internship report arslan
TRANSCRIPT
MASOOD SPINNING MILLS LTD.
KABIRWALA
INTERNSHIP REPORT
Participants
SHEIKH ARSLAN SHAUKAT
TE-15-05 RAO KAMAL TARIQ
TE-61-05
DEPARTMENT OF TEXTILE ENGINEERING, BAHAUDDIN ZAKARIYA UNIVERSITY,
MULTAN
August, 2006
PREFACE 1 ACKNOWLEDGMENT 2 COMPANY PROFILE 3 FACTORY LAYOUT 4 INTRODUCTION TO MSM 5 MACHINERY DETAILS 6 PROCESS LAYOUT 7 BLOW ROOM PROCESS 8 CARDING PROCESS 14 COMBING PROCESS 26 DRAWING PROCESS 40 ROVING PROCESS 52 RING SPINNING PROCESS 64 AUTOCONE PROCESS 80 RELATIVE HUMIDITY 92 QUALITY POLICY 93 REFRENCES 94
CONTENTS
Internship Report
PREFACE
This report is based on our four week internship at Masood Spinning Mills Ltd. (Unit # 1), Kabirwala. Rather going into the basics of every process, we focused ourselves to get the practical knowledge about the different processes. Our report will give all of its readers the insight of what really happens during a process and what are the different parameters that are kept under check by the Management to insure the process quality.
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ACKNOWLEDGEMENT We are thankful to all the Management at Masood Spinning Mills Ltd. Kabirwala, who made all of our time at MSM an opportunity to learn things. We want to especially thank Mr. Gohar Zaman Mulgani (GM), Mr. Khalid Rasheed (SM) and Mr. Naeem (ASM) for their personal interest in our training. They made all the things as smooth as they can for making us like at home during our training period. There are number of other people who were always like a friend, they made all this really an excellent learning experience. Sheikh Arslan Shaukat Rao Kamal Tariq
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COMPANY PROFILE MASOOD SPINNING MILLS LTD. KABIRWALA
Mill Location
4th-km MULTAN ROAD, KABIRWALA
Chief Executive MR.KHAWAJA MUHAMMAD MASOOD
General Manager
MR. GOHAR ZAMAN MULGANI
Year of Installation 2001
Brand name
AJWA
Certified By ISO9002
Technology
SPINNING COMPLEX
Specialty 100% COTTON YARN
Total No. Of Spindles
22176
Total Production/Year 8.4 MILLION KGS
Total No. Of Workers
260
Cotton Used PAKISTANI, AMERICAN PIMA AND EGYPTIAN
Email address
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FACTORY LAYOUT
MASOOD SPINNING MILLS LTD. UNIT # 1 GATE
G.M OFFICE
ROAD MAIN GATE MULTAN ROAD, KABIRWALA
RAW MATERIAL STORE
RAW MATERIAL STORE
BLOW ROOM
CARDING SECTION
DRAWING BREAKER SECTION UNILAP DRAWING FINISHER SECTION COMBING SECTION
ROVING FRAME QUALITY SECTION CONTROL LAB
RING SPINNING DEPARTMENT
AUTO CONE DEPARTMENT
PACKING DEPARTMENT
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INTRODUCTION TO MSM
In mid of 2001, a new spinning unit named Masood Spinning Mills Ltd. consisting of 18000 spindles (Toyoda Japan) was set up by Mahmood Group near Kabirwala. For this unit the most modern machinery was imported from world’s leader manufactures like Rieter, Trutzschler, Toyoda and Murata to provide the customers with state of the art yarn. With the passage of time more machinery was imported and now the mill has a total of 22176 spindles. The yarn produced is of export quality, free from all defects and suitable for the manufacturing of all sort of cloth.
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MACHINERY DETAILS
MACHINERY COMPANY COUNTRY MODEL YEAR QUANTITY Blow room with Chute Feed
Trutzschler Germany 2001 2 Lines
Card Trutzschler Germany DK 903 2001 14 Sets Drawing Breaker
Toyoda Japan DT100 2000 6
Lap Former Rieter Switzerland E32 2001 1 Comber Rieter Switzerland E62 2001 7 Sets Drawing Finisher with Auto Leveler
Rieter Switzerland RSB-D30 2001 6 Sets
Roving Frame Toyoda Japan FL100 2001 7 Sets Ring Spinning Frame
Toyoda Japan RX240
2001
18 Sets
Compact Ring Spinning Frame with Auto doffer
Toyoda Japan RX240 2002 3 Sets(1056 spindles each)
Autoconer with Visual Manager
Murata
Japan 7V-II and 7V with Auto Doffer
2001 8 Sets 1 Set
Yarn Clearers Loepfe Brothers
Switzerland TK 930S (Mill Master)
Two for one Twisters
Murata, Volksmens
Japan 28C and 3C1
Yarn Conditioning
OBEM Italy
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PROCESS LAYOUT FOR CARDED YARN FOR COMBED YARN
LAP FORMER
COMBING
DRAWING BREAKER
BLOW ROOM
CARDING
BLOW ROOM
CARDING
DRAWING BREAKER
DRAWING FINISHER
ROVING
RING SPINNING
DRAWING FINISHER
ROVING
RING SPINNING
AUTOCONE
AUTOCONE
PACKING
PACKING
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BLOW ROOM PROCESS
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MACHINE MAKER
TRUETZSCHLER (GERMANY) YEAR OF MANUFACTURING
2001
TOTAL LINES 2
FEEDING SYSTEM
Chute feed COTTON USED
Pakistani, American Pima and Egyptian
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BLOW ROOM MACHINERY LINE In Masood Spinning Mills Ltd. there are two lines of blow room made by Trutzschler (Germany). The machinery line is as follows;
BALE BREAKER
BALE OPENER
LATTICE
PLUCKER
CONDENSER
MFC (MAXI-flow)
MPM
CVT 1 (Cleanomat)
BE
CXL 3
VISION SHIELD
DX
COTTON
CHUTE FEED
Half Beating Point
Full Beating Point
Full Beating Point
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INTRODUCTION
When the bales of cotton arrive at a spinning mill, these are
subjected to the very first process, which is definitely Blow Room. In the blow room of Masood Spinning Mills Ltd. mainly opening and cleaning is done. In opening the bales of cotton are broken into small tufts. The higher the degree of opening, the higher is the degree of cleaning. The second main purpose is to clean the cotton. From boll to bale cotton goes through different processes due to which the bales arrive at mill contain different impurities. In blow room, we have to remove all these impurities to prepare our cotton for next process. OBJECTIVES
1. To reduce the density of raw cotton mass by an opening process
2. To reduce the tuft size exposing new fiber surfaces, that allows impurities to be removed
3. To reduce the tuft size in order to improve the mixing of cotton and regularity of the feedstock delivered to the next process.
4. To achieve these objectives with a minimum damage to the fibers
INPUT OF BLOWROOM The material input to the blow room was in the compressed form and full of trashes or impurities i.e. leaves, seed, chaff, metallic particle and dusts etc. OUTPUT OF BLOWROOM After going through the processes of the blow room, the output in the form of small tufts and it is cleaned and opened. MOISTURE AND HUMIDITY The relative humidity in Blow Room should be 50%-55%. The moisture in material of blow room should be 5.50%-5.75%.
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CLEANING EFFICIENCY OF BLOW ROOM The effectiveness of the cleaning machines of blow room is expressed as cleaning efficiency of hat machine. It is expressed as follows:
The standard blow room cleaning efficiency is 60%-65%. The amount of waste removed at each stage of cotton cleaning stage should be known for evaluation and can be found out as:
Any opening & cleaning machines must remove certain amount of useful fibers along with trash that is called “waste (trash useful fibers)”. 40-70% by weight of waste is present at blow room after processing. TRANSPORTATION OF MATERIAL FROM BLOW ROOM TO CARD For the transportation of the fibers from the blow room to the card the chute feed system is used in Masood Spinning Mills Ltd. In chute feed system the ducting pipes and the chute is used. The fibers are taken from the last roller through the condenser, which creates the suction and then feed them to the card machine. The condenser is very important part of the blow room. Its main function is to take the fibers from the back part and supply them to the next part. All this operation is down on the bases of the sucking function of the condenser. Basically the condenser consists on a fan, stripping roller and a perforated roller. The fan is connected with a high-speed motor, which rotates it at a high speed. The grid roller has holes on its surface, which helps it to suck the fibers from the back machine. When the fan and the grid roller rotates with the help of the motor, an air vacuum is generated which sucks the fibers from the back rollers
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through the holes of the grid roller. The stripper roller removes the fibers from the perforated roller and through them into the chute.
TRANSPORTATION OF MATERIAL FROM BLOW ROOM TO CARD FORMULAS Production Calculation per 8 hours
Beater Speed Calculation
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CARDING PROCESS
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MACHINE MAKER
TRUETZSCHLER (GERMANY) MODEL
DK 903
YEAR OF MANUFACTURING 2001
TOTAL MACHINES
14 DOFFING SYSTEM
Manual FEEDING SYSTEM
Chute feed
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INTRODUCTION
Carding is one of the most important processes of the short
staple spinning system. Carding is an operation where the tufty condition of the fibers is converted into an individual fiber form. The separation of fibers in individual form is one fundamental operation of carding while the other fundamental operation is the formation of the card sliver. The carding is a very important process because unless the fibers are separated into individuals, they can not be spun into smooth and uniform yarns neither can they be blended properly with other fibers. In Masood Spinning Mills Ltd. there are 14 DK 903 carding machines made by Trutzschler (Germany). OBJECTIVES Following are the objectives of carding process;
1. To open up the flocks into individual Fibers 2. Cleaning 3. Reduction of neps 4. Elimination of dust & Short Fibers 5. Fiber Blending & Fiber Orientation 6. Sliver Formation
MAIN PARTS The main parts of DK 903 card are following;
1. Tuft feeder directed DFK 2. Opening roller 3. Feed plate 4. Feed rollers 5. Taker- in 1, 2, 3 6. Segments of taker-in 7. 2 Mote knives with suction hoods 8. 6 Back stationery flats and suction hoods
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9. Lower profile plate and upper profile plates 10. Cylinder covering segment with suction hoods 11. Revolving Flats 12. Cylinder 13. 4 Front stationery flats and suction hoods 14. Doffer 15. Doffing roller (Stripping roller) 16. Cleaner roll 17. Squeezing rolls 18. Deflector blade 19. Trumpet 20. Calendar rollers 21. Coiler KH 22. Can Changer KHC
DK 903 CARDING MACHINE DK 903 is a high production carding machine made by Trutzschler. It helps a lot in improving the quality of yarn by controlling majority of the faults at this stage.
CROSS SECTIONAL VEIW
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DIFFERENT ACTIONS AT DK 903 CARD FEED ROLLER AND TAKER-IN Point to point action is taken place between them. Fibers are passed through feed roller to the Taker-in and at this point opening is taken place. There is a mote knife, which diverts the fibers to the main grids that are placed beneath the Taker-in. in this way heavy trashes are removed and main cleaning is taken place at this region.
TAKER-IN AND CYLINDER Point to back action is taken place between cylinder and taker-in. Fibers are transferred from taker-in on to the cylinder. Wires are mounted on the surface of the cylinder and taker-in so that the small tufts opened up into the individual fiber. Cylinder and taker-in are moved in opposite directions. The diameter of the cylinder is much greater than the taker-in.
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CYLINDER AND FLATS The main carding action is taken place between cylinder and flat. The speed of the flat is about 4 to 6 inches per minute. Due to the speed of the flat about 60 times lesser than the swift and due to the point-to-point action following actions/functions are taken place:
Fibers become in an individual form Extensive opening and cleaning is also taken place Removal of short fiber, embedded into the empty places
between flats Neps are removed
Cylinder moves clockwise and flat moves in anticlockwise direction. Distance between cylinder and flat is about 3/1000 inches.
CYLINDER AND DOFFER In this region web is formed. Doffer having diameter of about 27 inches rotates in anticlockwise direction just picks the fiber from the cylinder and web formation is occurred on the surface of the doffer. Surface speed of the doffer is about 25 times lesser than the cylinder for the web formation.
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TRASH AT CARD The trash that is present at the card consists of Neps, dust & foreign impurities. These wastes are collected in a separate waste collector after they pass through grid bars through air suction.
REMOVAL OF NEPS AT CARD Actually Neps are generated due to the seed and also due to the continuous beating at blow room. These Neps form thick and thin places in the yarn. Therefore for removing these Neps, wiry surfaces of different velocity are used at carding. Neps are removed at carding region (between flats and cylinder).
FORMATION OF THE SLIVER There is a stripping roller that removes the web from the surface of the doffer. After passing through the calendar roller (that grips the web) a funnel type device is used (called as trumpet guide), which condenses the web into the sliver.
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COILER MECHANISM This mechanism consists of two disks (coils) i.e. inside and outside disks. Sliver from the trumpet guide is dropped into the sliver can through inside disk in the form of coil.
SLIVER CAN It is a drum that collects the sliver from the card. The cans used at card DK903 in Masood Spinning Mills Ltd. have a height of 48 inches and width of 24 inches.
Cross-sectional View of an empty Sliver Can
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FUNCTION OF DIFFERENT PARTS The detail of the basic function of different parts at the DK903 card is given below: Tuft feeder Tuft feeder has the function to feed the fibers into the card. The fibers are taken from the chute and then are thrown on the feed plate. Feed Rollers Feed rollers take the fibers lab and feed them to the taker-in. Feed roller are of about 5/2 inches in diameter and the width of the card (39-40 inches). Between the feed roller and the taker in the point-to-point action is taking place and the trash is removed. Taker-In Taker-in has the main function of cleaning the fibers. It takes the fibers from the feed rollers and opens them. In DK-903 three taker in rollers (web feed rollers) are used each roller is of about 9 inches diameter. The 1st taker-in is covered with spikes while the 2nd and 3rd taker-in is covered with saw teeth wire. Below and above these rollers the suction is provided. As the fibers are opened the remaining trash from the fibers falls down and is collected into the trash collector. This trash is known as the TAKER-IN. This trash cannot be reused and is soled into the market. It is the last point where the trash can be removed. Between the taker in and the cylinder the point to back action is taking place. The fibers are transported to the cylinder from the taker in roller. Cylinder It is a large hollow cylinder mounted in the middle of the card. The main carding of the fibers takes place between the cylinder and the flat set. The cylinder has the diameter of 50 inches. The surface of the cylinder is also covered with the wire with the sharp head. The thickness, hardness and height of wire is less then that of doffer and the taker-in roller but the no of heads per inches are higher then that of the taker-in and the doffer. Between the main cylinder and the flats, the point-to-point action is taking place and the carding action is
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taking place. In Masood Spinning Mills Ltd. the speed of the cylinder is kept 500rpm. Revolving Flat Set The flat set is mounted on the top of the cylinder and helps in the doffing effect of the cylinder. In DK903 card there are a total of 84 flats usually made of aluminum, in one flat set out of which 30 are in working condition. Each flat set has the sharp wires on it. The top set or flat set has the length of about the 38-40 inches but the thickness, width; no of wires per inch vary with the flat set. Usually the flat set has the width of about 1.5-1.75 inches and the 450 wires per square of inch. There are two brushes on the top of the flats which are used to clean the flats. In Masood Spinning Mills Ltd. usually the speed of the flat set is kept between 230-280mm/min. Pre and Post Carding Segments The function of the pre and the post carding segments is to provide extra carding elements to the fibers. More the carding elements are in the carding zone better carding (opening and individualization) happens. These segments are provided between the taker-in and the flats (pre carding segments) and between the flats and the doffer (post carding segment). Point to point action id there between the pre/post carding segments and the main cylinder. In DK903 card there are 3 sets of stationary flats as the pre-carding segments and 2 sets of stationary flats as post-carding segments. *Each set contains two stationary flats. Doffer Roller Doffer roller has wire on its surface. It has the main function of transferring the fibers from cylinder to the take of roller. It takes individual fibers from the cylinder and converts them into a web. It rotates with the surface speed of about 22-24 rpm. Between the main cylinder and the doffer the point to point action is taking place and the neps are being created there in the fibers. Stripping Roller When the fibers from the doffer roller come out the stripping roller stripes them. It has the surface diameter of 7 inches.
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Calendar Rollers Calendar rollers have the sole function of calendaring i.e. to press the fiber stand (sliver). When the fibers (in the form of a fiber sheet) come out, they are passed through the trumpet and then to the calendar rollers. In DK903 card there are two types of calendars. One is at the front of the card called as the front calendar rollers (105 mm) and second on the coiler called as the coiler end calendar rollers (50 mm). Both have the smooth surface and press the sliver so that the sliver gets some strength and can easily be wound and unwound. Coiler KH or Can Changer KHC Coiler has the function of winding of the sliver into the can. Coiler has a calendar roller, which press the sliver before the winding. The sliver is wound in form of the circular sheets in the can. The coiler and the can rotate in such a way that the coiler rotates in high speed then that of can, forming the sliver sheets in the can. OPERATIONAL PROCESS OF THE CARD DK 903 Tuft feeder feeds fibers into the card back (taker-in). The taker-in (three rollers with the spikes and the sow teeth covering) removes the trash particles from the fibers. Then the fibers are fed onto the cylinder. The cylinder further spreads out the fibers with the help of the top set or flat set. The cylinder and the flat set rotate in opposite direction. The gauge between the cylinder and the top-set is set in such a way that the fibers should be completely parallelized in the axis of motion. Then the cylinder delivers the fibers in the form of a fiber sheet to the doffer. The doffer simply takes the fibers from the cylinder and delivers them to the take off roller or the doffing roller. From the doffing roller the fiber sheet is converted in the form of a sliver (fiber stand) with the help of a trumpet. Then it is passed through the front calendar rollers and then wound into the can with the help of the coiler. The coiler also has a metallic trumpet and calendar rollers. The coiler speed is more than that of the can. This difference in the speeds favors the winding of the sliver into the can.
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WASTES AT CARDING MACHINE Following are the types of waste at carding machine;
Taker-in 1 Taker-in 2 Taker-in 3 Fly Front Trash Back Trash
FORMULAS PRODUCTION RATE It can be calculated as follows;
DRAFT The degree of reduction in the linear density of the fiber material is called as the draft. Draft can be expressed in two forms: (1) Actual or Technical Draft
(2) Mechanical Draft
If the percentage waste removal during the carding machine is (W) then the actual and mechanical draft are related to each other as:
MOISTURE AND HUMIDITY The relative humidity at the carding section should be 50%-55%. The moisture in material should be 4.40%. CONTROL MECHANISMS IN THE CARD DK903 Various control mechanisms are installed in the card DK 903 all these are controlled by the main card commander. Main functions are given below;
To control and regulate the feeding and the production To control the speed of different rollers as required To control the pressure at different rollers
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COMBING PROCESS
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Combing Preparatory Machine
MACHINE MAKER
RIETER (SWITZERLAND)
MODEL E32
YEAR OF MANUFACTURING
2001
TOTAL MACHINES 1
DOFFING SYSTEM
Automatic
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INTRODUCTION
Since the main function of combing is to remove short fibres,
if the carded slivers are directly fed to the combing machine, the waste extraction would be very high and also lot of fiber breakage will take place. This is due to the fact that fiber orientation in the card sliver is very poor and also the card sliver has majority of hooked surfaces. So it is desirable for the card sliver to be prepared into such a form which is suitable for the combing operation. For this reason carded sliver is first passed through a breaker drawing machine. The sliver from the breaker drawing machine is then fed to the UNIlap machine which forms a suitable lap with straight and parallel fibres which is presented as a feeding material to the comber.
PROCESS
The working principle of the Unilap machine E32 machine is shown below:
In Masood Spinning Mills Ltd. feeding head is provided with 22 cans. All the slivers are passed through sliver guide elements which guide them to the drafting zone. The gentle sliver guide elements in E32 improve the run-ability of the machine and have a positive impact on better quality. Static and dynamic sensors are also installed in E32 which detect missing or stationary slivers and the fault signal is on.
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The drafting system in UNIlap E32 machine is 3/3 cylinder system.
After drafting the slivers are condensed to make a lap sheet. The lap sheet formed by the combination of these drafted slivers is passed through a pair of calendar rollers and is ultimately wound on the lap tube with the help of two winding rollers. The lap tube is placed on lap weighing device which automatically removes the lap roll on a semi automatic transport system SERVOtrolley E 6/4-T* when its required weight has been reached. This system automatically takes the lap roll away and automatically loads the empty lap tube and the lap winding begins. The regulated automatic lap loading safeguards the ideal pressure of the lap on the lap rollers during the complete build-up cycle.
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SERVOtrolley E 6/4-T*
MAIN FEATURES The main features of UNIlap E32 are;
2-zone drafting for ideal fiber drawing 4 calendar rollers and automatic regulation of the lap loading for
a perfect lap build-up High production rates and quality levels by means of the
VARIOspeed Improved running conditions-better reliability Function design for greater ease of operation
E32 combing preparatory machine
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The weight of the lap is 1100 g/yd. The length of the lap is approximately 120m The weight of the empty lap tube is more than 240g.
SPECIFICATIONS
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Combing Machine
MACHINE MAKER
RIETER (SWITZERLAND)
MODEL E62
YEAR OF MANUFACTURING
2001
TOTAL MACHINES 7
FEEDING SYSTEM
Lap Feed
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INTRODUCTION
Combing is an optional process in the processing of short
staple fibres necessary for the preparation of high quality combed yarn. The process of combing is carried out after carding and the combed sliver after passing through the draw frame follows the regular path of yarn formation. The carded sliver still has some trash particles, neps and short fibres in it. In addition to it, the individual fibres in the card sliver are not well aligned longitudinally and majority of them have hooked surfaces. The basic purpose of combing is to remove short fibres and remaining impurities and to make the fibres well aligned and straight so that only high quality long fibres are used for making a yarn. In Masood Spinning Mills Ltd. there are 7 E62 combing machines made by Rieter (Switzerland). OBJECTIVES Following are the main objectives of combing
1. To separate the long fibres from the short ones. The longer fibres are processed into a combed sliver whereas the shorter fibres are removed as a waste. Depending upon the quality of the yarn required, predetermined quantity of short fibres are removed during the combing process.
2. To eliminate the remaining impurities and trash left by the carding process. The waste combination of trash, short fibres and neps is collectively also called a noil. The amount of noil removed during combing ranges from 5% to 25% depending upon the quality of the yarn.
3. Elimination of majority of the neps in the fiber material 4. To straighten and align the separated long fibres. 5. To create a combed sliver with maximum possible evenness.
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MAIN PARTS The main parts of E62 comber are following;
1. Lap roller 2. Lap 3. Cushion plate 4. Feed roller 5. Cylinder (toothed wire) 6. Nipper knife 7. Top comb 8. Detaching rollers (top and bottom) 9. Clearer arm 10. Flocks 11. Web pan 12. Table trumpet 13. Drafting rollers 14. Coiler
Parts of Comber
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WORKING OF E62 COMBING MACHINE 1. FEEDING The combing cycle begins with the feed of the lap. The lap sheet is fed to the comber between the feed roller and smooth cushion plate also called as the bottom nipper. The top nipper or the nipper knife moves down to fix on the bottom nipper (cushion plate). Hence the lap sheet is gripped between the top and the bottom nippers.
2. CYLINDER COMBING As the lap is held by both the nippers, the half lap or the cylinder comb rotates and the protruding fringe of the fibres is combed with the help of needles mounted on the cylinder comb. Any fibres not held by the needles will be treated as short fibres and will be removed as a waste during the rotation of the circular comb. The waste (noil) is removed from the surface of the needle with the help of a revolving brush mounted just below the cylinder. The waste removed is then collected by suction at the back of the comber.
Cylinder Comb
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3. PIECING As the half lap or circular comb has finished combing and has cleared the fiber fringe, the detaching roller remains stationary and does not rotate however only the back top detaching roller rocks backward. At the same time the top nipper is raised while the cushion plate or bottom nipper rocks forward. Also the feed roller rotates by a small and amount feeds a predetermined length of lap. This increases the length of the lap fringe and as the bottom nipper moves forward, the leading edge of the lap fringe is entered into the nip of the detaching rollers and initiates piecing. During piecing the top comb also starts descending.
4. TOP COMBING Just as the piecing has started, a top comb with one row of needles is descended into the fiber fringe from the above. As the combed web of fibres is pieced or connected to the surface of the detaching rollers, the detaching rollers now start rotating forward and the combed web of fibres is pulled through the top comb. As the fibres web is pulled through the top comb, short fibres, neps and entanglements not removed by the circular comb is removed here by the top comb. As the bottom nipper reaches its maximum forward position, the detaching is completed because the detaching rollers continue to move forward while the bottom nipper begins to rock backwards. As detaching finishes the top comb is withdrawn upwards.
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The feed roller again rotates and advances a new short section of the lap to be combed by the bottom circular comb and the same combing cycle continues.
5. SLIVER CONDENSING & DRAFTING The combed web taken by the detaching rollers is delivered to the web pan having a trumpet guide on its one side as shown below:
The hardness of the top rollers is 70 shore. The combed web is pulled through the trumpet guide with the help of a pair of calendar rollers that converts the web into a combed sliver. The diameter of the table trumpet is 6mm. there are total 8 delivery points on E62 comber. The combed slivers coming from all the 8 points of the comber are laid side by side and are passed through a draw box where draft is given. On E62 comber 3/5 roller drafting is used where the rollers are inclined at an angle of 60°.
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Drafting Rollers Drafting Gears In Masood Spinning Mills Ltd. main draft given is 16.6 while break draft given is 1.36 No. of teeth on gear A_______________________ 40 No. of teeth on gear B_______________________ 33 No. of teeth on Break Draft gear_____________ 38 PNEUMATIC PRESSURE (Top Rollers) Main pressure______________________________ 6 Bar Front Roller________________________________ 2.5-3 Bar Draft Roller________________________________ 3-4 Bar Back and Middle Roller_____________________ 3.5-4.5 Bar 6. COILING The drafted slivers are coiled into sliver cans after passing through calendaring rollers. On E62 combing machine, the sliver cans are automatically doffed on completion.
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FORMULA
MOISTURE AND HUMIDITY The relative humidity on Comber should be 57%. The moisture in material should be 4.65%. SPECIFICATIONS
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DRAWING PROCESS
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DRAWING BREAKER
MACHINE MAKER
TOYODA (JAPAN) MODEL
DT 100
YEAR OF MANUFACTURING 2000
TOTAL MACHINES
6 CAN DIMENSIONS
20” X 42”
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DRAWING FINISHER
MACHINE MAKER
RIETER (SWITZERLAND) MODEL
RSB-D30
YEAR OF MANUFACTURING 2001
TOTAL MACHINES
6 CAN DIMENSIONS
20” X 48”
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INTRODUCTION
Despite of many advantages of the carding process it has a
big draw back of producing variation and misalignment of the fibres with in the card sliver. The alignment and the slight parallelization achieved at the carding region between the main cylinder and flat largely disappears again because of the doffing action at the doffer. During the transfer of the fibres from the cylinder to the doffer hooked surfaces in the fibres arise. About 50% of the fibres in the card sliver has trailing hooks, 15% fibres have leading hooks and 15% of the fibres have double hooks and only a small portion (20%) of the fibres remain straight.
In order to produce a strong and uniform yarn it is necessary to straighten and align the fibres and to improve the evenness of the sliver. All of these objectives are achieved by the drawing process carried out by a machine called as the draw frame. At the draw frame a number of card slivers are drawn or stretched between several pairs of rollers. As the fibres are attenuated or drafted, the fibres are straightened and aligned to the axis of the sliver in the direction in which they are drawn.
Drawing is the final process of quality improvement in the spinning mill.
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OBJECTIVES
1. Fiber Parallelization through drafting rollers 2. Improving Fiber Orientation along sliver axis. 3. Fiber Blending 4. Some dust removal
MAJOR ZONES Rieter RSB-D30 draw frame can be divided into following zones
1. Creel Zone 2. Drafting Zone 3. Sliver Condensing Zone 4. Coiler Zone 5. Suction Zone
1. CREEL ZONE Creel is the portion of the RSB-D30 draw frame where the card sliver cans are placed. It has the main function of guiding the sliver into the doubling and drafting zones. The creel consists of rods, which guide the slivers. It also has photocells, which detect the breakage of the sliver and stop the machine when sliver breaks. In Masood Spinning Mills Ltd. 8 cans are placed under the creel and one end of the sliver in taken and fed into the breaker drawing machine.
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2. DRAFTING ZONE It has the sole function of drafting. Drafting means the reduction of mass of sliver per unit area or the increase in the length per unit mass (two ways of describing the function).
The drafting zone consists of rollers arrangement. Top rollers are synthetic while bottom rollers are made up of steel and are fluted. These rollers are driven by a single belt. On Rieter draw frame RSB-D30 the roller arrangement is 4/3.
Drafting performed by back rollers is not so prominent; however
front rollers perform the actual draft. The draft in the back rollers is known as the Break Draft because the back rollers just break the sliver stand and there is no effect in the mass per unit length. The Main Draft occurs in the front rollers. Here the sliver stand is reduced to the required mass per unit length value or the draft. The total draft is the multiple of the break draft and the main draft.
3. SLIVER CONDENSING ZONE
The flat fiber web (consisting of several card slivers) exiting the drafting section is converted back into a sliver. The fiber web leaving the front pair of drafting rollers is passed through a converging tube and is guided to a specially designed condensing funnel called as the trumpet guide.
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The degree of condensing at the trumpet guide is essential for providing a good fiber to fiber cohesion to hold them better in a sliver. After condensing of fibres at the trumpet guide back into a sliver form, the sliver is passed through a pair of calendar rollers which does a further compressing of the fiber mass and ultimately deposits the drawn sliver into a sliver can. 4. COILER SECTION
The drawn sliver coming out of the calendar rollers is passed through a coiler tube fixed on a coiler plate.
The coiler gears fixed on the coiler plate help to rotate the coiler tube so that sliver can be laid in the can in form of special coils.
The dimensions of the can are 20” X 48”.The can rests on the rotating plate, with the rotation of the plate the can also rotates. The rate of rotation of the can is kept slower than the rate of rotation of the coiler tube. This helps in proper deposition of drawn sliver in a spiral arrangement. The sliver deposition rate is kept slightly higher than the sliver delivery so that blockage of the sliver in the tube may be avoided. However this difference should not be too large to avoid false drafts.
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5. SUCTION SECTION
In RSB-D30 draw frame as the fibres move swiftly over the
surface of the drafting rollers, dust and lint may be dislodged into the air. The purpose of the suction system on the draw frame is to remove these particles so that they might not get deposited on the surface of the drafting rollers and also to maintain a dust and lint free working environment. The accumulation of the fibrous mass on the surface of the rollers causes unevenness in drafting and sometimes also causes sliver breakages causing the machine to stop. Air suction system used on the RSB-D30 draw frame is shown below:
STOP MOTIONS
There are four types of the stop motion are used in the RSB-D30 draw frame
Sliver breakage stop motion (on the creel) Stop motion for overlapping (on the drafting rollers) Stop motion on the web gathering Stop motion on the coiler
MOISTURE AND HUMIDITY The relative humidity on Drawing Frame should be 57%. The moisture in material should be 4.40%.
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FORMULAS
Production =
OR
AUTO-LEVELING AT RSB-D30 Leveling principle The Autoleveler draw frame RSB-D30 is equipped with a digital leveling system. This function has the principle of open loop control. By means of this system, mass variations of feed slivers are leveled out in a range of ±25 %. The result is a sliver with excellent short, medium and long-term evenness. Measuring Scanning with a well known principle of tongue-and-groove rollers take place with shortest and especially constant scanning distance. Therefore, these signals are independent of the feeding speed. The pneumatic loading of the tongue-and-groove rollers guarantees constant scanning pressure. This is independent of feed sliver weight
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variations unlike conventional spring loaded systems. Surroundings and fiber related interference have no influence on the measuring system. Compared to a caning sliver by means of a fixed-position lever, the well-proven principle of tongue-and groove rollers shows certain fundamental advantages. Tongue and groove rollers produce scarcely any friction between fibers and metal. This reduces the amount of deposits-an essential issue for perfect long term count stability. On the other hand, the lower friction allows the application of higher compression forces with the rollers on the incoming sliver. Variations in mass can thus be measured more precisely. Digital Autoleveling Based on the measured values, the leveling processor calculates a nominal value for the high-dynamic AC servo drive. It is transferred exactly in the moment, when the measured piece of sliver arrives at the leveling point within the main drafting zone. A planetary gear superimposes the constant basic speed of the main motor with the variable speed of the servo drive. It then only needs to provide the differential power for the Autoleveling function.
Ensured by this concept and supported by the increased dynamics of the servo drive, the correction speed is always sufficient even with delivery speeds up to 1000m/min. thus, piecing and unevenness in combed sliver are also eliminated.
Leveling Principle of RSB-D30
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RIETER QUALITY MONITOR
The Rieter Quality Monitor (RQM), placed after the drafting system, reliably avoids the production of faulty sliver. This system, independent from the leveling unit, controls the sliver mass continuously and stops the machine in case of exceeding preset limits. The new sensor unit delivers values of highest accuracy. The quality Monitor can be connected to the Rieter Mill Monitoring System SPIDERweb for further analysis. Quality data of RQM
Sliver count A% Sliver evenness CV% and length variation for 1m, 3m, 5m Actual spectrogram Advanced diagram displays, e.g. up to timeframe of 24
hours Detection of thick places
Benefits through detection of thick places
Monitoring of cleaning & maintenance jobs at card, comber and draw frame
Monitoring of sliver piecing quality Support for technological optimizations Improved sliver and yarn quality Assurance of high productivity in roving, spinning and winding
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MASOOD SPINNING MILLS LTD. UNIT # 1
RSB-D30 MAIN SCREEN READINGS DATE 15-07-06 TIME 10:20
Machine # 4 Machine # 5 A % 0.3 % A % -1.3 % CV % 2.1 % CV % 2 % Efficiency 24.4 % Efficiency 21.8 % Can Capacity 3000 yds Can Capacity 3000 yds Delivery Speed 444 yds/min Delivery Speed 444 yds/min MAIN SPECIFICATOINS
Draw frame with Autoleveler RSB-D 30Material cotton, man-made fibres and
blendsstaple length 10 to 80 mm
Doubling 6 to 8 foldFeed weight 12 to 50 ktexDraft 4.5 to 11.6 foldSliver weight 1.25 to 7 ktex
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ROVING PROCESS
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MACHINE MAKER
TOYODA (JAPAN)
MODEL FL1OO
TOTAL ROVING FRAMES
7 TOTAL NO OF SPINDLES
840 (120 Spindles/Machine) DOFFING SYSTEM
Manual DUST REMOVAL SYSTEM Automatic Pneumatic System for Removal of Fly and Dust Manufacturer: Luwa (Japan), Model: 2001
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INTRODUCTION
The drawn sliver is composed of clean and straightened fibers
lying parallel to one another and to the axis of the sliver. These characteristics of a drawn sliver are ideal for creation of a yarn. However this is not possible because if the drawn sliver is to be directly converted into a yarn it would require a mechanical draft of a range of 300 to 600. But this is impossible. So an intermediate stage of drafting is carried out using the roving frame. The draft given at the roving frame reduces the linear density of the drawn sliver into a less thick strand of fibers suitable as an input to the ring frame. This roving which is fed to the ring frame can then be easily converted into a yarn by giving a draft of 15 to 40.
Another advantage of making roving is to have a better package as an input to the ring frame. The roving frame produces roving on compact small packages called as bobbins. The bobbins are much more convenient to transport and have less chances to get damaged as compared to the can sliver mode of package. In Masood Spinning Mills Ltd. there are 7 FL100 roving frames made by Toyoda (Japan). Each machine has 120 spindles. OBJECTIVES There are three basic objectives of the roving frame process
1. To draft the material to the required linear density. 2. To insert the required twist. The twist level in simplex frame is
usually very low because this is an intermediate stage between sliver and yarn formation.
3. To produce a stable package that is suitable for transport, handling and storage.
MAIN PARTS OF ROVING FRAME Drawing Sliver Can These cans are the output of drawing process and input for roving process. The dimensions of the can are 20” X 48”.
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Roving Frame Creel It is used for lifting the drawing sliver in the space between sliver can and drafting zone. Drafting Rollers There is three or four pair of rollers, which convert a drawing sliver into roving sliver. Flyer The purpose of flyer is to insert twist. Each flyer rotation creates one turn in the roving. Spindle Drive and Support Spindle holds the bobbin and this mechanism drives the spindle and also gives support to the spindle. Carriage Lifting Works Help the bobbin to do vertical motion due to which the sliver is wound on the bobbin in a proper manner. FL100 ROVING FRAME The FL100 is a high-speed roving frame that drafts sliver into high-quality roving and is simple to operate. This all is possible due to the advanced technology of its automatic computerized control of flyer speed adjustment and winding tension. With a high-speed flyer and cone drum less operation, it gives excellent productivity. FL100 roving frame can be divided into following zones:
1. Creel zone 2. Drafting zone 3. Twisting and Winding zone
1. CREEL ZONE The creel of the roving frame has the cans with the drawn sliver. It guides the sliver to the drafting zone. Following are the main parts of creel;
a) Cans b) Sliver guide rollers
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The creel in the FL100 roving frame is the area designated for the drawn sliver cans which are positioned at the back of the machine. Just above the cans number of independently driven guide rollers are provided that helps the sliver to move toward the drafting section. Since the fibers in the drawn sliver have less coherence so it is necessary to keep the surface speed of the guide rollers equal to the surface speed of the back drafting rollers so that any false drafting may be avoided that can damage the sliver. Just before the drafting section a photo-electric sensor is used which detects the presence of the sliver and as the sliver breaks it automatically stops the machine. 2. DRAFTING ZONE Following are the main parts of drafting zone;
a) Condenser bar b) Apron bar c) Fiber collector d) Apron e) Bottom rollers (4) f) Cleaning cloth (top and bottom) g) Trumpet (smooth and grooved)
Drafting section of the FL100 roving frame is composed of 4/4 roller arrangement. Bottom roller used are steel fluted rollers (Diameter 28.5mm) while the top rollers (Diameter 28mm) are covered with some synthetic rubber covering. The hardness of the top rollers is 75 shore. The top rollers are pressed down with sufficient force on to the bottom rollers to ensure proper grip of the fibers. Due to four pair of rollers there are three drafting zones.
1. Back zone drafting or break draft (between back and 3rd roller). 2. Middle zone drafting or carrier draft (between 2nd and 3rd
roller). 3. Front zone drafting or main draft (between front and 2nd roller).
The drafting is done by increasing the speed of rollers as the first roller speed is lesser than the second one, the second roller speed is
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lesser than the third roller and third roller speed is lesser than the fourth roller. The stop motion is with every drafting roller.
4/4 Drafting System at FL100 roving frame
APRON SYSTEM In the FL100 roving frame a double apron system is provided at the middle pair of drafting rollers. The top apron is short while the bottom apron is longer. Both of these aprons are made of synthetic rubber. Both these aprons in cooperation with each other guide and transport the fibers during drafting. The aprons help to support the floating fibers and drastically reduce the drafting wave. It is important that the aprons should extend as close as possible to the nip line of the front rollers. The length of the aprons also called as the cradle length is kept approximately equal to the staple length of the fibers. DRAFT DISTRIBUTION An important consideration of the drafting zone is the draft distribution i.e. how much draft should be given in the back and front zones. The draft at the back zone is called as break draft and it should be as low as possible while majority of the draft is given at the front zone where there is an apron control over the fibers and is called as the main draft. The total draft is the product of break and main draft. Generally the break draft for cotton lies in the range of 1.05 to 1.15 and all the remaining draft is given at the main drafting zone. The break draft is just meant to straighten the fibers and to prepare them for a major draft at the front drafting zone. If the break draft is increased beyond an optimum value then the evenness of the spun yarn drastically reduces due to the formation of thick and thin places.
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3. TWISTING AND WINDING ZONE Following are the main parts of this zone;
1. Flyer 2. Spindle 3. Spindle rail (bobbin rail) 4. Bobbin
The winding section comprises of a spindle and a flyer. A spindle is a long steel shaft that acts as a support and a driving element for the flyer. The flyer is a special component of the roving frame that helps to insert twist in the roving. The spindle is mounted at its lower end in a bearing which gets its drive from the train of gears and transmits it to the flyer. Just around the flyer a shaft is fixed around the spindle with a collar that gets its drive independently from a separate set of gears. An empty bobbin made of plastic is mounted on this shaft. The bore of spindle is 20mm while the bore of simplex bobbin is 21mm. The arrangement of a spindle and a flyer is shown below:
TWISTING MECHANISM Roving from the front rollers passes into the top of the flyer and down to hollow leg to emerge next to the 3 presser winder and is wound on the bobbin. Weight of the simplex bobbin is 231-235g.
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The dimensions of the simplex bobbin are;
Length: 452 mm, Base Diameter: 45 mm, Collar Diameter: 60 mm Surface speed of bobbin is greater than he flyer speed hence on each revolutions of the flyer one turn is given to the material as the end of roving at the delivery roller is not rotating but the end at the top of the flyer is rotating. Flyer speed is kept constant; hence twist level remains constant during the whole process. WINDING MECHANISM The drive to all spindles is given from one motor. As the package builds up, the spindle speed decreases so as to facilitate even winding. Flyer and spindles both are positively driven so as the bobbin diameter increases speed of spindle also decrease to compensate. Winding tension is maintained by the precision sensors and computer control.
STOP MOTIONS Stop motions installed on FL100 simplex frame are:
a) Creel Stop Motion. b) Sensor before back rollers. c) Sensor after front rollers.
MOISTURE AND HUMIDITY The relative humidity on Roving Frame should be 57%. The moisture in material should be 5.25%-5.75%.
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FORMULAS
OUTSTANDING FEATURES Outstanding productivity made possible by microcomputer control
A newly developed high-speed flyer is incorporated to ensure high-quality roving when operating at a high speed.
The new flyer reliably operates at speeds up to 1,500 rpm. The flyer speed is automatically regulated by microcomputer
control. Instead of a cone drum, a winding motor is used to enable
superior, high-speed operation. Microcomputer control makes it possible to stop roving at both
a fixed position and a specified length.
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Creel Tension Management System A creel tension fine adjustment mechanism maintains uniform roving thickness and a balanced rate of sliver draw from the feed cans.
Simple Operation And Easy Maintenance With minimal required data input from the easy-to-use large function panel, appropriate winding tension and speed control patterns are set to eliminate roving breaks. The panel also provides easy monitoring of operational status and controls. Up to 10,000 hours of continuous operation
hanism for bobbin and
vice
plifies
ew drafting system
without major lubrication. An automatic oil supply mecflyer gearing ensures trouble-free operation. An automatic roving-end positioning de further reduces manual restart procedures. Large LCD touch-screen function panel siminput and monitoring N
ng system The four-roller draftiplaces a collector between the front and second rollers, separating drafting and collecting zones for superior roving softness and smoothness.
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Automatic traveling suction cleaner
An traveling suction device automatically collects dust and fiber from the top cleaner when operating with a wagon doffer.
An optional flyer rail cover cleaning device reduces the frequency of operator cleaning procedures as well as improving the quality of the roving.
An optional cross flow fan type dust collector reduces the necessity for rear frame cleaning to intervals of six months or a year as its fan discharge blows into the interior of the frame, preventing fly build-up. This collector is fully adaptable to various dust collection methods which may be already installed.
A stop motion device located at the middle part of package stops the machine when roving breaks occur, preventing further damage.
Automatic flyer rail cover cleaner Crossflow fan type dust collector
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MAIN SPECIFICATIONS Staple le 44-76 mm*
ngth 22-40 mm 40-51 mm 51-76 mm
(Unit mm)
Drafting roller 3-roller system 4-roller (D type) 4-roller (D type) 3-
Maker SKF SKF SKF SKF Weightinarm PK
1500-02
g Type PK
1500-001938 PK 1500-001938
PK 1500-02
F 9-12-15 9-12-15 20-25-30 20-25-30
2 15-20-25 15-20-25 10-15-20 10-15-20 3 10-15-20 10-15-20 15-20-25 15-20-25
Weight (kg/ 2 spin
-- dles)
B 10-15-20 10-15-20 --
Cradle ty OH534-110 pe OH514-110 OH534-110 OH524-110 Cradle g(mm) 39.8 x 40 auge x width 31.5 x 40 39.8 x 40 54.3 x 40
F 28.5 28.5 31.75 31.75
2 28.5 28.5 28.5 (knurled) 28.5 (knurled) 3 28.5 (knurled) 28.5 (knurled) 31.75 31.75
Bottom roller diameter(mm)
B 28.5 28.5 -- --
Top e roll r diameter (mm) 28 28 35 35
F-2 35-42 42-57 73-86 60-86
2-3 47-52 56-60 57-90 52-90 Roller gauge (mm)
45-52 45-62 -- -- 3-B Clearer Positive intermittent revolving clearer with comb Feeding can Up to 508 mm (20") diameter x 1,150 mm (45") high
Creel Positive revolving feed roller with extended creel (single sliver feed system)
Power required Main motor: 11kW or 15kW
High speed Automatic flyer-speed control with inverter
Quality
Automatic tension controllprevention, roving stop at set lpackage shoulder collapse prelectronic stop motion on front
er, roving irregularity ength/position,
evention, optical & back sides
Operation and maintenance
LCD touch-screen function pmisplacement prevention devilubrication for main and droil supply system for flyer ansuction device for bottom clearer
anel, bobbin ce, oil bath
aft gearing, automatic d bobbin gears,
Special devices (included)
Automation Automatic roving positioning for machine restart
New SL Flyer
High speed Bobbin jumping prevention device
Quality Stop motion upon roving breaadjustment mechanism
kage at middle part of package, creel tension fine
Operation and Flyer-rail cover cleaning devic
maintenance
e, automatic traveling suction cleaner, cross flow fan type dust collector
Options
Automation Roving cutting device (synthetic fiber at up to 76 mm length)
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RING SPINNING PROCESS
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MACHINE MAKER
TOYODA (JAPAN)
MODEL RX240
TOTAL SPINNING FRAMES
21 (18 Ring Spinning Frames + 3 Compact Ring Spinning Frames) TOTAL NO OF SPINDLES
22176 MAJOR COUNT SPUN
20/s, 24/s, 30/s, 40/s, 60/s DRAFTING SYSTEM
US
SKF PK 225
T REMOVAL SYSTEMD Automatic Pneumatic System for Removal of Fly and Dust
anufacturer: Luwa (Japan), Model: 2001 M
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INTRODUCTION
Spinning is the final process in production of a single yarn.
s drafted to the desired diameter, and the desired amount of twist is added. The method o g used in spinning is the same
and by the speed of rotation of the
the drafting elements, fed , which moves freely around
e bobbin spindle on a circular ring, and wrapped around the ring spinning because the twist in the
yarn is produced as a g. In the ring-spinnin Mills Ltd.
spinning frames producing export quality yarn. Each machine has 1056 spindles each on which yarns of different ounts are being produced.
The roving if draftin
as used in drawing and roving. The movement of the fiber strand imparts the twist around the bobbin
spindle holding the bobbin. The fiber strand is pulled fromthrough a U-shaped guide called a traveler
track orthbobbin. The process is called
traveler moves around the ring department of Masood Spinning
Kabirwala there are 21 ring
c OBJECTIVES There are three basic objectives of ring spinning process.
1. To draft the input material to the linear density required in the final yarn.
2. To insert the required amount of twist. 3. To wind the yarn onto the package, that is suitable for
handling, storage, transportation and is capable of being unwound at a high speed in subsequent processes.
RX240 RING SPINNING FRAME RX240 Ring spinning frame can be divided into three zones:
1. Creel Zone 2. Drafting Zone 3. Twisting Zone and Winding Zone
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1. CREEL ZONE The creel of the ring spinning frame is a simple device that holds the
d on a frame so
ng, the roving bobbins are held vertically y inserting the roving bobbin on the bobbin hanger placed at the
he frame. A typical bobbin holder is shown in the gure below:
roving. The standard height of the hanger creel is 1450mm. Main parts of creel are;
a) Main creel rod b) Bobbin hanger c) Guide bars
Main Creel Rod It is long rod on which Bobbin Hanger is fixed. It helps to unwind the bobbin taken from roving frame. There are total six rods at RX240 spinning frame. One rod on each side is allotted for the spare bobbin hangers. About 84-85 spare roving bobbins are hangethat machine can work at a constant speed. Bobbin Hanger To facilitate proper unwindibupper portion of tfi
The upper end of the bobbin hanger is suspended by a bearing.
ger. Since the ring of the bobbin holder is attached to the retainer device so as the bobbin is pushed upward, the ring will also move upward causing the tion of the roving bobbin tube.
The roving bobbin is pushed upward on to the bobbin han
retainer device to grab the inner por
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As the roving is pulled forward by the drafting rollers, the roving
perly and se drafts or roving breakages. If the roving
breakage is repeatedly taking place then the bobbin hanger should be rep
o Toyoda Textile Bulletin, the average life of the obbin hangers on the spinning frame is five to seven years.
bobbin rotates and unwinding takes place. It is very important that the roving should unwind pro
evenly to avoid any fal
laced. According t
b Guide Bars Guide bars are used to lead the roving to the drafting zone. These are necessary to reduce the breakage of roving. 2. DRAFTING ZONE Parts of drafting zone are;
f) Pressure Arm g) Spacer h) Flocks
Roving Guide It is just like trumpet and used to give proper way to the roving to the drafting zone. It has to and fro motion. Drafting Rollers There
a) Roving Guide b) Drafting Rollers (Top and Bottom) c) Aprons(Top and Bottom) d) Apron Bar e) Cradle
is 3/3 drafting system installed in RX240 ring spinning frame. 1) Back rollers(Top and Bottom) 2) Middle rollers(Top and Bottom) 3) Front rollers(Top and Bottom)
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Each roller has flutes for better gripping. All rollers except front rollers
ted according to the staple length. Middle roller is knurled
hese are covered with synthetic rubber also called as Rubber Cots.
Brand of rubber cots used at Masood Spinning Mills
can be adjusso as to produce fine grip on apron. Drafting rollers consists of top and bottom rollers.
1. Top Rollers T
DiBARKOL
mensions Outer diameter 28 mm
ameter 19mm 26 mm
Degree of grinding stone: 65 grains Grind period: 1 month ortion removed 0.3
p Rollers 65 shore
s checked by hardness meter.
e
2.It i flutes to increase their ability to
iameter of bottom rollers is 27mm.
Inner diWidth
PHardness of ToLife of rubber cots: 1 year *Shore is the degree of hardness and it i Top Roller GaugDistance between top rollers is called as Top Roller Gauge.
Bottom Rollers s made of steel and formed with
carry the fibers. The surface of middle bottom rollers is knurled. D
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Bottom Rollers
DRIVING MECHANISM Front roller is driven by Twist Wheel Back Roller is driven by Draft Wheel Middle roller is driven by Back Draft Wheel
a) For Pakistani Cotton (Carded)
dle and Front rollers— 43mm
ollers— 50mm rollers—43mm ptian (Compact)
le ro m dl and ont r 4mm
Compact) mm
nd ont r 43mm
cover of top and bottom middle rollers, used to guide fibers to main drafting zone is called aprons. Aprons have definite length
zone. peed of aprons depends upon the speed of middle pair of
r
Gauges (Centre to Centre Distance)
Back and Middle rollers— 49mm Mid
b) 2. For Pakistani Cotton (Combed) Back and Middle rMiddle and Front
c) For Pima and EgyBack and Midd llers— 58mMid e Fr ollers— 4
d) For Pima and Egyptian (Non-Back and Middle rollers— 58Middle a Fr ollers—
Aprons A
and thickness. They maintain the fibers in main drafting Sollers.
There are two aprons 1. Top apron 2. Bottom apron
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Brand used at Masood Spinning Mills
KUREHA Dimensions
Top apron 37 x 28 x 1.1mm Bottom Apron 73 x 30 x 1.1mm
Average Life Top Apron: 1Year approximately Bottom Apron: 1Year approximately
It is a long bar made up of steel. Bottom apron rotates on it and it hel
radle spacer and apron are present is
called cra
Apron Bar
ps to keep it tight.
CTop middle drafting roller in which
dle.
Pressure ArmIt is made on it and it is used to maintain t Masood Spinning Mills Ltd. its
ttom t for for
Flocks are made up of wood and iron rod and have a sticky surface. They are used to remove the fibers from the surface of front top roller.
of metal. Top rollers are fixed
pressure on the top rollers to make yarn. A gauge is 3mm.
Spacer Spacer is used to maintain the distance between top and borollers regarding the count. It is made of plastic. It is differendifferent counts. For fine roving, spacer of small size is used andcoarser roving, big size spacer is used. Flocks
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DRAFT
Draft is given in two stages; 1) Break draft 2) Main draft
BREAK DRAFT The draft given in iddle rollers is alled break draft. The basic purpose of the break draft is to prepare
l for further process i.e. main draft
AIN DRAFT
back zone, between the Back and mcthe materiaIt also unwinds the roving preparing it for further processing. M
ft in front zone, between front and middle rollers is called main
ose of the main draft is to get our required count.
DRAFT = Weight/yard Fed
Weight/yard Delivered TOTAL DRAFT
The dradraft.
The basic purp
It is the product of break draft and main draft
TOTAL DRAFT = Break Draft x Main Draft
ecause if roving passes through exactly e same portion of the rollers it may cause damage to the rollers. The
t of rollers have different speeds, due to the difference in
llers is called gauge. Gauge epends upon the staple length.
PROCESS The roving through the roving guide enters the drafting zone. Roving guide has traverse motion bththree sespeed of the rollers drafting is done, so length increases and weight decreases. Every advanced set of rollers has more speed than the previous one. The pressure on the rollers is maintained according to the count. Distance between the rod 3. TWISTING AND WINDING ZONE Parts of this zone are
a) Lappet rail with snail wires
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loon breakers
is called nail wire. The main purpose of snail wire is to lead the yarn centrally
xis.
Breaker l. Its
size of balloon of yarn and prevents the balloon
t
It is a long rail on which rings are fixed. Rings and travelers are present over it. It moves up and down to facilitate proper winding of
he bobbin.
ue to its massiveness. ifting Motion is done by Lifting Gear Box which has two gears
ing Lappet Rail
b) Balc) Ring rail with rings and traveler d) Balloon separators e) Spindle f) Bobbin
Lappet Rail It is a long rod made up of iron. Snail wires are fixed over it. Snail Wires The part of lappet, made of iron wire, through which yarn passes,sover spindle a BalloonIt is also called as Balloon Control Ring. It is made up of steediameter is 45mm. It is used to control theto remove the impurities in the yarn. It alsoouching from the surface of separator.
Ring Rail
the yarn on tThe distance covered by the ring rail to wind a specific portion of the bobbin is called as Chase Length. It is 44mm at RX240 ring spinning frame. LIFTING MOTION The up and down motion of the ring rail is known as lifting motion. For coarse count its motion is fast and for fine count its motion is slow. It has fast motion for coarser count because in very short span of time it covers the required area dL
One for lifting Ring Rail The other for lift
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At RX240 ring spinning frame, drive for lifting ring rail and lappet rail has
000 rpm ing
f steel. Its diameter is 45mm. The traveler revolves on it.
following specifications Power; 12kW Speed; 3
RIt is made oThe part of ring on which traveler revolves is called flange.
Ring is adjusted in adapter made up of aluminum. The bore of adapter adjusted by just adding 10.5 in the ring cup diameter.
le if the ring cup diameter is 40mm the bore of the adapter
nt part in giving twist to the yarn. Its speed is less than spindle peed.
isFor exampwill be 40+10.5=50.5 Traveler It is very important part of ring frame. It is changed according to count. For fine count, light weight traveler is used. It plays an importas
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of yarn from beating against each other, thin metal plates called separators are located half way between spindles above the ring rail.
s main objectives are to separate the yarn balloons of two cutive bobbins and to protect the yarn balloons of two
Benefits of Balloon Separator
Better quality of yarn is produced End breakage is reduced
Spindle Winding and Twisting is its main object of the spindle. In Masood Spinning Mills Ltd. Blade type spindle is used. It has basically three main parts;
The upper part
h the spindle tape runs. Bolster
ade up of cast iron or steel. It is fixed on the spindle rail by
indle oil is 4000hours.
Spindle Tape For driving the spindle, spindle tape is used. Dimensions Length; 2440mm, Width; 11mm, Thickness; .8mm Life When breakage rate of spindle tape exceeds certain limits then the spindle tape should be replaced (often 3-4 months).
Balloon Separators To prevent adjacent strands
Itconseconsecutive spindles from entanglement.
It is usually made up of aluminum alloy and is slightly tapered in shape. Spindle Wharve
It is the part on whic
It is mmeans of nuts. It contains spindle oil for the smooth running of the spindle. Oil prevents spindle from friction and heating. According to Toyoda Textile Bulletin the maximum time for the replacement of sp
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DRIVING MECHANISM At RX240 ring spinning frame 4 spindles are driven by a single tape.
ing main parts 1. Main Motor
: 1090 X 110 X 3mm)
4. Tin Pulley ad Weight
MAIN SHAFT DRIVING MOTOR SPECIFICATIONS Co
Driving mechanism has follow
2. Main Shaft Driving Belt (Dimensions3. Main Shaft
5. De6. Jockey Pulley 7. Spindle Tape
mpany MEIDENSHA Model 2001 Type Inverter driven Mo ion motor tor 3 phase inductPoles 4 Output 55-60 kW Volts 360 Frequency 60 Hz Ampere 110 Speed 1760 rpm Motor belt company HABASIT Spindle Gauge T between centers of two consecutive spindles is called as
Spindle Break
e break against
he distanceSpindle Gauge.
It is made up of plastic and is used to stop the spindle when required. In case of yarn breakage the worker presses the spindl
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the spindle, the spindle stops due to friction between spindle and the spindle break. Ring Bobbin It is made up of plastic. It has definite diameter and length. Length of bobbin is usually 7 inches to 8 inches for fine count.
sting zone. Yarn passes through snail wire, which guides it to the balloon breakers. After bal n the bobbin. Traveler, ring and the spindle basically do winding. Speed of traveler is less than spindle speed. Ring rail moves up and down so that proper tapered winding is done. Twist is given by maintaining speeds of spindle and traveler. Twist per inch (TPI) depends upon the amount of material delivered by the front
llers. By increasing the delivery speed, twist is decreased and the twist
f yarn is increased.
AGE OF MATERIAL ME
PROCESS OF TWISTING AND WINDING After drafting zone the yarn enters the twi
loon breaker it passes through traveler and is wound o
roproduction is increased and vices versa. By increasing strength o PASS IN RING FRA
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MASOOD SPINNING MILLS LTD. UNIT # 1
RX240 MAIN SCREEN READINGS DATE 11-07-06 TIME 12:40 Type Count Spindle Hank Delivered Remaining M/C # Yarn
(Ne) Speed Time(Min)1 Co- 24 16825 3.17 0.66 80
Knitting 2 Co-
Knitting 24 16150 3.17 0.32 92
3 Co- Knitting
24 17400 3.17 1.59 50
4 Co- Knitting
24 17400 3.17 2.75 14
5 Cd- Knitting
20 17200 2.46 1.27 37
6 Cd- Knitting
20 16900 2.46 0.80 51
7 Cd- Knitting
20 17200 2.46 1.20 39
8 Cd- Warp 20 18800 2.46 0.73 50 9 Cd- Warp 20 19000 2.46 1.14 38 10 Cd- Warp 20 18670 2.46 0.66 54 11 Cd- Warp 20 18745 2.46 2.44 0 12 Cd- Warp 20 Machine was Stopped for Over Hauling 13 Cd- Warp 30 20100 2.64 1.77 34 14 Cd- Warp 30 20100 2.64 2.09 22 15 Cd- Warp 30 20100 2.64 1.90 28 16 Co- Warp 60 18590 5.29 0.16 225 17 Co- Warp 60 22827 5.29 1.83 149 18 Co- Warp 60 22857 5.29 1.97 143 19 Co-
Compact 60 22800 5.82 2.24 141
20 Co- Compact
60 17780 5.82 0.14 229
21 CoCompact 60 17220 5.82 0.06 235
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MOISTURE AND HUMIDITY The relative hum 62%-63%. The moisture in
idity in Ring Frame Room should bematerial should be 6.50%.
FORMULAS
Draft = Count v .I = Co
ing Hank Ro
T.P T.M X √ unt
Spindle S pm peed in r
Ring Fram ion rmue Product Fo la
MAIN S CA ONPECIFI TI S
Maximum pe 50 spindle s ed 2 00 Spindle g 0 5 mage 7 mm, 7 m Bobbin le 80 m (185 ,
30 m (255 ngth (lift): 1 (155) m, 210 ) mm
2 (205) m, 250 ) mmSpindle d em sp by le tariving syst : 4 indles spind pe Dust removal system
Pneumatic suction cleaning s Lu ute, ssy
nozzle tem by wa: fl ingle
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CONE PROCESS
AUTO
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MACHINE MAKER
MURATA (JAPAN) TOTAL MACHINES
9 (60 Spindles/Machine)
ODELM M/C 1-8 7V-II M/C 9 7V
OTAL NO OF SPINDLES T
540
OFFING SYSTEM D
Manual
DUST REMOVAL SYSTEM
AutomaticManufactu
Pneumatic System For Removal Of Fly And Dust rer: Luwa (Japan), Model: 2001
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INTRODUCTION
Ring spinning produces yarn in a package form called cops or
ring frames are not suitable for further processing, because, amount of yarn on bobbins is very little(50-100gms) besides this the winding process serves to achieve additional
made necessary by the requirements of the subsequent processing stages.
BJECTIVES
bobbins. Since cops from
objectives
O
1) To prepare a bigger packa ving a sufficient length of yarn on it.
faults e.g. tick and thin places. 3) To improve the quality of4) In some cases, the yarn is also treated with certain chemicals or
cess. Waxes are also applied to the he winding
5) To produce a package of required density and shape suitable for
ge ha
2) To remove spinning yarn.
dyes during the winding proyarn to reduce the abrasion and friction during tprocess.
the next stage of processing. MAIN COMPONENTS
1) Bal-Con (Balloon Controller) 2) Yarn Guide 3) Pre-Clearer Guide 4) Yarn Tensioner 5) Splicer 6) LOEPFE(Electronic Clearer) 7) Cutting Device 8) Waxing Unit 9) Yarn Trap 10) Grooved Drum
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MURATA AUTOMATIC WINDER The m
6) Drum Belt uide
8) Splice Box
10) Suction Mouth
14)15)16) wisting Pipe
18)
20) Laying Lever 21)22) utter 23)24)25) ng Plate 26)27)28)29) utter 30)31) Gate Feeler 32) Retie Pipe 33) Pre-Cleaner 34) Pre-Cleaning Dial
ain parts of Murata Automatic Winder 7V II are: 1) Cradle 2) Carrier 3) Drum 4) Drum Brush 5) Drum Pillar
7) Traversing G
9) Retie Pipe
11) Suction Mouth Pad 12) Clamp Plate 13) Yarn Stopper
Right-in Lever Left-in Lever Unt
17) Splice Cutter Holding Lever
19) Splice Nozzle
LOEPFE Yarn Clearer Shutter C Wax Lever Wax Waxi Wax Pressing Lever Washer Tensor Tensor C Finger Plate
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36) Bobbin Peg
arn Guide l-Con
opper il
zine utton
MA S
35) Bobbin Chute
37) Bobbin Ejector 38) Y39) Ba40) Bobbin Pad 41) Yarn St42) Solino43) Maga44) Drum Start B
JOR ZONE Bas y Mu be divided into following zones;
1. EL Z
icall rata Auto-Coner can1) Creel Zone 2) Tension Zone 3) Clearing Zone 4) Yarn Joining Zone 5) Winding Zone
CRE ONE Creel is the ring bobbins are held. The creel in Murata Auto-Coner is so designed so that it should assist in continuous uniform unwinding of the yarn at high machine speed of up to 2000 me per m Bal ConIn Murata Auto-Coner Bal-Con is used as balloon controller which is made up of metal and does not allow bigger balloons to get formed du unwiBal-Con unwinds the spinning bobbin more efficiently while maintaining quality. It continuously moves along with the bobbin cre a b order to maintain an even winding from start to the end of the winding.
part on which
ters inute.
loon troller
ring nding.
ating allooning in
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Movement of Bal-Con with the unwinding of bobbin
the yarn from the package is called as the ithdrawal of the yarn or package.
in is eing
per
The unwinding of wIn Murata Auto-Coner over end withdrawal is done. The bobbfixed on bobbin peg and is kept stationary while unwinding is b
formed.
Over End Withdrawal
E 2. TENSION ZON
e compact and dense package can be obtained. However the amount of tension to be applied on the yarn
n the count.
is applied uniformly. This tension will cause the
. The tension on the yarn is applied by passing it through a tensioning device or Tensioner.
Tension zone performs the following two main objectives:
1) To apply a uniform tension on the yarn so that uniform package with required density can be obtained. Greater the tension on the yarn, mor
depends upo2) The tension on the yarn helps to remove thin or weak places in
the yarn. To remove thin places, a sufficient tension for a certain count of yarnthin or weak places in the yarn to break however the regular yarn will not be affected. In this way, these faults are removed. The amount of tension applied should be about 10 to 15% of the single yarn strength
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In Murata Auto Coner 7V disc type tensioner is used in which the yarn is passed through two disc plates and a sufficient pressure is applied to the plates. The amount of tension produced in this case would be directly proportional to the amount of pressure on the discs. However in Murata Auto Coner 7V-II gate type tensioner is used. 3. CLEARING ZONE The purpose of the clearing zone is to eliminate yarn defects such as thick places, thin places and slubs. In Masood Spinning Mills, LOEPFE TK930S el rinciples. hese clearers are very efficient, reliable and durable and even the
.
ce is generated by the emitter or the transmitter and is passed through the yarn and received on the other end by the receiver. The amount of light received after passing through the yarn is translated into an electric ple, for coars yarn less ght and for fine yarn more light will be received. The LOEPFE clearer
unt of yarn and if any slub or thin place comes n the yarn, it is detected by variation in the light and hence it is
ectronic clearers are used which work on optical pTslightest of variation can be detected and removed by them. In LOEPFE TK930S photoelectric cells are used Basic Principle A light sour
current. For exam eliis set for a particular cooremoved by the cutter.
Principle of LOEPFE YARN CLEARER
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Working of LOEPFE TK930S
NING ZONE 4. YARN JOI
n, ballooning effect, etc. As the yarn breaks, the stop motion installed on the machine causes the machine to stop immediately. Murata Automatic Winder 7V-II makes use of optical sensors for stop motion. The yarn is passed through a pair of sensor having a transmitter and a receiver. The transmitter transmits light which can only be received by the receiver when there is no yarn between them i.e. when the yarn breaks. As soon as the receiver starts receiving the light, the machine is stopped immediately.
During the winding process, breakage of threads may take place. The breakage of threads may occur due to;
1) The deliberate action of the electronic clearer for the removal of thick and thin places.
2) The result of extra force build-up on the yarn due to many reasons like frictio
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Piecing or Joining of Broken Threads In Murata Automatic Winder 7V-II splicing method is used for the joining of broken ends. The splicing is done in the Splice Box. The procedure of splicing is as follows:
1) Suction mouth takes the yarn from the upper side (cone) and retie pipe goes down opens its mouth about 5mm takes the yarn from the lower side. Both suction mouth and retie pipe make use of air suction to pull the yarn.
2) Each broken end is untwisted in Untwisting Pipes by applying twist in the opposite direction to the twist in the yarn.
3) Both broken ends of the yarn are placed on each other in splicing nozzle G
4) They are joined together by twisting and slight stretching in G2Z 2Z.
nozzle. 5. WINDING ZONE The yarn after being cleared from spinning faults has to be wound on pac zone. The package built is in the form of cone. The shape of the cone is tFollow considered at the
inding zone;
age.
kages of suitable shape, size and built. This is done at the winding
apered. ing are the important parameters to be
w1) Size and weight of the package. 2) The compactness of the pack3) Angle of taper
The package is wound by using the grooved drum type of drive.
Grooved Drum
The drum is mounted on the shaft or spindle that directly gets its drive from the motor by a drum belt. Each spindle is supplied with an independent motor for its drive that can produce a speed of up to
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Internship Report
2000 meters per minute. The package is mounted on a cradle which
sure ive. The
hanged. The cradle is lifted as oon as the yarn breaks or the ring bobbin is emptied so that the
pac CreeliRemov g bobbin) when it is emptied and rep as the p er 7V-II arr rocess. The C oes the following necessary tasks:
1) machine when the supply package exhausts. 2) Removes the empty bobbin tube and ejects it to conveyer belt.
ly package from the Magazine. 4) Performs the splicing of the thread.
ckage size is obtained and replacing it with a new empty
manually or automatically. However the efficiency of the Automatic Doffer is very less as compared to manual doffing. In fer is installed only on Murata Automatic Winder 7V. However on Murata Automatic Winder 7V-II
anual doffing is performed.
1) Stops the machine when the required size of the package is wound.
2) Removes the full winding package and transfers to a conveyer belt.
not only holds the package but also applies considerable presagainst the winding drum to avoid any slippage in the drpressure applied on the drum can be cs
kage drive may be disconnected.
ng and Doffing ing of the supply package (rin
lacing it with a new full supply package (ring bobbin) is called rocess of Creeling. In Murata Automatic Wind
angements are given that automatically does the Creeling preeling arrangement d
Stops the
3) Inserts a new supp
5) Restarts the winding process. Similarly removing the full wound package (cone or cheese) when the required paone is called as the process of doffing. It can be done
Masood Spinning Mills, Automatic Dof
mThe Automatic Doffer performs the following functions:
3) Places an empty tube into the cradle 4) Pieces up the yarn on the new package. 5) Restarts the winding process
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WINDING PACKAGE DEFECTS
Following are some of the package defects, which will result in complaints
1) Yarn waste in the cones 2) Stitch, drop over, web 3) Damaged edges
the cone
0)11)
MO
4) Broken ends of 5) Ring formation 6) Without transfer tail 7) Ribbon formation 8) Displaced yarn layers 9) Misguided yarn 1 Soft and hard yarn layer
Soft and Hard cones
ISTURE AND HUMIDITY Th e section should be 65%-67%. The
oisture in material should be 6.5%. e relative humidity at the Autocon
m
FORMULA
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MAIN SPECIFICATIONS
High speed Super high speed Model 7V 7V-II
Winding speed (max.) 1500 m/min 2000 m/min Balloon control Bal-Con Bal-Con Tensor Disk Gate tensor Tension control Tension manager Cra dle Gamma Gamma Drum drive Individual Inverter Mo oring device MMC MMC nitSplice check Splice monitor Yarn clearer Yarn speed responding control Yarn trap W Shape type-Only for splice monitor Splicer Cassette type Residual yarn feeler Gate feeler Drum Steel drum Winding shape 3o30`, 4o20`, 5o57`, 9o15`, 0o
Winding traverse 83mm, 108mm, 125mm, 152mm Others Package cover, package break, BQC (bobbin
quality control), EBC (Empty Bobbin control), cradle lifter, cradle initial pressure device, pre-clearer, yellow button clearer
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RELATIVE HUMIDITY
The ratio of the actual pressure of the water vapor in the
atmosphere to the satu ure of wat me
ercenta
ed as:
ration press er vapor at the satemperature is called as Relative Humidity. This ratio is usually expressed as a p ge. It can be calculat
* The temperature should be in Fo
MASOOD SPINNING MILLS LTD. UNIT # 1
IDITIES OF DIFFERENT DEPARTMMENTS 05-08 PM
Department
RELATIVE HUMDATE -06 TIME 03:00
Relative Humidity %
Blow Room 58.4 Carding 61.1 Drawing 61.49 Combing 61.40 Roving 64.22 Ring Spinning 67.45 Auto Cone 69.25
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QUALITY POLICY
ENT HIGHLY DEVELOPED AND MODERNIZED MACHINERY
F THE QUALITY OF PRODUCTS SATISFACTION OF BUYERS FULFILLMENT OF COMMITMENT COMPETITIVE PRICES SPEEDY REDRESSAL OF GRIEVANCES OF THE CUSTOMERS, IF ANY.
EMPLOYEES
CORP
COMITTMENT RELIABILTY QUALITY CONTROL CONTINOUS IMPROVEM
RIGID CONTROL O
DEVOTION OF WORKERS AND
ORATE EXCELLENCE CERTIFICATE
xport du nd other igh-ups through Federation of Pakistan Chambers of Commerce &
Industry, an f Trade & In Management Association of Pakistan (MAP) has awarded
corporate Excellence Certificate 1998, to the Company in textile and allied sector. The Certificate was awarded to the companies who performed he financial di e and also in management practices such as Corporate Go ce, Social Responsibility, Research & Development etc. Certificates under ISO 9002 have been achieved fr ed Registrar of System Ltd. UK.
Mah hies for mood Group has been awarded seven merit tropring past years by the Prime Minister of Pakistan ae
h Apex body o dustry in Pakistan.
well in t sciplinvernan
om Unit
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REFRENCES
Bulletin group.com
hler.de/ ewdetail.asp?uid=masoodspinning
Toyoda Textileod www.mahmo
http://www.truetzsc http://www.aptma.org.pk/vi www.rieter.com www.muratec.net www.textileworld.com www.loepfe.com
y.com www.toyota-machiner www.ptj.com.pk
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