YMIISpeed Frame
YMIISpeed Frame
In conventional ring spinning system, conversion of sliver into yarn through a single step has not succeeded
since the total draft needed is in the range 300-500 which is very difficult to apply on sliver in a single
step and obtain good quality yarn .
Draw frame cans represent the worst conceivable mode of transportation and method of feeding material to
the ring spinning frame as it occupies large space in comparision to the space of one spinning position of
ring spinning frame
Sliver is a thick, untwisted strand that will lead to more hairs and fly while converting it directly to yarn
when high draft is applied.
With ring spinning technology, the use of the roving frame is still remaining.
While using other newer spinning methods, the roving frame has been made as superfluous.
Disadvantages :
Advantages :
Condensers used in the drafting system help to bring the fibre strand together again, since during drafting
fibres may tend to spread apart. Twist is inserted by means of flyer setup and the roving is wound onto
bobbin through pressure arm. The spindle is simply a support and drive element for the flyer
without any ancillary function. Bobbin rack moves up and down so that roving coils are placed
adjacent to each other on the surface of the bobbin.
Figure 3 Pattern of coil winding on roving bobbin
Figure.3 represents the pattern of winding coils on the roving bobbin. Roving ends are placed layer by
layer on the bobbin surface in such a manner that it will create tapered ends at top and bottom of the
bobbin. Pressure arm which is attached to lower end of hollow flyer leg assists in placing the coils.
The arm guides the roving from the exit of the flyer leg onto the package surface. The roving is
wrapped two (or) three times around the yoke and the number of turns determines the roving tension.
CREEL:
Drawn slivers used in creel section, especially combed slivers have high degree of fibre parallelization
and low strand coherence. If these slivers are not handled properly in the creel section of the roving frame,
it will produce more mass variations in the roving because of uneven and uncontrolled stretching of the
slivers which is also called as ‘false draft’. In order to avoid this, following steps should be taken.
Sliver feed cans should be arranged in a simple manner so that the operator can access every can
easily, in case of sliver breakage, replacing empty cans and any other work in the feed creel section.
Slivers should be drawn vertically out of the cans. The relative placement of the cans and the guide
rollers should be such that the slivers are withdrawn vertically from the cans. If not, slivers will rub
against the edges of the cans leading to sliver damage and increased mass variation.
Guide rollers should run smoothly.
DRAFTING ARRANGEMENT
3/3 system with double apron is quite commonly used in roving frame.
Figure.1 shows the placement of the top and bottom aprons in the drafting arrangement of roving
frame. Pressure is applied by top aprons on the lower aprons and the distance between them
decides the intensity of fibre clamping and fibre guidance. The apron arrangement must permit
precise adaptation of the minimum distance to the fibre volume. It is done by placing “spacers”
between the nose bar of the lower apron and the cradle edge of the top apron, i.e at the exit
opening M(Figure.2) .
Double apron enables draft up to 20 with proper fibre control during drafting.
Bottom rollers are fluted metallic rollers and the top rollers are rubber covered with hardness 80 0 to 850 shor
(Top rollers over which aprons move have hardness slightly above 600 shore.)
Brake draft of 1.1 for cotton and slightly higher for synthetics (up to 1.3)
Aprons:
Flyers :
s
Figure 3 : Components and structure of the flyer
The flyers are made of light alloys instead of steel.
Figure 3 represents the structure and components of the flyer used in roving frame. Flyer is doing a
major part that it has to lead the very sensitive strand from the flyer top to the package without
introducing the false drafts. Because,
Fiber strand has only protective twist and is very liable to break.
It is passing through flyer which is rotating more than 1500 rpm, so it should be protected
against air current.
To overcome this problem, one of the flyer legs (4) is usually hollow as shown in figure 3, with a deep
guide groove roving is passed. If guide groove is very smooth then occurrence of false draft is reduced.
However piecing of broken strands is very difficult
Figure 4 shows schematic diagram of top mounted and closed flyer. In most of the industries, top
mounted flyer is used since it allows automation of the doffing operation. The flyer is supported at top
and driven by gear wheel running by toothed belts.
Closed flyers are mainly used for high speed operation. It also has advantages of reduced spreading of
the legs at high operating speeds.
Figure below represents the roving path geometry for flyers located in the front and back rows as in the
case of conventional roving machines. Bobbins placed in these front and back row spindles will the
following differences in the spinning conditions following variations.
The angle of approach of the roving to the flyer top is different for the two rows. This
will create different rolling conditions at the entry point of the roving to the flyer top.
Both rows of spindles will have different spinning triangles (Figure 6).
Difference in the unsupported lengths (L), i.e the lengths between the drafting
arrangement and the flyer top.
Difference also occurs in twisting of roving which leads to variation in fineness between
the front and rear ends.
The top mounted flyers also enable to have constant angle of wrap and similar spinning triangles for the
roving with the front delivery roller for both front and back rows of spindles. This is obtained by having
longer extension sections on top of the back row of spindles.
Flyer top
The passage of roving at the entry point of the flyer (Figure 8) determines the degree of
twist and the winding tension.
If the roving has only low twist or is coarse, so that there is a risk of false drafts the strand passes through th
the guide groove without wrapping (A) [Figure (8)].
Earlier model flyers had smooth flyer tops made out of metal. But most modern flyers have
rubber insert formed with grooves, notches or indentations. These flyer inserts exert a strong
influence on the level of twist in the roving in the unsupported zone by introducing false twist.
This also has strong influence on winding conditions.
False twist
The additional false twist reduces the roving break in the Spinning.
Spinning triangle is reduced so that quality of roving is improved.
Fly and lap formation also reduced.
False twist enables compact rovings which increases the bobbin capacity and leads to
higher flyer speeds.
Spindle
It is simply a support and drive element for the flyer.
Mounted at its lower end in a bearing and the bobbin tube acts as neck bearing.
Flyer:
Leads the sensitive strand from the flyer top to the bobbin without introducing false draft
Guide groove
Guide tube
Guide groove – ‘service friendly’
Guide tube – ‘better protection of roving’s.
THE PRESSURE ARM
The pressure arm made up of steel yoke is attached to the lower end of the hollow flyer
leg.
It guides the roving from exit of the flyer leg to the package.
The roving is wrapped two (A) or three (B) times around the yoke.
No. of turns determines the roving tension and package hardness.
If this is high, then a hard, compact package is obtained. If it is too high, false drafts or
roving breaks may happen.
Number of turns depends upon the fibre type and twist level.
....................................Roving break
Figure above shows the relationship between the TPI and count. As the count increases, in order to hold
the fibres, twist multiflier also increases, so that corresponding twist per inches also increases.
Builder Mechanism-
Builder Motion :
Builder motion is used to wind the roving in a parallel wound package with conical ends as shown in
Figure 1. The package is formed layer by layer. The lift of each layer is shortened by a small length which
decides the taper angle ‘α’.
The rovings are wound in coils around the bare bobbin to start with. The winding of coils starts from the
bottom position determind by the position of the bobbin rail. As the bobbin rail moves up the coils are
wound upwards forming the first layer of rovings on the bare bobbin. After reaching the top position of
the lift for the first layer, the bobbin rail reverses the direction of movement and starts to move
downwards. Now the coils are placed downwards and second layer of roving are wound on the first
layer of rovings. This time the bobbin rail does not go all the way to the starting point of the first layer.
Instead, it returns and start to move upwards from a level just above the starting level of the first layer,
the difference in these levels is called as ‘shift’ (S). The third layer of roving is wound over the second
layer of rovings upwards. Again the bobbin rail does move all the way up to the starting level of the
second layer but returns from a level just lower by ‘S’ and starts forming the fourth layer. The distance
‘S’ decide the taper angle. Higher is S, smaller will be α.
The roving can be wound onto the bobbin using either Flyer lead method or Bobbin lead method.
Flyer Lead
Bobbins Lead
Figure 2 : Spindle speed and Bobbin speed for different Winding methods
In both the cases, the spindle speed remains constant through out the winding process, since changing the spindle
speed will change the twist density in the roving. The bobbin speed is changed according to the requirement.
Figure 2 shows the manner in which the bobbin speed has to be changed in case of bobbin lead and flyer lead
methods.
In both the cases, the roving delivery speed is constant decided by the surface speed of the front pair of drafting
rollers. But, as the bobbin builds up the diameter and the circumference of the bobbin increases. If the bobbin rotates
at a fixed speed, then the roving will get stretched more and more in case of bobbin lead method since the bobbin is
leading and winding the roving on to itself as the winding proceeds; the roving will get slackened more and more
in case of flyer lead method as in this case the flyer is leading and winding the roving onto the bobbin. The difference
between the peripherals speeds of the flyer and the bobbins needs to be kept constant for proper winding.
Hence, in case of bobbin lead method the bobbin speed has to be gradually decreased and in the case of flyer lead
the bobbin speed has to be gradually increased in order to keep the roving tension constant while winding the rovings
on the bobbin.
For cotton system, because of the advantages of bobbin lead method and the difficulties associated with flyer lead
method, the bobbin lead method is always used.
REQUIREMENTS FOR BOBBIN BUILDING :
Based on the above discussions, in order to have proper winding of the rovings on the bobbins, the following
requirements should be met:
The rotational rate of the bobbin should be reduced for layer formation
Shorten the lift after each layer to form tapered ends on the bobbin
Reverse the direction of movement of the bobbin rail after each layer formation
The speed of the movement of the bobbin rail should be reduced after formation of every layer, as it will take
more time to lay one coil as the bobbin builds up.
Drive system in Roviing Frame :
The reduction in the rotational rate of the bobbin and the reduction in the speed of movement of
bobbin rail are obtained with a cone drive mechanism. In this mechanism, shown in Figure 4 there are
two cone drums out of which the top cone drum receive a constant rate of rotation from the motor.
Depending up on the position of the drive belt between them, the speed of the bottom cone drum
changes. Hence, at any given position of the belt the sum of diameter of the top cone drum (d1) and
diameter of the bottom cone drum (d2) should be a constant.
Cone Profile
-Variation in bobbins rotation rate occurs in small steps owing to shifting of the cone belt after each lift
stroke.
-The bobbins winding speed reduces in a hyperbolic fashion as the bobbins building up. If the shifting
of belt is constant for each lift stoke then the cone profile should be
(i) Convex for top (driving cone)
(ii) Concave for bottom (driven cone)
Figure 5 represents speed of flyer and wind-on speed with differential gear box. Over the cone pulleys
belts are shifted, due to which differential speed is obtained from differential gear box as U output = U 1≠
U2 rpm.
Figure 6 : Principle of winding on roving bobbin
Winding Speed profile
Let us take the following parameters and calculate the winding speed for different bobbin diameters
and plot it.
Bare bobbin dia=50mm Spindle speed=1000 rpm
Roving =1.2 mm TPI =1.68
Delivery = 15 m.min
Figure 7 represents relationship between winding speed and bobbin diameter. As the diameter of the
package increases, winding speed is decreases to maintain the same same winding rate.
BOBBIN DRIVE
The continuously reducing rotational rate from the bottom cone drum is combined with the constant
speed of main shaft using a differential mechanism. The output of the differential gear mechanism is
provided to the bobbins which are housed in the bobbin rail which is moving up and down. Since the
bobbin rail is moving up and down, there is a need for a flexible drive. One example of such drive
known as knee swinging joint is shown in Figure 1.
Figure 1 : Swinging knee joint at the bobbin drive shaft
The swinging knee joint method causes additional revolutions that are either added or subtracted from
the basic package rotation, depending on the direction of the lift stroke. This leads to tension variation.
On the bobbin rail, bevel / helical gears fixed on the longitudinal shaft drive the bevel / helical gears of
the bobbin support.
The other method is to use chain and sprocket with suitable mechanism to adjust the varying tension in
the chain because of the movement of the bobbin rail.
Cone drum types and belt shifting:
The cone drums can be of two types. In first type which is conventional one, a pair of convex and concave
cone drums are used and in second type a pair of cone drums having straight surface is used. In the first
type, the belt is moved a constant length every time to get the required speed profile for the bobbin. In
the second case, the belt is shifted through different lengths through out the bobbin build up.
Figure 2 : Shifting the belt with hyperbolic and straight sided cones
Hyperbolic cones are difficult to design (Figure 2).
During the winding operation the belt is moved on surface of varying inclination.
To-day the cones are made straight sided. The belt is shifted through varying magnitude.
The mechanism is fixed to the bobbin rail and raised and lowered as a unit.
Striking of a stationary pin by rods (5/6) makes the micro switch to emit a pulse, which permits
the ratchet wheel to rotate by ½ tooth (Figure 3).
Correction Rail:
Useful when the required bobbin speeds are not attained by changing the change wheel only.
Normal position of this rail is parallel to belt guide.
If this rail inclination is more steep, the extension of the wire rope is not completely transferred to
the belt guide. Shifting of the belt taken place through smaller steps than those corresponding
directly to paging out of the rope in the builder motion.
Reverse effect if the rail inclination is made less steep
Figure 4 : Reversing mechanism for bobbin rail movement
From Figure 4, reversal of the rail movement originates from the reversing gear (1/2/3).
An electrically operated valve pressurizes the left and right chambers of the double acting cylinders
alternatively.
So that, the left hand clutch (1) and right hand clutch (2) are operated successively so that the
pinion (3) is meshed either with gear wheel 1 (or) gear wheel 2.
The shaft 10, on which gear wheels 1 & 2 are mounted, always rotates in the same direction.
Accordingly, operation of clutch (1) or (2) causes left or right hand rotation of the pinion 3 and
shaft 4. The bobbin rail is correspondingly raised or lowered via the bevel gear 5, pinion 6,
sprocket 7 and lifting chain 8.
Cone drum change wheel: If the diameter of the tube is altered. The starting speed of the bobbin
must be adapted correspondingly. Since the ratchet wheel has not been operated at this stage, the
adaptation cannot be performed by way of the builder motion.
Ratchet change wheel determines the amount by which the belt is shifted upon each operation of
the ratchet and therefore must be adapted precisely to increase in the bobbin diameter.
LIFTER MOTION
Bobbin are raised and lowered to place the coils placed next to each other.
Lifter motion work with levers or with racks.
To compensate for the increase in bobbin diameter the lift speed is reduced after each lift stroke.
Drive to the bobbin rail is provided from driven cone drum, but not through the differential gear
mechanism.
Lifter motion is used to wind the roving on the package layer by layer i.e placing new coils near to
neighboring layers by moving bobbin package up and down, so that winding point is continuously
varied.
The required raising and lowering can be carried out by means of several racks secured to the rail
(Figure 6).
However several manufactures mount the bobbin rail on a lever and move the rail by an up and
down movement of that lever (Figure 5).
As diameter increases, lift speed must be reduced by a small amount after each completed layer.
Developments in roving frames-
The speed frame is the machine that has gone least change. This can be realised from the fact
that a spindle speed of 1,500 rpm as on date as compared to 600 rpm in 1950s. Still there are
certain changes that have been carried out for better production and quality like, increase in the
roving bobbin diameter from 4" to 7" and lift from 8" to 16", use of straight cone drum instead of
hyperbolic cone drum for better control over the roving tension etc. Now all closed (AC Type)
flyers are used to overcome the problem of air drag on roving.
These flyers are aerodynamically balanced and are of light weight. The roving frames are
equipped with auto doffing system that, apart from avoiding manual handling, reduces doffing
time. Roving bobbins auto doffing and transportation, to the ring spinning through over head
rails, becomes a standard feature of the roving frame. Apart from above, some of the
developments those are really significant will be discussed in subsequent sections.
Equal roving geometry for front and back row roving
Deposition of roving spindles in two rows leads to variation in roving twist and count in front
and back row due to different level of twist attained by roving in front and back row. This is
due to change in roving path geometry . Modern speed frames have raised flyer top of the
back row as compared to the front row to maintain the roving delivery angle. Rieter F15/F35
roving frame, Zinser 668 roving frame, Marzoli FTN roving frame and Lakshmi LFS 1660
speed frame incorporate this development in their machines.
Drive System
Main drive changed from loose/fast pulley system to centrifugal clutches.
To reduce noise and vibrations spur gears are replaced with helical gears with thrust
bearings.(smooth & gradual engagement of teeth)
For same speed reduction ratio helical gears are smaller in size – less pitch line velocity of
gears.
Self-aligning ball bearings for top drafting rollers and use of needle bearings for bottom
drafting rollers.
Replacement of bush bearings by ball bearing for creel rollers and gear shafts.
Latest trend is to use timing belts:
Greater flexibility in location of elements.
Power transmission efficiency as good as gears.
Less power consumption and noise compared to gears.
Simple drive system.
Less maintenance.
Individual motor drive
In multi-motor drive system, drafting rollers, flyers, bobbins and bobbin rail are driven
directly by individual servomotors and are synchronised throughout package build by the
control system. The advantages of this system are like, no need of heavy counter weight for
bobbin rail balancing and differential gear, reduced maintenance, lower energy consumption,
etc. All machine manufacturers incorporate four-motor-drive system except Toyota that uses
three servomotors on FL100 roving frame. One motor for drafting system and flyer while one
motor each for bobbin drive and bobbin rail.
Figure 1 : Schematic of the multi-motor drive system.
3. Improper Supervisor should train his workers in a proper way. If end breakage is
piecing in disturbed then its treatment should be proper. If piecing will not be proper
roving then it will affect the next process.
4. Roving This problem is caused due to maintenance problem. Maintenance required
breakage machine stoppage but it is against the production. To enhance the quality of
product, the machine maintenance is the chief requirement. For the proper
solution of roving breakage, speed of machine, trained operator and proper
management should be must otherwise it create severe problems in ring
section.