Masood Spinning Mills operates a spinning mill in Kabirwala, Pakistan with over 22,000 spindles. The document discusses the internship report of two students who interned at the mill. It provides details of the blow room, carding, and other processes at the mill. Key machinery includes blow room lines from Trutzschler, carding machines from Trutzschler, and ring spinning frames from Toyoda. The internship report aims to provide practical knowledge of the processes used to transform cotton into yarn.

1. 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

2. 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

3. 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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4. Internship Report
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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5. Internship Report
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
mtm@mahmoodgroup.com
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6. Internship Report
FACTORY LAYOUT
MASOOD SPINNING MILLS LTD. UNIT # 1
GATE
G.M
OFFICE
ROAD
MAIN GATE
MULTAN ROAD, KABIRWALA
RAW MATERIAL STORERAW 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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7. Internship Report
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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8. Internship Report
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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9. Internship Report
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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11. Internship Report
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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12. Internship Report
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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13. Internship Report
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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14. Internship Report
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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15. Internship Report
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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18. Internship Report
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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19. Internship Report
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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20. Internship Report
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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21. Internship Report
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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22. Internship Report
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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23. Internship Report
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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24. Internship Report
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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25. Internship Report
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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26. Internship Report
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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27. Internship Report
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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28. Internship Report
COMBING PROCESS
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29. Internship Report
Combing Preparatory Machine
MACHINE MAKER
RIETER (SWITZERLAND)
MODEL
E32
YEAR OF MANUFACTURING
2001
TOTAL MACHINES
1
DOFFING SYSTEM
Automatic
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30. Internship Report
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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31. Internship Report
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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32. Internship Report
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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33. Internship Report
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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34. Internship Report
Combing Machine
MACHINE MAKER
RIETER (SWITZERLAND)
MODEL
E62
YEAR OF MANUFACTURING
2001
TOTAL MACHINES
7
FEEDING SYSTEM
Lap Feed
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35. Internship Report
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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36. Internship Report
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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37. Internship Report
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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38. Internship Report
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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39. Internship Report
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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40. Internship Report
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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41. Internship Report
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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42. Internship Report
DRAWING PROCESS
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43. Internship Report
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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44. Internship Report
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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45. Internship Report
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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46. Internship Report
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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47. Internship Report
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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48. Internship Report
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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49. Internship Report
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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50. Internship Report
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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51. Internship Report
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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52. Internship Report
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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53. Internship Report
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 30
Material cotton, man-made fibres and
blends
staple length 10 to 80 mm
Doubling 6 to 8 fold
Feed weight 12 to 50 ktex
Draft 4.5 to 11.6 fold
Sliver weight 1.25 to 7 ktex
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54. Internship Report
ROVING PROCESS
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55. Internship Report
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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56. Internship Report
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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57. Internship Report
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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58. Internship Report
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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59. Internship Report
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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60. Internship Report
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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61. Internship Report
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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62. Internship Report
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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63. Internship Report
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 mec
flyer gearing ensures trouble-free operation.
An automatic roving-end positioning de
further reduces manual restart procedures.
Large LCD touch-screen function panel sim
input and monitoring
N
ng systemThe four-roller drafti
places a collector between the
front and second rollers,
separating drafting and
collecting zones for superior
roving softness and
smoothness.
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64. Internship Report
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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65. Internship Report
MAIN SPECIFICATIONS
Staple le 44-76 mm*ngth 22-40 mm 40-51 mm 51-76 mm
(Unit mm)
Drafting roller 3-rollersystem 4-roller (D type) 4-roller (D type) 3-
Maker SKF SKF SKF SKF
Weightin
arm 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 OH534-110pe 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 eroll 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 controll
prevention, roving stop at set l
package shoulder collapse pr
electronic stop motion on front
er, roving irregularity
ength/position,
evention, optical
& back sides
Operation
and
maintenance
LCD touch-screen function p
misplacement prevention devi
lubrication for main and dr
oil supply system for flyer an
suction 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 brea
adjustment 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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66. Internship Report
RING SPINNING PROCESS
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67. Internship Report
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: 2001M
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68. Internship Report
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 i
f 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 from
through a U-shaped guide called a traveler
track orth
bobbin. The process is called
traveler moves around the rin
g 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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69. Internship Report
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 hange
that machine can work at a constant speed.
Bobbin Hanger
To facilitate proper unwindi
b
upper portion of t
fi
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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70. Internship Report
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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71. Internship Report
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 adjus
so as to produce fine grip on apron. Drafting rollers consists of top
and bottom rollers.
1. Top Rollers
T
Di
BARKOL
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 di
Width
P
Hardness of To
Life of rubber cots: 1 year
*Shore is the degree of hardness and it i
Top Roller Gaug
Distance 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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72. Internship Report
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 r
Middle and Front
c) For Pima and Egy
Back and Midd llers— 58m
Mid e Fr ollers— 4
d) For Pima and Egyptian (Non-
Back and Middle rollers— 58
Middle a Fr ollers—
Aprons
A
and thickness. They maintain the fibers in main drafting
S
ollers.
There are two aprons
1. Top apron
2. Bottom apron
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73. Internship Report
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.
C
Top middle drafting roller in which
dle.
Pressure Arm
It 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 bo
rollers regarding the count. It is made of plastic. It is differen
different counts. For fine roving, spacer of small size is used and
coarser roving, big size spacer is used.
Flocks
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74. Internship Report
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 m
c
the materia
It 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 dra
draft.
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 b
th
three se
speed 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 ro
d
3. TWISTING AND WINDING ZONE
Parts of this zone are
a) Lappet rail with snail wires
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75. Internship Report
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) Bal
c) 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,
s
over spindle a
Balloon
It is also called as Balloon Control Ring. It is made up of stee
diameter is 45mm. It is used to control the
to remove the impurities in the yarn. It also
ouching from the surface of separator.
Ring Rail
the yarn on t
The 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 d
L
One for lifting Ring Rail
The other for lift
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76. Internship Report
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
R
It is made o
The 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.
is
For examp
will 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
importa
s
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77. Internship Report
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
It
conse
consecutive 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 m
means 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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78. Internship Report
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 (Dimensions
3. Main Shaft
5. De
6. Jockey Pulley
7. Spindle Tape
mpany MEIDENSHA
Model 2001
Type Inverter driven
Mo ion motortor 3 phase induct
Poles 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 distance
Spindle 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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79. Internship Report
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
ro
production is increased and vices versa. By increasing
strength o
PASS IN RING FRA
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80. Internship Report
MASOOD SPINNING MILLS LTD. UNIT # 1
RX240 MAIN SCREEN READINGS
DATE 11-07-06 TIME 12:40
Type Count Spindle Hank Delivered RemainingM/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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81. Internship Report
MOISTURE AND HUMIDITY
The relative hum 62%-63%. The
moisture in
idity in Ring Frame Room should be
material should be 6.50%.
FORMULAS
Draft = Count
v
.I = Co
ingHank Ro
T.P T.M X √ unt
Spindle S pmpeed in r
Ring Fram ion rmue Product Fo la
MAIN S CA ONPECIFI TI S
Maximum pe 50spindle 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 ) mm
Spindle 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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82. Internship Report
CONE PROCESSAUTO
- 80 -

83. Internship Report
MACHINE MAKER
MURATA (JAPAN)
TOTAL MACHINES
9 (60 Spindles/Machine)
ODELM
M/C 1-8 7V-II
M/C 9 7V
OTAL NO OF SPINDLEST
540
OFFING SYSTEMD
Manual
DUST REMOVAL SYSTEM
Automatic
Manufactu
Pneumatic System For Removal Of Fly And Dust
rer: Luwa (Japan), Model: 2001
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84. Internship Report
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 of
4) 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 pro
yarn to reduce the abrasion and friction during t
process.
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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85. Internship Report
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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86. Internship Report
36) Bobbin Peg
arn Guide
l-Con
opper
il
zine
utton
MA S
35) Bobbin Chute
37) Bobbin Ejector
38) Y
39) Ba
40) Bobbin Pad
41) Yarn St
42) Solino
43) Maga
44) Drum Start B
JOR ZONE
Bas y Mu be divided into following zones;
1. EL Z
icall rata Auto-Coner can
1) 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 Con
In 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 unwi
Bal-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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87. Internship Report
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
w
In Murata Auto-Coner over end withdrawal is done. The bobb
fixed on bobbin peg and is kept stationary while unwinding is b
formed.
Over End Withdrawal
E2. 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 upo
2) 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 yarn
thin 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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88. Internship Report
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 p
T
slightest of variation can be detected and removed by them. In LOEPFE
TK930S photoelectric cells are used
Basic Principle
A light sour
current. For exam e
li
is set for a particular co
o
removed by the cutter.
Principle of LOEPFE YARN CLEARER
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89. Internship Report
Working of LOEPFE TK930S
NING ZONE4. 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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90. Internship Report
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 t
Follow 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
w
1) Size and weight of the package.
2) The compactness of the pack
3) 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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91. 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
Creeli
Remov 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 pres
against the winding drum to avoid any slippage in the dr
pressure applied on the drum can be c
s
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 p
reeling 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 pa
one is called as the process of doffing.
It can be done
Masood Spinning Mills, Automatic Dof
m
The 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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92. Internship Report
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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93. Internship Report
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
Cradle Gamma Gamma
Drum drive Individual Inverter
Mo oring device MMC MMCnit
Splice 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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94. Internship Report
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 sa
temperature 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 HUM
DATE -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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95. Internship Report
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 formood Group has been awarded seven merit trop
ring past years by the Prime Minister of Pakistan ae
h
Apex body o dustry in Pakistan.
well in t sciplin
vernan
om Unit
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96. Internship Report
REFRENCES
Bulletin
group.com
hler.de/
ewdetail.asp?uid=masoodspinning
Toyoda Textile
odwww.mahmo
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www.rieter.com
www.muratec.net
www.textileworld.com
www.loepfe.com
y.comwww.toyota-machiner
www.ptj.com.pk
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