Method for optimally processing materials in a machine

Methods for optimally processing materials in a machine, such as a weaving machine, employing modular environmental control apparatus to control the conditions of gas flows sourced to or captured from various critical zones in materials processing machines. A plurality of processing performance parameters, part of which may respond differently to environmental conditions in one or more process zones, and thus may be in conflict with each other, are jointly controlled to yield maximum gross profit, to produce highest quality, to operate at highest throughput, etc., (but not necessarily simultaneously). One method includes the step of measuring at least one processing performance parameter, and at least partially controlling the processing performance parameter in accordance with a predetermined optimal control strategy by deliberately applying a gas flow conditioned by at least one controlling parameter, the gas flow being applied by a modular control unit. The disclosed embodiments are directed toward modular process zone environmental control in textile processing machines, both in yarn and fabric manufacturing processes, including weaving machines. However, Modular Process Zone Environmental Control (MPZEC) is applicable to materials processing in general.

BACKGROUND OF THE INVENTION 
This invention relates generally to control of environmental parameters for 
manufacturing processes and, more particularly, to the control of 
environmental parameters within manufacturing process zones and within 
employee work zones associated therewith. 
Relevant prior art includes central air conditioning systems which can 
control to or "hold" reasonably uniform (spatially) and stable 
(temporally) desired humidity and temperature conditions, as monitored by 
one or more chart recorder/controllers in the process room. They 
generally, cannot, however, "hold" such air conditions in each and every 
weaving process zone and cannot always achieve compliance with the OSHA 
respirable dust standard. Nor can prior art central air conditioning 
systems significantly effect collection of dust and fiber or reduce noise 
emissions. 
Further, prior art central air conditioning typically cannot control the 
process zone environmental conditions on a machine-by-machine basis. 
Relevant prior also includes travelling cleaners, described hereinbelow in 
detail. 
Relevant patent prior art includes Shofner U.S. Pat. Nos. 4,512,060, 
4,631,781 and 4,686,744; Shofner U.S. Pat. No. 4,881,957; and Leifeld et 
al U.S. Pat. No. 5,121,522. 
SUMMARY OF THE INVENTION 
Briefly, the invention provides a method for processing materials in a 
machine, including the steps of measuring at least one processing 
performance parameter; and at least partially controlling the at least one 
processing performance parameter in accordance with a predetermined 
optimal control strategy by deliberately applying a gas flow conditioned 
by at least one controlling parameter, said gas flow being applied to the 
machine by at least one modular control unit. 
A more particular aspect of the invention is a method for optimally 
processing materials in a material processing machine such as a weaving 
machine, having at least one material input, at least one processing zone 
and at least one material output. First a machinery model is determined 
which simulates the operation of the materials processing machine given a 
range of input material parameters at least at a first time by measuring 
materials processing characteristics of the machine over ranges of 
environmental parameters within the at least one processing zone, the 
materials processing characteristics defining the interrelationships 
between input material parameters and output material parameters over the 
ranges of environmental parameters; and then defining the machinery model 
from the characteristics. The step, of determining a machinery model at 
least a first time may further include measuring material processing 
characteristics of the machine over ranges of machinery settings. The 
characteristics then also define the interrelationships between input 
material parameters and output material parameters over the ranges of 
machinery settings. 
Next, at least some of the input material parameters at the material input 
of the materials processing machine are measured at least at a second, 
later time. 
At least some of the measured input material parameters are introduced into 
the model, and environmental parameters within the processing zone are 
then determined, within a predetermined range of acceptable variation, the 
environmental parameters optimizing at least one output material 
parameter. Machinery settings within a predetermined range of acceptable 
variation may also be determined, which settings also optimize at least 
one output material parameter. 
Finally, material is processed while applying controlled conditioned gas 
flows to the processing zone to achieve the environmental parameters which 
optimize at least one output material parameter. In addition, processed 
with the optimally adjusted machinery. 
Another more particular aspect of the invention is a method for processing 
material in a machine, such as a weaving machine, having at least one 
processing zone. At least one processing performance parameter is measured 
and at least partially controlled in accordance with a predetermined 
optimal control strategy by employing a modular environmental control unit 
to deliberate apply a gas flow conditioned by at least one controlling 
parameter to the processing zone of the machine. 
The at least one processing performance parameter for example may be trash 
content, nep content, short material content, trash removal efficiency, 
nep removal efficiency, short material removal efficiency, machine 
production efficiency, material value, material throughput, cloth 
throughput, cloth cleanliness, machine production efficiency, stop 
frequency, stop rate, machinery production cost, input material value, 
output material value, input yarn value, output cloth value or profit. 
The modular environmental control unit includes a gas flow source element 
and/or a gas flow capture element. There is a mechanism for selectively 
portioning the gas flow source element or gas flow capture element in a 
mechanically predetermined operate position proximate the processing zone, 
or in a mechanically predetermined retracted position. Elements are 
provided to control conditions of the gas flow, and there is at least one 
blower for causing gas flow through the processing zone of the machine. 
Yet another more particular aspect of the invention is a method for 
optimally processing input materials into output materials wherein the 
method is carried out in a materials processing machine having at least 
one processing zone, with the machine operating near target operating 
point parameters. The method includes the steps of providing a range of 
input material having parameters corresponding to a usable range of such 
input material, including a substantially complete set of samples of 
various usable qualities of the input material available; operating the 
machinery over the entire range of provided input materials to generate 
output materials having a range of output material parameters; varying 
environmental parameters within the at least one processing zone over a 
range of environmental parameters while operating the machine over the 
range of input material to generate the output material such that 
substantially all combinations of input materials and environmental 
parameters are used to generate output materials; testing the input and 
output materials to determine various output material parameters at 
substantially all combinations of input material parameters and 
environmental parameters; generating a database of substantially all 
combinations of input material parameters, process zone environmental 
parameters, and output material parameters; selecting a target operating 
point including at least one parameter selected from the group consisting 
of input material parameters, process zone environmental parameters, and 
output material parameters; defining a model of machinery performance 
based upon a selected portion of the database which is within a 
predetermined region of the target operating point; using the model for 
determining at least one optimal parameter from the group consisting of 
the optimal input material parameters, the optimal process zone 
environmental parameters, and the optimal output material parameters; and 
operating the machinery to process input material and to produce output 
material in accordance with the selected optimal parameter being within 
acceptable variability of the target operating point. 
The step of varying environmental parameters while operating the machine 
may further include varying the control settings of the machine over their 
full range such that substantially all combinations of input materials, 
machine control settings and environmental parameters are used to generate 
output material. The step of testing may further include testing the input 
and output materials to determine various output material parameters at 
substantially all combinations of input material parameters, machine 
control settings, and environmental parameters. The step of generating a 
database may further include generating a database of substantially all 
combinations of input material parameters, machine control settings, 
process zone environmental parameters and output material parameters. The 
step of selecting a target operating point may further include selecting a 
target operating point including at least one parameter selected from the 
group comprising the input material parameters, machine control settings, 
process zone environmental parameters, and output material parameters. The 
step of using the model may further include using the model for 
determining at least one optimal parameter from the group consisting of 
the optimal input material parameters, the optimal machine control 
settings, the optimal process zone environmental parameters, and the 
optimal output material parameters. 
Another more particular aspect of the invention is a method for selecting 
input materials having optimal input material parameters for input into 
materials processing machinery to achieve an output of material parameters 
corresponding to a target operating point. A machinery model is determined 
which simulates the operation of the materials processing machine given a 
range of input materials parameters by measuring materials processing 
machinery characteristics over ranges of operational settings and 
environmental parameters within processing zones, the materials processing 
characteristics defining the interrelationships between input materials 
parameters and output materials parameters over the ranges of machinery 
settings and environmental parameters; and then defining the machinery 
model from the machinery characteristics. 
Next, characteristics of a desired output materials parameter or profit are 
determined. The output material parameters are introduced into the 
machinery model which determines the optimum range of input material 
parameters. Input materials are selected having parameters coinciding, 
within an acceptable range of variability, with the determined optimum 
range of input materials parameters. The selected input materials are 
provided as input to the materials processing machine, and the machinery 
is operated with the selected input materials to produce the output 
corresponding to the target operating point. 
Still another more particular aspect of the invention is a method for 
optimally processing materials in a plurality of sequentially related 
materials processing machines, each of which has a material input, a 
material output and a processing zone. A composite machinery model is 
determined which simulates the operation of the plurality of materials 
processing machines by measuring materials processing machinery 
characteristics over ranges of operational settings and ranges of 
environmental parameters within the processing zones for each of the 
machines, the characteristics defining the interrelationships between 
input material parameters and output material parameters over the ranges 
of machinery operational settings and environmental parameters within the 
processing zones; and defining the composite machinery model from the 
measured characteristics. 
Input material parameters at the inputs to said material processing 
machines are measured at least at a second, later time. The input material 
parameters are introduced into the composite model and then settings and 
environmental parameters are determined for each machine, within a 
predetermined range of acceptable variation. The settings and 
environmental parameters are adjusted to optimize at least one output 
parameter, and materials are processed with said optimally adjusted 
machines.

DETAILED DESCRIPTION 
A. Weaving Essentials: Air Jet Looms 
Presented initially below is an overview of the essential elements and 
operations of the weaving process, and particularly of an "air jet" 
weaving process zone 60 to be environmentally conditioned and optimally 
controlled in accordance with the invention. This overview is particularly 
useful because the apparatus and methods of the invention are much more 
highly integrated with the weaving process than are prior art 
environmental controls. 
Thus, referring first to FIGS. 1 and 2, a representative environment for 
the invention is a weaving machine 20 or loom 20 within a weave room 
environment 112. The weaving machine 20 converts warp yarn 21, supplied 
from the warp beam 22, plus filling yarn 23 (called weft-yarn in British 
English), supplied from filling packages 24, into cloth 25. FIGS. 3A and 
3B are enlarged views of the Weaving Process Zone, generally designated 
60. Also shown in FIGS. 1, 2, 3A and 3B are a number of elements 
comprising the invention and described hereinbelow, such as a Modular 
Environmental Control Apparatus (MECA) unit 100, a collector 120, a 
directed source air conduit 190, and a directed source air diffuser 194. 
The weaving process zone more particularly includes the filling packages 
24, accumulators 26, filling yarn 23, and primary air jet nozzles 27 (FIG. 
2). Accumulators 26 facilitate feeding the filling yarn 23 into the 
primary air jet nozzles 27 and then into a front shed 28 (FIGS. 3A and 
3B). Compressed air and electrical power are supplied by pipe 12 and wire 
conduit 14. 
Filling insertion by means of air jet nozzles 27 leads to the designation 
"Air Jet Loom." Air Jet Looms are manufactured, for example, by Nissan 
Motor Company, Textile Division, Tokyo, Japan and Toyota Motor Company, 
Textile Division, Tokyo, Japan. Toyota manufactures air jet looms under a 
license from Sulzer-Ruti Company, Ruti, Switzerland. Air jet looms 20 have 
the major advantage of very high filling insertion or "pick" rates, about 
600 per minute, currently. These high production rates lower production 
costs but place heavy demands on yarn strength and elongation, both of 
which are influenced strongly by environmental conditions in process zone 
60, and which high production rates lead to severe environmental problems 
including but not limited to those associated with high energy 
dissipation, high release of dust and fibers, high generation of static 
electricity, and high noise emissions and turbulent air flows from the 
weaving process zone 60. Filling insertion rates have risen from about 
80/min in 1950 (shuttle looms) to about 250/min in 1970 (projectile, 
rapier), to about 600/min beginning in the 1980s and operating currently. 
Next-generation air jet looms having filling insertion rates of 1800/min 
and even higher are already under field trials. 
The revolution in weaving and its associated heavy demands on environmental 
conditioning will thus be appreciated. Similar considerations apply to all 
materials processing in general. 
Referring again to FIG. 3A, there is a back shed 29 which corresponds to 
the front shed 28, being respectively in back of or in front of the 
harness 52. A shed opening 50 is produced by alternating vertical 
movements of heddle wires 51, through which each of the several hundred to 
several thousand warp yarn ends 21 pass. The heddle wires 51 are carried 
by harnesses 52, which harnesses 52 are driven up and down 53 by the 
harness drive machinery 54 of the loom. Typically, the maximum shed 
opening is four inches at heddle wires 51 for weaving denim. Openings of 
two to six inches are found for other fabric constructions. 
During operation, when the reed or beater 56 is in its back position, as 
shown in FIG. 3A, the filling yarn 23 is rapidly inserted by one or more 
of the primary air jet nozzles 27 (FIG. 2) and carried across the front 
shed 28 by secondary air jet nozzles (not shown) in the reed tunnel 57. 
Reed 56 next moves forward to pack or beat the filling yarn 23 into cloth 
25. Upon the beater 56 moving backward, the filling yarn 23 remains at the 
apex 28A of the front shed 28 and moves out of tunnel 57, while heddles 51 
(carried by harness 52) shift to cause the warp yarn 21 to envelop the 
filling yarn 23 and form cloth 25. 
Also shown in FIG. 3A is a drop wire stop motion assembly 58 the function 
of which is to stop the loom 20 in the event of a warp yarn break. This 
stop motion is achieved when any one of the hundreds to thousands of drop 
wires fall onto an electrical shorting bar within assembly 58 due to loss 
of tension in the warp yarn end 21 supporting it. There are also stop 
motion sensors associated with correct filling yarn insertion, selvage 
formation, below. Described hereinbelow is the manner in which the 
apparatus of the invention responds to such stop motions to enable the 
weaver to access all parts of the weaving machine 20 when repairing the 
problem that caused the stop; safety and non-interference are critical 
practical design parameters. Also described hereinbelow is the manner in 
which several environmental conditions within various parts of process 
zone 60 are individually controlled. 
It will be appreciated that the rapid and intense actions imparted upon the 
warp 21 and filling yarns 23 yield copious release of dust and fibers, 
heat, ions, noise, turbulence, etc. in the weaving of spun yarns, 
especially with cotton, and most especially with denim fabrics. The power 
consumed by the loom is typically four horsepower, as supplied by loom 
motor 44. Most of this power dissipation occurs within or under the front 
and back sheds 28 and 29. Consequently, heated, dried, electrically 
charged, dust- and fiber-laden air rises as represented by wavy arrows 47, 
48, 49 or is fanned away from sheds 28 and 29 in the weaving zone 60 as 
represented by wavy arrow 46. Noise emissions and turbulence are high as a 
result of the high production rates and mixing or fanning action of beater 
56. 
B. Prior Art Environmental Control for the Weaving Process 
Accordingly, and as is also illustrated in FIGS. 1 and 2, there are a 
central conditioned air supply duct 30, having discharge grills or louvers 
33, underfloor air return ducts or tunnels 34, and a travelling cleaner 36 
having blow-nozzles 35A, 35B, 37, 38 and 39, all previously known. The 
underfloor return duct 34, with floor grate 31, is found in about half of 
the weaving processes; wall return is found in the rest, except for a few 
ceiling returns. The subject invention may be employed in new equipment 
and in some retrofit installations in conjunction with such prior art 
apparatus and methods, and they are accordingly described herein in some 
detail. That is, not only must the subject invention be integrated with 
the weaving process, it must also be compatible with and integrated into 
prior art environmental control apparatus. 
The subject invention may also be employed alone, thus handling all aspects 
of weaving materials processing zone environmental control and employee 
zone environmental control. 
More particularly, the air supply ducts 30 and grills 33 in FIGS. 1 and 2 
deliver conditioned air 42 from central filtration, refrigeration, ion 
control, and humidification systems well known in the art. A typical 
central air conditioning system, designed and constructed according to 
prior art, delivers about 800,000 cubic feet per minute (CFM) to the 
typical large weave room processing cotton and attempts to maintain 
conditions of about 76.degree. F. dry bulb temperature, 70% relative 
humidity, neutral charge concentrations, and respirable dust 
concentrations below 750 .mu.g/m3 (8 hour shifts) or 500 .mu.g/m.sup.3 (12 
hour shifts). In an increasingly large fraction of installations, the 
attempts are unsuccessful and conditions in the weaving process zone 
and/or in the employee zone are not satisfactory. Failures to achieve 
desirable process zone environmental control (PZEC) or employee zone 
environmental control (EZEC) are in major part attributable to increased 
production rates associated with modern looms. Further, little or no 
attention is given to noise control (pressure fluctuations) or to 
turbulence parameters (velocity fluctuations) in conditioned air 42 
supplied to or returned from 34 weave rooms because the weaving machines 
are very noisy (approximately 95 dBA) and because the vigorous fanning 
actions of the beater or reed 56 enforce mixing. 
It is useful to note that typical prior art central air conditioning 
systems for cotton fabric weaving have volumetric air exchange rates of 
about 25/hour or supply and return air flow rates of approximately 2000 
CFM/loom. In sharp contrast, one of the important aspects of the invention 
described hereinbelow is a high localized air exchange rate. 
It should also be appreciated that conditioned air 42 is supplied from 
grills 33 that are typically between eight and thirty feet removed from 
the process zone 60. Conditioned air 42 provided at such large distances 
fails to achieve good Process Zone Environmental Control (PZEC) within 
process zone 60 or control of dust and fiber and other emissions from 
process zone 60; exemplary data are provided hereinbelow. 
It will be appreciated that floor grate inlets 31 into underfloor return 
air tunnels 34 cause the "sink" for return air to be no closer than about 
2.5 feet when the floor grate inlets 31 are located precisely under each 
shed 28, 29. However, the typical weaving plant must accommodate five to 
ten weaving machinery changes during its service lifetime of twenty five 
to fifty years. Different looms will have different "foot-prints." 
Accordingly, since it is prohibitively expensive to relocate the 
underfloor tunnels 34 which are usually formed in a massive concrete 
floor, distances between the weaving process zone 60 and return air inlets 
31 can also be as large as 30 feet. If wall and ceiling returns are used, 
these distances can be as large as 200 feet. 
A new but still essentially "central" air conditioning system, modified to 
deliver different environmental conditions, on a machine-by-machine basis, 
to the process zones of the textile fiber process known as carding, is 
disclosed in Shofner et al U.S. patent application Ser. No. 999,226, filed 
Dec. 31, 1992, now U.S. Pat. No. 5,361,450, titled "Direct Control of 
Fiber Testing or Processing Performance Parameters by Application of 
Conditioned Gas Flows." 
It may be noted that over shed air supplies (not shown) from central air 
conditioning systems, provided the supply ducts therefor are compatible 
with travelling cleaners, and underfloor returns 34, provided they are 
directly under the process zone 60, coupled closely thereto, and sink 
several thousand CFM each, can provide good results on a few environmental 
parameters in the few cases where the weaving room and loom construction 
permit. Such improvements, using central conditioning, broadly comprise 
subject matter of the above-referenced U.S. Pat. No. 5,361,450. 
Nevertheless, in accordance with the present invention, it is recognized 
that one of the fundamental limitations of prior art environmental 
controls is large and varying distances from the weaving process zone. 
Further realizations of limitations in prior art devices are significant. 
Whereas central air conditioner recorder/controller 13 charts may indicate 
desired 76.degree. F/70% conditions and respirable dust samplers 18 (such 
as Portable Continuous Aerosol Monitor (PCAM), manufactured by PPM, Inc., 
Knoxville, Tenn.) may indicate readings below 750 or 500 .mu.g/m.sup.3, 
the reality of denim weaving process zone environmental conditions, for 
example, are 80.degree. F./60% and 3,000 .mu.g/m.sup.3 respirable dust. 
Total dust mass concentration is much higher. 
Travelling cleaner 36, a purpose of which is to blow dust and fibers 
(sometimes called "fly") from top surfaces onto the floor, moves on 
electrified track 41 and passes over each loom 20 approximately every 
eight minutes for a duration of approximately thirteen seconds. In some 
processes (but not in weaving), travelling cleaners 36 also have capture 
or suction flows. Travelling cleaner 36 thus serves any one loom, in 
average, less than 3% of the time. Such travelling cleaners 36 are well 
known in the art and are manufactured, for example, by Luwa Parks-Cramer, 
Winston-Salem, N.C.. Carolina. 
The travelling cleaner 36 does serve to blow dust and fibers (sometimes 
called "fly") from top surfaces onto the floor. Unfortunately, a 
travelling cleaner 36 also blows, with high velocity, hot air jets 40, the 
dust and fiber accumulations into sensitive parts of the weaving machine, 
causing stoppages and, sometimes, damage to the machine. A travelling 
cleaner also blows dust and fibers onto the finished cloth, sometimes 
causing second quality. Further, the "blowing around or stirring up" of 
dust or fibers is often a serious aggravation to employees. Finally, 
travelling cleaners are completely unable to control air conditions, most 
especially in the weaving process zone 60. Thus, one of the purposes of 
the subject invention is to supplement or replace such infrequent, 
ineffective, and troublesome "cleaning" actions with continuous push-pull 
cleaning actions. 
Still further, it can be appreciated that travelling cleaners, which 
operate on a given loom less than 3% of the time the loom is operating, 
fail to adequately remove dust and fiber accumulation and have no positive 
impact whatsoever on process zone environmental conditions. Indeed, except 
for short-duration removal of dust and fly, their effects on weave zone 
environmental conditions, on weaving performance, or on personnel are all 
negative. 
From the above discussion, it will be appreciated that a purpose of the 
subject invention is to replace travelling cleaners. However, such is not 
the highest objective, which is to improve weaving performance while 
enhancing gross profit. 
C. Modular Process Zone Environmental Control (MPZEC) 
The subject invention enables process zone environmental control results 
heretofore impossible with central air conditioning supplies 30 and 
returns 34 and travelling cleaners 36. Equally important, MPZEC generally 
also enables optimal control for materials processing machines according 
to predetermined optimal control strategies, on a machine-by-machine 
basis; that is, using a textile example, adjacent weaving machines of the 
same model can operate with very different process zone environmental 
conditions, said conditions being provided by a modular environmental 
control apparatus for each such machine even when weaving the same 
pattern, to achieve maximum profit for each machine. Clearly, when 
adjacent machines are weaving different patterns, different process zone 
conditions will in general prevail to achieve maximum profit. This 
flexibility is not possible with prior art central air conditioning or 
travelling cleaners. 
FIGS. 1 and 2 illustrate left end and front views of a modular 
environmental control apparatus (MECA-1) unit 100 which provides 
environmental control for the process zone 60 of a weaving machine or loom 
20. The MECA-1 unit 100 is integrated with loom 20, travelling cleaner 36, 
A/C supply ducts 30 and returns 34. 
After the following disclosure of MECA-1, including prototypical test 
results, and disclosure of other preferred embodiments, we shall revert to 
clarification of the differences between central air conditioning, 
improvements thereon, and MPZEC. 
One major difference is much closer proximity of source-capture elements to 
the process zone. Closer proximity translates into high volumetric 
exchange rate, a basic concept and engineering parameter in environmental 
conditioning and which concept is employed hereinbelow to partially 
explain the subject invention. 
C1. Modular Environmental Control Apparatus-Weaving (MECA-1) 
FIG. 4A provides front view details for MECA-1 unit 100, seen first in 
FIGS. 1-3A. Only the loom 20 left and right end frames 20L and 20R and the 
top and bottom of the back shed 29T and 29B are shown for reference and 
scale 5. FIG. 5A is a right end view corresponding to 4A. Call-out S in 
FIGS. 4A and 5A is included to clarify the inclination of the top surface 
of collector 120. 
The main elements of this simplified embodiment for a self-contained, 
modular, "push-pull", "over-under" unit are: 
110--Capture Surface(s) 
120--Collector (Shown in Operate Position 120-Op in FIGS. 1-3A, 4A, 5A) 
130--Collector Mount (Rotating Joint) 
140--Air and Collector Drive Unit 
150--Control and Monitoring Electronics 
152--Collector Position/Function/Selector Switch 
160--Control Power (115 VAC, 1.phi., 60 Hz) 
170--Main Power (Disconnect and Circuit Protection) 
(575 VAC, 3.phi., 60 Hz); 
(Other excitation voltages and frequencies may be used for 160 and 170.) 
175--Mounting Frame (FIGS. 4A, 6A) 
180--General Source Air Diffuser 
190--Directed Source Air Conduit 
194--Directed Source Air Diffuser, under back shed 
These representative elements are further described by their functions 
which enable advantageous source and capture conditions for air flow 
components delivered to and taken from the weaving process zone 60. 
When loom 20 is in normal operation, collector 120 is in its OPERATE 
position 120-Op, as seen in FIGS. 1-3A, 4A and 5A. FIGS. 5A and 3A depict 
an "over/under", "push-pull" embodiment in which only one capture surface 
110, over the back shed 29, captures airflow components 181, 182, 121, 122 
and 123 and transports these components into collector 120. One general 
diffuser 180 (FIGS. 4A, 6A) provides source air components 181, 182 back 
towards the process zone 60 and source air components 183, 184 to the 
general room environment 112. Capture surface 110 in FIGS. 3A, 4A and 5A 
captures air flow component 123 almost completely because said flow 123 
originates directly (i.e., more tightly coupled) with air from directed 
source diffuser 194. This source-capture air flow component 123 is 
delivered to diffuser 194 by conduit 190 and is driven into conduit 190 by 
blower 147 (FIG. 6A). All other source air components are also driven, in 
this embodiment, by blower 147. Dust, fibers, heat, ions, gases, etc 
generated (and absorbed) by the intensive weaving actions and materials in 
process zone 60, and which net emissions are represented in part by "wavy" 
arrows 46-49, mix with capture (or "sink" or "return") air flow components 
181, 182, 121, 122 and 123. Dust and fibers are collected as a mat 114 on 
the exterior of surface 110 and are held onto surface 110 by a pressure 
differential of preferably 1-3 inches water column across it. 
Significantly, as disclosed in Shofner U.S. Pat. No. 4,881,957, the entire 
disclosure of which is incorporated herein by reference, this dust and 
fiber mat 114 becomes a remarkably efficient filter for respirable or 
so-called "microdust" when the face velocity is about 200 FT per minute. 
The instant embodiment employs total flow of 2000 CFM and has surface area 
110 of 10 FT.sup.2, so the desired face velocity is achieved. This mat can 
in many cases be easily cleaned manually, as shown in this preferred 
embodiment. Importantly, this mode of capture and mat formation enables by 
far the most cost-effective (i.e. lowest capital and operating costs) 
apparatus design. 
In FIG. 6A source components 181, 182 and 123 are also designated in FIG. 
5A as capture components 181, 182 and 123. That is, in addition to source 
component 123, which is almost completely recirculated, and is thus 
designated source-capture component 123, other air 181, 182 from diffuser 
180 is captured in significant portion by capture surface(s) 110, after 
mixing with air flow components 121, 122 which originate from the room 
environment. For flow balance, yet other source components 183, 184 are 
not immediately captured but return to the room environment. 
Source air diffuser 180 in FIGS. 4A, 5A causes, by internal vanes 185 or 
partitions 186 (FIG. 6A) air flow components 183, 184 to move more or less 
radially away from diffuser 180 and air flow components 181, 182 to move 
more or less in a conical pattern back towards process zone 60 where these 
particular flow components 181, 182 mix with room environment air 121, 122 
and are recirculated. 
FIG. 6A shows how blower 147 pushes source air into conduit 190 and how 
said conduit 190 is integrated into diffuser 180. 
More to the present point of functionality, in the relatively open and 
simple over/under, push-pull embodiment of FIGS. 1, 2, 3, 4A, 5A and 6A, 
the capture air flow components 181, 182, 121, 122 and 123 carry various 
emissions 46-49 from process zone 60 and the room 112 and are drawn 
through capture surface 110 and into collector 120 by fan or blower means 
147 in drive unit 140. Source air 181-184 and 123, whose total volumetric 
rate is preferably about 2000 CFM, and which source volumetric rate is 
essentially identical to the capture air 181, 182, 121, 122 and 123 
volumetric rate, is moved back into the process zone 60 and room 112 via 
general source air diffuser 180 and directed source air diffuser 194. This 
source air 181-184 and 123 may be filtered, cooled, humidified, 
ion-controlled, directed, calmed (turbulence) or silenced (noise 
abatement) as necessary and as further described hereinbelow, or as is 
well known in the art. We note now, for later reference, that the 
environmental conditioning (filtration, cooling, etc.) may be different 
for the different source air flow components, some of which move to the 
process zone, and others of which move to the employee zone. 
It can now be more fully appreciated that one of several novel and 
important features in our invention is the close proximity of source (such 
as 194) and capture (such as 110) air flow surface(s) to the weaving 
process zone 60. We discovered that close proximity greatly facilitates 
provision of effective air flow components. By close we mean, for example, 
less than about 2.5 feet between the bottom of collector surface(s) 110 
and the top of back shed 29T. 
Similarly, superior results are obtained when the top of directed diffuser 
194 is less than about 2.5 feet below the bottom of back shed 29B. These 
specifications of "close" are consistent with the relative relationships 
in FIGS. 1-3A, 4A and 5A. Some of our trials have been as close as 3 
inches, wherein we discovered significant improvement over our own results 
at thirty inches (2.5 feet) and vast improvements over the 8 to 30 or 2.5 
to 30 foot distances for prior art devices described above. 
Contrariwise, we also confirmed the obvious negative impact of interference 
of sheet metal components (such as collector 120) with weaver and fixer 
access to back shed 29 and we disclose in the next section novel, 
automatically retractable air flow components to overcome this and other 
fundamental problems. Before these disclosures, however, we now conclude 
this section with some clarifying and broadening comments. 
Whereas FIGS. 1-3A, 4A, 5A, 6A combine source-capture elements for various 
air flow components, and these elements of our invention are closely 
proximate to the weaving process zone, other combinations are provided by 
our invention. One such alternative configuration is to omit directed 
source diffuser 194. All source air is thus provided from general diffuser 
180 which then operates in combination with capture surface(s) 110. This 
results in a simpler, more self-contained, modular design. 
Another combination is to position capture surface(s) 110 well above 2.5 
feet, for example, the weaving process zone 60 but to retain the closely 
proximate directed source diffuser 194 and general diffuser 180. This 
design has the advantages of non-interference and collecting cleaner, 
cooler, moister air from the room environment 112 into collector 120 and 
sourcing it via diffusers 194 and 180. 
Those two comments illustrate simplifications in the direction toward less 
tightly-coupled configurations. In the other direction, when it is 
advantageous, more of the source air can be recirculated more immediately 
back into capture surface(s) 110 in relatively more tightly coupled and 
more complex designs described in further embodiments of our invention 
hereinbelow. These more tightly coupled designs enable high local air 
exchange rates, among other advantages which offset their increased 
complexity. 
C2. Retractable Collector Operational Functions 
When loom 20 is not in normal operation, in some cases collector 120 must 
be rotated (counter-clockwise in the orientation of FIGS. 5A, 5B and 5C) 
to RETRACT position 120-R depicted in FIG. 4B and 5B. Collector 120 is 
supported and driven by collector mount 130 seen in FIGS. 4B and 5B and 
which consists of a ball bearing outer ring assembly 131-O seen in more 
detail in FIG. 6A. Collector mount 130 must freely move and be very 
structurally sturdy to withstand the large overhung load presented by 
collector 120 when it moves off rest 129 (FIGS. 4A, 4B). 
Collector 120 attaches to outer ring 131-O by means of bolts 132 (or by 
quick-connect devices, not shown) and is supported and rotated thereby. 
Robust support and low friction rotation are enabled by sixteen balls 133, 
0.5 inch diameter, in each of the inner and outer races for them machined 
into rings 130-O and 130-I and frame 175. Mounting frame 175 is preferably 
0.5 inch thick steel and rings 130-O, 130-I are preferably 0.75 inch 
thick.times.1.5 inch width steel. In preferred embodiments for which 
capture air volumetric flow rate is about 2000 CFM, the inner diameter 
D.sub.i 134 of collector 120 at collector mount 130 is about 14 inches, 
the outer diameter D.sub.o 135 of diffuser 180 is about 20 inches, and 
length L 136 of diffuser 180 is about 20 inches. 
Inner and outer rings 131 are held together by bolts (not shown) into 
spacer ring 137. Balls 133 are conventionally lubricated with a medium 
viscosity grease and are protected from contamination with elastomer seals 
138. In particularly dirty environments, felt or metal shields (not shown) 
are used to keep dust and fibers away from seals 138. Chain 139 (FIGS. 6A, 
6B) couples the dual ring, collector mount assembly 130 to gear motor 141 
(FIG. 6B). During movement between the OPERATE, RETRACT and CLEAN 
positions, the collector mount has a rotational velocity of preferably 
about 1.5 revolutions per minute. Reversible gear motor 141 is controlled 
by control and monitoring electronics 150, shown as a separate unit in 
FIG. 4A and mounted above drive unit 140. FIG. 6B shows control power 160 
and control and monitoring electronics 150 combined within a single 
enclosure 150, 160 which is mounted on collector drive unit 140. 
Two cases will illustrate an automatic RETRACT function. First, if any one 
of the warp ends 21 in FIGS. 3A or 5 breaks, the drop-wire stop motion 58 
will stop loom 20. In FIGS. 6B and 7, MECA-W electronics 150 receive two 
signals from loom electronics 155, warp stop 158 (12 changing to 0 volts, 
seen across shorting bars within stop motion 58) and LOOM NOT RUN 156 
(opening of dry contacts). When both conditions exist, microcontroller 200 
or other electronics means causes gear motor 141 to drive collector 120 
from OPERATE position 120-Op (FIGS. 4A, 5A) to the RETRACT position 120-R 
(FIGS. 4B, 5B), in about fifteen seconds, where it remains until the 
broken warp yarn end 21 is repaired by the weaver. When the repair is 
finished, the weaver restarts loom 20. Microcontroller or other 
electronics 200 recognizes that all warp yarn ends 21 are intact (12 volts 
at input 158) and that the loom is running 156 (closure of LOOM RUN dry 
Contacts). After a user-settable delay, typically of ten seconds, 
microcontroller 200 causes collector 120 to rotate clockwise until it 
again reaches OPERATE position 120-Op (FIG. 5A), where collector 120 
remains until another stop occurs which requires retraction. 
As the second illustrative example, one such other stop is a "Leno" stop 
motion 159. The Leno apparatus 19, shown only in FIGS. 4A and 4B, enables 
formation of a better selvage for the woven cloth and is located behind 
harness 52 but in front of warp stop motion apparatus 58. Left 19 and/or 
right (not shown) Leno apparatus are used, depending on the fabric being 
woven. Free access to correct Leno 19 stops also necessitates rotation of 
collector 120 to RETRACT position 120-R. The signals 159, 156, logic, and 
microcontroller 200 actions to this stop, its repair, and to loom restart 
are identical to the warp stop case just explained above. 
Other loom stops do not necessarily require automatic movement to RETRACT 
and return (after delay) to OPERATE positions. Stops related to failure to 
insert filling yarn 23 correctly also stop the loom and provide 
annunciation for the weaver. But in these cases, repair is made in front 
of harness 52, in front shed 28, to filling yarn deliveries 26 or packages 
24, to the right selvage, etc., and collector 120 can remain in OPERATE 
position 120-Op. 
As seen in FIG. 7, the automatic control functions of microcontroller 200 
can be overridden by moving mode selector switch 152B from AUTO (A) to 
HAND (H) position. The operator can then cause gear motor 141 to move the 
collector from OPERATE (fully CW in FIG. 5A) to CLEAN (C) (fully CCW in 
FIG. 5C) by means of momentary rotation direction switch 152C. HAND 
movement of collector 120 is used when major loom changes or repairs are 
required, or when it is desired to move to CLEAN position 120-C (FIG. 5C) 
under HAND control. 
HAND (or AUTOMATIC) movements beyond fully CCW (CLEAN 120-C) or fully CW 
(OPERATE 120-Op) are precluded by customary limit switches 161, 162 in 
FIG. 7. However, if limit switches 161,162 fail, strong mechanical limits 
stop any further movement after the shearing of a torque-limiting pin in 
inner ring 130-I which engages chain 139 (FIG. 6B). 
Unattended movement to CLEAN 120-C may be realized by placing MODE switch 
152B to CLEAN and pulling mushroom switch 152A fully out, momentarily. 
Momentary contacts in switch 152A cause microcontroller 200 to rotate to 
CLEAN position 120-C, at which position CCW limit switch 162 stops 
rotation. This motion is also achievable with remote initiation via 
microcontroller 200 communication interface 178 to external computer or 
control electronics. 
Collector 120 is rotated to CLEAN position 120-C (FIG. 5C) for removal of 
dust and fibers from capture surface 110. This removal is preferably by 
hand; about one pound of total dust is typically captured on capture 
surface 110 in 12 hours of processing denim. Following the cleaning step, 
which takes less than one minute (10-15 seconds, typically), mode switch 
152B is moved to AUTO (A) and collector 120 rotates, after a delay of 
preferably ten seconds, toward OPERATE position 120-Op (FIG. 5A). Travel 
time from CLEAN 120-C (FIG. 5C) to OPERATE 120-Op (FIG. 5A) is about 
thirty seconds. 
A brief overview of the main and control power elements 170,160 in FIG. 7 
completes our disclosure of blower motor excitation and MECA collector 120 
motion control. Three phase power, preferably 575 volts AC, 60 Hertz in 
the United States or 380 V, 50 Hz in Europe, for example, is delivered by 
disconnect and circuit protection 171 to variable frequency converter 172 
and then to blower motor 146. One phase of this electrical power is 
carried from main power box 170 to control power box 160, where single 
phase control power, 115 VAC, 60 Hertz, is developed by control 
transformer 163. This power is then used to supply gear motor 141 via 
well-known and conventional solid state relays 164 and dry contact relay 
165. Relay element 165 is a reversing relay which enables gear motor 141 
to rotate CW or CCW. Gear motor 141 is preferably a split phase 
alternating current motor having running coil 167, starting coil 168, and 
brake coil 169. Thermal switch 173 disconnects starting coil 168 
excitation, via reversing relay 165, after the motor 141 is up to speed. 
Other control power voltages, including DC and control components, are 
well known in the art and may be used. Pneumatic or hydraulic means could 
also be used. 
Special notes are made in reference to frequency converter 172 and lock-out 
relay 166. Converter 172 is controlled by microcontroller 200, by other 
computer means, or manually. This enables controlling the pressure and/or 
flow performance of blowers 147, 148 (FIGS. 6A, 6C) according to optimal 
control strategies to be discussed later. Lock-out relay 166 assures 
safety. Relay 166M coil is excited only when the loom lock-out switch 166L 
is in ON. This means that when the loom 20 motion is locked out, so is 
motion of MECA collector 120. 
C3. Continuous Blow-Off cleaning (MECA-2) 
FIG. 6C shows again the high flow (approximately 2000 CFM), low static 
pressure (approximately 2 inches water column) blower wheel 147, described 
above and in FIG. 6A, in combination with a low flow (approximately 300 
CFM), high static pressure (8 inches WC) blower wheel 148 mounted on a 
common shaft 202 extended from motor 146 and driven thereby. Blower wheel 
148 preferably has forward curved blades 204 (FIG. 6D) and a larger 
diameter than blower 147, which preferably has backward inclined blades. 
The different flow and static pressure capabilities required lead to the 
different blower blade configurations and sizes. 
Blower 147 delivers its high flow, low static pressure air flow components 
181, 182 in FIG. 6C more fully around the periphery of general diffuser 
180 since directed source-capture air 123 (FIG. 5A) and the elements which 
enable this air 123, namely, directed diffuser 194 and conduit 170, are 
omitted. These air flow components 181, 182 produce a more or less conical 
air flow pattern, which is caused by internal vanes 185. Those air flow 
components 181, 182 move back toward capture surface 110, as seen in FIGS. 
4A and 5A, where they mix with room air components 121 and 122 upon 
entering collector 120. 
Blower 148 derives its inlet flow 208 from holes 206 in the back plate 210 
of blower wheel 174 and delivers its low flow, high pressure outlet flow 
211, 212 into conduits 191, 192. Also shown in FIG. 6D are usual flow 
strippers 213, 214 for forward curved blowers which facilitate pressure 
recovery in conduits 191, 192. FIG. 6D shows dual deliveries into conduits 
191, 192 but one or three or four or more may be used. 
To summarize, this second embodiment, MECA-2, consists of air and collector 
drive unit 140 (FIG. 6C), having dual delivery (via conduits 191, 192) low 
flow, high pressure blower 148 (FIGS. 6C, 6D), in combination with 
directed distributors 230, 232 shown in FIG. 3B. MECA-2 supplies source 
air flow components 181, 182 from high flow, low pressure blower 147 in 
the more or less conical pattern described above. MECA-2 otherwise 
externally resembles the MECA-1 embodiment of FIGS. 1, 2, 3A, 4A and 5A 
except for the omitted diffuser 194. 
Referring to FIG. 3B, which shows the important internal arrangements of 
elements, we now explain how continuous blow-off cleaning is realized. 
Conduits 191, 192 deliver low flow, high pressure air flow components 212, 
214 (FIG. 6D) to blow-off distributors 230, 232 which are seen to apply 
high velocity blow-off jets 234, 236 to the drop wires in stop-motion 
assembly 58 or to the reed 56. Dust and fibers are thereby released and 
carried by capture air flow components 181, 182, 121, 122, along with 
other emissions 46-49, to capture surface 110. 
Blow-off jets 234, 236 are elongated slots in conduits 230, 232 which are 
preferably 6 inches in diameter and extend fully under shed 28, 29 and 
cloth 25 for a length of, typically, 66 inches. Conduits 230, 232 can 
oscillate around their axes, thus sweeping or scanning blow-off jets 234, 
236. 
Blow-off jets 234, 236 continuously operate and furthermore operate 
continuously across the weaving machine in this MECA-2 embodiment. 
In some weaving applications, it is necessary to have blow-off jets having 
higher velocities (i.e., driven by higher static pressure) than can be 
achieved with a single stage forward curved blower 148. In those cases, 
well-known multiple stage blowers can be used or a single blower operating 
at higher speed can be used. However, since blower power requirements 
increase as the product flow rate and total pressure, and since in some 
cases periodic blow-off is acceptable, FIGS. 3C and 3D show a scanning 
blow-off distributor 240. 
Holes 242 are provided in a serpentine or barber-pole pattern around and 
along internal cylinder 244 which is supported and rotated by motor 246. 
Bearing 243 supports the left end of cylinder 244. Low flow, high pressure 
air 212 is delivered, via conduit 192, from blower 148 (FIGS. 6C and 6D) 
or from alternate means having higher pressure. Preferably, the outside 
diameter of blow-off distributor 240 is 4 inches, holes 242 are 0.75 inch 
diameter and drilled on 1.0 inch centers. Motor 246 rotates internal 
serpentine cylinder 244 at about 30 RPM, thus scanning the blow-off jet 
250 across the length of the distributor 240 once in 2 seconds. The length 
is set by the cloth 25 being woven in loom 20 (FIG. 2) but is typical 66 
inches. 
C4: High Local Exchange Rates and Tightly-Coupled Process Zones (MECA-3) 
Loom/Room 
It was noted above that major distinguishing features of MPZEC methods and 
apparatus are the proximity of source and capture elements to the process 
zone; flexibility, generality, and speed of controlling a plurality of 
environmental parameters within a plurality of process zones within each 
machine; and ultimately, optionally controlling process performance 
parameters which respond to environmental parameters. Since volumetric 
exchange rate calculations are well known in the art of central 
environmental control, we now briefly develop this concept to the end of 
more fully explaining some of the novel features of our invention which 
dramatically distinguish it from prior art. 
Consider first a loom 20 situated in a processing room environment 112. 
Associate with the loom 20 a floor area of 16 feet by 16 feet=256 FT.sup.2 
and a ceiling height of 18 feet. This is clearly a per loom expression of 
this totality of looms 20 situated in the entire processing environment 
112. If a central air conditioning system supplies and returns 2000 CFM to 
the volume associated with this one loom 20, 256 FT.sup.2 .times.18 
FT.sup.3 =4,608 FT.sup.3, the volumetric exchange rate E is 
##EQU1## 
This rate is representative of current practice, as noted above. MECA-1 
Next consider the MECA-1 embodiment in FIGS. 1, 2 and 3A. By design, much 
of the air flow captured by collector 12D is sourced, in close proximity, 
from general diffuser 180 and directed diffuser 194. Assume 50% 
recirculation and total flow=2000 CFM. This means that 50% of the captured 
air flow components 121, 122, 123, 181, 182 originates with the room 
environment 112 air flow components 121, 123. Alternatively, air flows 
121, 122 are numerically equal to air flows 123, 181, 182. Assume further 
that close proximity means that the 50% recirculated is confined to an 
effective volume defined by the loom width and depth, both about 8 feet. 
Assuming an effective height of 6 feet gives 
##EQU2## 
The interpretation of this result is simple and significant: proximity 
enhances exchange rate. This means that emissions are far more effectively 
captured. Also, the effective volume is much more quickly changed or, 
alternatively stated, the response time is much shorter. 
There are "down-sides": proximity can mean interference with weaving 
operations; quick response requires fast sensors and controls; and 
recirculation can lead to different equilibrium levels for environmental 
parameters (dust and heat build-up, moisture loss, etc). Those "down-side" 
problems are readily solved in the methods and apparatus described herein. 
MECA-3 
Noting the up-side or positive results associated with higher exchange 
rate, and recognizing the down-side solutions, it is most informative to 
compute a limiting exchange rate for MECA-3 described in FIG. 8A. The 
volume 260 within the insulated (thermally and acoustically) process zone 
envelope 260 is roughly 6 FT (cloth 25 width) by 4 FT (front to back 
depth).times.2 FT (effective height)=48 FT.sup.3 and, for Q=2000 CFM, 
##EQU3## 
Evidently, proximity indeed enhances exchange rate. 
It is also informative to calculate the minimum clearing or change time for 
this tightly-coupled embodiment: 
##EQU4## 
This result represents a characteristic time for the flow Q to exchange or 
"clear out" volume V of process zone volume 260. This is the minimum time 
in which changes to environmental parameters (dust concentration, 
temperature, humidity, etc.) in process zone 260 can be made. 
Process zone enclosure 260 in FIG. 8A represents a limiting concept wherein 
the process zone 60 is isolated by thermal and acoustic insulation 262. 
The materials to be processed, warp 21 and filling 23 yarns, are 
introduced into the process zone through seals 266, for the warp yarn 21, 
and similar but unshown seals for the filling yarn 23. Cloth 25 is 
delivered from envelope 260 via seal 268. Seals 269A, 269B operate against 
bottom harness frame 52B. Additional seals are, of course, required and 
their designs are well known. In some cases it is also necessary to 
enclose filling yarn packages 24 and accumulators 26 (FIG. 2). 
Whereas the process zone 260 volumetric calculated above was seen to be 
very high, E=2500 changes/hour, which is about 100 times higher than prior 
art central air conditioning systems, and the cleaning time T=1.4 seconds 
is very short, these parameters only partially explain the benefits of our 
invention. Major advantages of "tightly-coupled", modular process zone 
environmental control over prior art include: 
1. Possibilities to process materials in process zone environments totally 
different from or incompatible with employee zone environments. To 
dramatize: when economically justified, weaving can be performed at 
extremes of temperature or gas composition, at 300.degree. F. or in a 
noble gas for examples. In some cases, different process zone environments 
facilitate the justifications. Weaving at 150.degree. F. in an insulated 
process zone can lead to dramatic savings in air conditioning costs. 
2. Control of the processing machines on a machine-by-machine basis. 
3. Rapid control response. 
4. Almost complete capture of emissions. 
It is now clearer that "tightly-coupled" means more than a closely 
proximate, small, tightly-sealed process zone 60 within envelope 260; it 
means that the process zone 60 environmental parameters are almost 
completely controlled by, or are "tightly-coupled" to, the modular 
environmental control apparatus. Tightly-coupled also means, 
machine-by-machine, gross profit optimization. 
FIGS. 8A and 8B show for MECA-3 downward flow from directed source diffuser 
270 to capture surface 272 in contrast to upward flow for MECA-1. Downward 
flow components 274, 276, 278, 280 carry emissions 46-49 into capture 
surface 272. Dust is not collected on capture surface 272 but is 
transported by collector-conduit 282 to filtration means in air drive unit 
300 such as is taught in FIG. 12 of Shofner U.S. Pat. No. 4,881,957 
Collector-conduit 282 is stationary because it is less practical to move it 
out for cleaning than to perform the filtration externally in air drive 
unit 300. Source diffuser 270 and its air supply conduit 284 must be 
retractable and, of course, process zone envelope 260 must also 
automatically retract. Conduit 284 is rotatably retracted by rotary joint 
130, exactly as collector 120 was retracted as described in FIGS. 5A and 
5B. The retraction of the top of envelope 260 follows the design of 
MECA-4, described below. 
FIG. 8B shows a pure water conduit 302 feeding into drive unit 300 for 
humidification of the process zone environment. A humidity sensor within 
said environment impresses a signal onto one of microcontroller 200 inputs 
400 (FIG. 7) and the amount of moisture delivered to the environment is 
controlled by one of microcontroller 200 outputs 500. Conduits 304, 306 
deliver cooling fluid to drive unit 300. Heat is exchanged via well-known 
coils and the cooling fluid parameters are sensed and controlled by 
microcontroller 200 inputs 400 and outputs 500. Electrical conductors 308, 
310 similarly enable control of ion content, under microcontroller 200 
control. All of these, and other environmental parameters within process 
zone 60 are supplied, sensed, and controlled by well-known means. 
Similar environmental controls 302, 304, 306, 309, 310 are shown servicing 
drive unit 140 in FIG. 4A. 
MECA-4 
Whereas MECA-3 represents a limiting concept for proximity or tight 
coupling, the embodiment of FIG. 9A represents a practical compromise 
which is particularly effective for retrofit installations. Much of the 
detail in FIG. 9A is seen hereinabove in FIGS. 3A and 3B in the MECA-1 and 
MECA-2 embodiments and the elements included in FIG. 9A have the same 
meanings and functions. The directed diffuser 194, seen under shed 29 in 
FIG. 3A, is excluded, and one continuous blow off air 234 distributor 230, 
as first seen in FIG. 3B, is added. Humidification water via conduit 302 
(FIG. 4A), cooling fluid via conduit 304, 306, and electrical power via 
conductors 308, 310 would be used as necessary and justified. 
To complete the major elements for MECA-4, partial envelope 360 is added 
and comprises three sets of hinged covers 361,362; 363,364; and 
365,366,367. When envelope 360 is closed, as in FIG. 9A, preferred 
patterns in capture air flows 121, 122, 181, 182 and including continuous 
blow-off jet 234 are established. Covers 361,362 cause air from the MECA-4 
general diffuser, components 181, 182 and from the room environment 112, 
namely 121, 122, to mix and flow down into and then up through the warp 
yarn 21 in back shed 29. This results in significantly improved 
environmental parameters in back shed 29 (reduced temperature, elevated 
humidity, and lower dust and fly concentration and deposition). 
Covers 363,364 and 365,366,369 confine and constrain the vigorous fanning 
action of reed 56 and provide a flow path for emissions 46,47 to reach 
collector 120. Release and transport of emissions 46,47 are aided by 
continuous blow-off air jet 234. 
Note that cover plate 367 does not contact or seal against cloth 25, but 
rather allows air flow component 181 to enter. Note also that continuous 
blow-off air jet 234 may be highly humidified to enhance warp 21 yarn 
strength and elasticity, i.e., to "toughen" the yarn in front shed 28. 
FIG. 9B shows partial envelope 360 folded into RETRACT mode and collector 
120 moved partially toward RETRACT position. (The individual segments 
361-367 are shown slightly open or separated for clarity.) The elements in 
FIG. 9B are the same as in FIG. 9A. Only essential reference numbered 
elements are retained in order to show how completely partial envelope 360 
is retracted. 
C5: Exemplary Results 
Two secret trials have yielded the following performance results with air 
jet looms operating at 600 picks/min. 
1. Denim, MECA-4 
Respirable Dust 
Employee Zone 1300.fwdarw.350 .mu.g/m.sup.3 
Process Zone 3000.fwdarw.500 .mu.g/m.sup.3 
Total Dust Captured 1 pound/12 hours 
Process Zone Thermal--1.7.degree. F., +5.5% RH 
Weaving Performance Not Yet Evaluated 
2. Twill, MECA,1 
Dust Performance Not Evaluated 
Weaving Performance: 
Filling Stops Reduced from 4 to 2 per 100,000 picks. 
Optimal Process control 
The invention also enables implementation of one or more optimal process 
control strategies. Whereas the first major objective is provision of 
conditioned gas flows to and from one or more process zones in each 
machine, said conditioned gas flows enabling the control of one or more 
environmental parameters therein, this second objective extends most 
significantly the utility of the invention by enabling optimal control of 
one or more performance parameters of each materials processing machine. 
This optimal control of processing performance parameters is achieved in 
two ways: first, by controlling those processing performance parameters 
which respond, at least in part, to process zone environmental parameters 
and, second, by controlling machinery settings to realize the overall 
optimal process performance. To emphasize and clarify, we are not 
attempting to hold any process zone environmental parameter constant; 
rather, we intend to optimize one or more processing parameters which 
respond to the process zone environmental parameters. In usual practice, 
overall optimal process performance means maximizing gross profit, but it 
can mean maximizing quality, efficiency, throughput or production rate, 
employee morale, etc. Of course, it is highly unlikely and unnecessary 
that any two or more of these overall process parameters will or can 
maximize simultaneously for any one materials processing machine. 
Shofner et al U.S. Pat. No. 5,560,194, titled "Method for Optimally 
Controlling Fiber Processing Machines," issued from application Ser. No. 
341,292, filed Nov. 15, 1994 as a continuation of Ser. No. 999,212, filed 
Dec. 31, 1992, and now abandoned, the disclosure of which was published as 
European Patent Application Publication No. 0,604,876 titled "Methods for 
Optimally Controlling Fiber Processing Machines"; and Shofner et al U.S. 
Pat. No. 5,361,450 titled "Direct Control of Fiber Testing or Processing 
Performance Parameters by Application of Controlled, Conditioned Gas 
Flows" the entire disclosures of which are hereby incorporated by 
reference, represent "state of the art" concepts at the time of their 
initial U.S. filings. 
U.S. Pat. No. 5,560,194 is directed toward fiber processing, ending with 
spinning fibers into yarn, and is totally silent on optimal controls via 
control of environmental parameters in the machinery process zones. (The 
preferred embodiment for U.S. Pat. No. 5,560,194 is open end spinning, 
FIG. 1 therein.) 
U.S. Pat. No. 5,361,450 is also directed toward control of fiber processing 
performance parameters (preferred embodiment carding, FIG. 6 therein), via 
control of environmental parameters in the machinery process zones, but 
the process zone environmental parameters are themselves controlled by 
application of controlled, conditional gas flows delivered from improved 
central air conditioning systems (FIG. 10 in U.S. Pat. No. 5,361,450). 
U.S. Pat. No. 5,361,450 is totally silent on fabric formation (weaving or 
knitting), on generic materials processing, or on modular process zone 
environmental control. 
In view of the foregoing, it will be appreciated that extensive research 
and development by the present inventors has revealed limitations of the 
prior art, and has led to the inventions with respect to modular process 
zone environmental control disclosed hereinabove. 
While prior art central air conditioning systems can control to or "hold" 
reasonably uniform (spatially) and stable (temporally) desired humidity 
and temperature conditions, as monitored by one or more chart 
recorder/controllers 13 in the process room, they cannot, without the 
improvements of U.S. Pat. No. 5,361,450, "hold" such air conditions in 
each and every weaving process zone and cannot always achieve compliance 
with the OSHA respirable dust standard. Nor can prior art central air 
conditioning systems significantly effect collection of dust and fiber or 
reduce noise emissions. 
Prior art central air conditioning typically cannot control the process 
zone environmental conditions on a machine-by-machine basis. The subject 
invention, for all weaving manufacturing processes, operates to generate 
or hold more favorable environmental conditions in the weaving process 
zone, to capture dust and fibers, including respirable dust, before they 
spread into the workplace, and to suppress noise emissions. 
The invention provides further fundamental advantages over travelling 
cleaners and prior art central air conditioning, further improves the 
improvements disclosed in U.S. Pat. No. 5,361,450. Whereas it is a purpose 
of the invention to replace travelling cleaners with MECA-W units in most 
cases, it is not intended to eliminate central air conditioning, in 
general, but rather to reduce the demands on it to primarily provide 
conditioned air for the employee zones. Central air conditioning can 
effectively meet these demands of air conditioning employee work zones but 
cannot effectively handle process zone environmental control. The methods 
and apparatus of the instant invention can advantageously handle process 
zone environmental control. 
While specific embodiments of the invention have been illustrated and 
described herein, it is realized that numerous modifications and changes 
will occur to those skilled in the art. It is therefore to be understood 
that the appended claims are intended to cover all such modifications and 
changes as fall within the true spirit and scope of the invention.