for the selection of needles for the next latitude.
. At the same time, the tension sensor monitors the thread tension in real time to ensure that the warp yarn does not loosen or break.IV. Monitoring and Dynamic Adjustment (During Weaving)
Real time Monitoring: The HMI screen displays real-time data such as "number of woven shuttles", knife box temperature, hook failure rate, warp tension, etc.
Parameter fine-tuning: If the pattern is found to be misaligned, the operator can correct it through the "weft search" function (forward or backward shuttle count); If abnormal tension is found, the height of the rear beam or the tension plate nut can be adjusted.
Automatic protection: Once a warp or weft break occurs and the sensor detects an abnormality (such as a sudden change in tension), the system will automatically trigger a shutdown or alarm to prevent the expansion of defective products.
.Fifth, Shutdown and Production Change (End)
Normal Parking: After weaving is completed, press the stop button or click stop on the screen, and the machine will stop in the "ready" state.
.Cutting and taking fabric: Cut the warp yarn, remove the fabric, and trim the edges of the fabric.
.Production change process: if the pattern needs to be changed, just call the new pattern file in the computer and click Send. There is no need to change the pattern plate like the old mechanical jacquard machine, and the change time is shortened from hours to minutes. Shutdown maintenance: Close the control software, disconnect the power and air sources, and the automatic lubrication system will inject lubricating oil into the guide rails and gears within the set time. In summary, the workflow of a high-speed jacquard machine is as follows: digitizing pattern data → triggering synchronization signals → selecting needles in milliseconds using solenoid valves/servo motors → forming openings through high-speed lifting and lowering of the cutter box → inserting and weaving into fabric → repeating this process at a speed of hundreds of weft per minute to turn "data" into "patterns".