Finding what costs a weaving hall its efficiency
A digital twin of a weaving hall with 32 air-jet looms: efficiency through the shift, stops by cause and the hall's humidity, with an advisor that puts the loss in metres of fabric and shows where it comes from. The data is simulated; orbit the hall, switch on the humidity map and scrub through the shift.
What's on the screen
- The 3D hall. 32 air-jet looms in four rows, two humidifier lines and their pump skid. The light on each loom shows its state: green running, red a warp break, amber a weft break. The humidity map paints the hall's relative humidity on the floor.
- Efficiency. The last hour's efficiency against plan, zone A and zone B apart. The fabric woven this shift in metres, next to the plan.
- Stops and humidity. The shift's stops by cause (warp breaks, weft breaks, other), the two zones side by side. Six humidity sensors, each against the 75–80% target.
- The advisor. It matches the gap in efficiency with the data that changed in the same period. Here, at 07:40 the humidifier line that feeds zone B loses pressure, the zone's humidity falls to 64% and its warp breaks climb past twice zone A's. The advisor names what to check and how much fabric the shift will be short at this rate.
How to try it
- Use the camera buttons to move from the whole hall to zone B, a single loom and the humidifier pumps, or drag to orbit.
- Scrub the shift back and forth in the bar below. After 07:40 the red lights multiply in zone B and its humidity falls; the advisor gives its finding at 08:30.
- "Humidity map" paints the hall's humidity on the floor. "Show in the hall" on the advisor card goes to the pump skid and marks the line that lost pressure.
- "Watch the film" plays the same scene full screen as a 26-second walkthrough.
In a real installation
Everything on this page is simulated: the hall, the looms and the numbers are representative. In a real hall, the loom states and stop causes come from the looms' controllers or the hall's monitoring system, humidity and temperature from sensors, and line pressures from the humidification system. The advisor's rules are set up for that hall's plan and its yarns and fabrics.
We run the same analysis on your hall, with your data. If you are thinking about it for your own plant, write to us with your loom list and the data sources you have.