Itru-Company Products- Card Fibre Transfer Test Pc-Program

Process and Quality Improvement in Spinning Mills -Card Fibre Transfer Test Pc-Program

Card Fibre Transfer Test Pc-Program by Itru Group Ltd.

Introduction

This Pc-program has been developed through research projects carried out in spinning mills. As a result of these mill works it has been found more important and useful than our expectations in terms of reducing carding waste, causes of carding waste, improving yarn quality especially evenness and finding out faulty running parts in carding.

Carding Machine in cotton and man made fibre spinning plays the most significant role in determining yarn quality in terms of evenness and strength.

Carding procedure is a repeating cycle of subsequent events these are
a) Lap feed by feed roll to taker-in then to cylinder
b)Carding by cylinder and flats and fixed flats
c)Web formation on doffer
d)Detaching of web by detaching roller
e)Feeding of sliver by card delivery roller

Although all the rotating parts run continuously sliver formation is realized by repetitive cycles and could be called as a Carding Cycle. Therefore variation in card sliver evenness could be analyzed as
a) Variation within cycle
b) Variation between cycles

Therefore to check the evenness of Carding Sliver should be done after determining the length of card sliver per Carding Cycle which is defined as Carding Cycle Sliver Length .

Main function of carding machine is to form a sliver to spin a yarn . In addition to these carding machine should achieve following points

  • Effectively removing of short fibres and non-lint materials
  • Parallelizing of fibres and straightening of hooks in fibres
  • Opening of fibre tufts into fibres to form regular web
  • Correcting and evening out in the chute feed lap weight variation along and across to get optimum sliver evenness.

It has been proven by many experimental results that Spectrograph CV values are related to short term regularity in card sliver does not affect yarn quality as much as variation values between and within Carding Cycle Sliver Length

1.2 Machine Card Input Data

Machine Card Input data consists of following items to be inserted to the data base.

Machine Card Input data consists of following items to be inserted to the data base.


    Machine Card Input Data Parameters

  • Mach No :Machine Number
  • Lot No : Lot Number
  • Mach Type :Machine Type
  • Test Date : Test date
  • Lap weight: Gram/meter
  • Delivery Sliver :Gram per meter of sliver after calender roller i.e. before coiler
  • Delivery speed :Speed of calender roller m/min
  • Cylinder rpm : rpm
  • Doffer rpm : Rpm
  • Taker-in Rpm:Rpm
  • Detaching Roller rpm (Roller after Doffer):Rpm
  • Diameters in mm of card feed roll ,taker-in(licker-in),cylinder,doffer, detaching roll and calender roll .
  • Card Setting Data Base :For each machine connected Machine Input Data

2.0 Test Results

Test Results
-------------------------------------------------------
Machine no :: 2:
LotNo :: b:
Machine type ::DK740:
Date ::10/21/99:
No of total tests : 51:
----------:----------:----------:----------:----------:-
Speeds and carding
----------:----------:----------:----------:----------:-
Feed cm/min : 157,080:
Taker-in rpm : 800,000:
Cylinder rpm : 412,000:
Doffer rpm : 55,000:
Doffer m/min : 120,951:
Detaching roller m/min : 120,519:
Delivery m/min : 125,000:
Taker-in blow /cm -feed : 5,093:
Carding/cm feed : 2,623:
----------:----------:----------:----------:----------:-
Transfer functions parameters
----------:----------:----------:----------:----------:-
Doffer/Calender Draft : 1,033:
Weight of free fibres in g : 5,220:
Carding sliver weight in g : 101,500:
Carding time in sec : 1,296:
Sliver length/cylinder 1 turn : 30,340:
No of plies : 8,899:
Carding -Cylinder/Feed cm : 2,623:
Carding- Taker-in/Feed cm : 5,093:
Sliver Length cm : 270,000:
Residual Ratio % : 77,202:
Transfer ratio % : 22,798:
----------:----------:----------:----------:----------:-
Nominal Count G/m Sliver : 5,800:
Min G/m : 5,400:
Max G/m : 5,900:
Mean deviation % : 8,621:
Standard deviation : 0,172:
A% : -2,966:
CV% : 3,057:
Average G/m : 5,628:
Doffer lamda cm : 227,273:
Carding Power : 0,642:
Total k : 27:
----------:----------:----------:----------:----------:-
Drafts
----------:----------:----------:----------:----------:-
Feed-Taker-in : 400,000:
Taker-in-Cylinder : 2,657:
Cylinder-Doffer : 0,072:
Doffer-Detaching : 0,996:
Detaching-Calender : 1,037:
Total Draft : 79,577:
----------:----------:----------:----------:----------:----------:----------:-
Wave lengths
Feed -:-Taker-in-:Cylinder--:Doffer----:Detaching-:Calender -:-
2500,00: 15,63: 30,34: 227,27: 55,56: 22,62
1250,00: 7,81: 15,17: 113,64: 27,78: 11,31
833,33: 5,21: 10,11: 75,76: 18,52: 7,54
----------:----------:----------:----------:----------:----------:----------:-
Test L :Time s : g/m : aqsl :pqsl :
----------:----------:----------:----------:----------:-
10: 0,05: 0,900: 15,52: 10,52:
20: 0,10: 1,000: 17,24: 19,93:
30: 0,14: 1,300: 22,41: 28,35:
40: 0,19: 1,800: 31,03: 35,88:
50: 0,24: 2,000: 34,48: 42,62:
60: 0,29: 2,300: 39,66: 48,66:
70: 0,34: 2,200: 37,93: 54,06:
80: 0,38: 3,000: 51,72: 58,89:
90: 0,43: 3,400: 58,62: 63,21:
100: 0,48: 3,700: 63,79: 67,08:
110: 0,53: 3,700: 63,79: 70,54:
120: 0,58: 3,900: 67,24: 73,64:
130: 0,62: 4,100: 70,69: 76,41:
140: 0,67: 4,500: 77,59: 78,89:
150: 0,72: 4,200: 72,41: 81,11:
160: 0,77: 4,500: 77,59: 83,10:
170: 0,82: 4,600: 79,31: 84,88:
180: 0,86: 4,500: 77,59: 86,47:
190: 0,91: 4,800: 82,76: 87,89:
200: 0,96: 4,900: 84,48: 89,16:
210: 1,01: 4,700: 81,03: 90,30:
220: 1,06: 5,200: 89,66: 91,32:
230: 1,10: 5,000: 86,21: 92,24:
240: 1,15: 5,300: 91,38: 93,05:
250: 1,20: 5,100: 87,93: 93,78:
260: 1,25: 5,500: 94,83: 94,44:
270: 1,30: 5,400: 93,10: 95,02:
280: 1,34: 5,400: 93,10: 95,54:
290: 1,39: 5,400: 93,10: 96,01:
300: 1,44: 5,500: 94,83: 96,43:
310: 1,49: 5,400: 93,10: 96,81:
320: 1,54: 5,700: 98,28: 97,14:
330: 1,58: 5,600: 96,55: 97,44:
340: 1,63: 5,800: 100,00: 97,71:
350: 1,68: 5,900: 101,72: 97,95:
360: 1,73: 5,500: 94,83: 98,17:
370: 1,78: 5,600: 96,55: 98,36:
380: 1,82: 5,700: 98,28: 98,53:
390: 1,87: 5,600: 96,55: 98,69:
400: 1,92: 5,800: 100,00: 98,83:
410: 1,97: 5,600: 96,55: 98,95:
420: 2,02: 5,900: 101,72: 99,06:
430: 2,06: 5,500: 94,83: 99,16:
440: 2,11: 5,500: 94,83: 99,25:
450: 2,16: 5,900: 101,72: 99,33:
460: 2,21: 5,500: 94,83: 99,40:
470: 2,26: 5,500: 94,83: 99,46:
480: 2,30: 5,600: 96,55: 99,52:
490: 2,35: 5,700: 98,28: 99,57:
500: 2,40: 5,800: 100,00: 99,61:


3- Mill Practice of Card Fibre Transfer Test and Pc-Program

Card Fibre Transfer Test ver 1.0 Pc-Program has been effectively used in optimization in rotor spinning(material/spinning data) parameters to minimize costs as well as carded and combed cotton yarn manufacturing . The most important research finding was found to be Card Fibre Transfer Ratio % and yarn evenness correlation . Therefore ,improving of quality of yarn especially for knitted yarns this program contributes to improving of yarn evenness ,reducing carding waste , and correct maintenance of card clothing, settings

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4- Card Fibre Transfer Test for Carding Machine Spinning Mill Data Bank

To correct the defects in Carding Machinery Carding Machinery Spinning Mill Data Bank could be effectively used .

The program calculates: optimum and actual ratch setting distances for front and back draft zone according to fibre properties of the sliver entry and distances between bottom rollers gauge A and Gauge B restepectively. This system eliminates carbon paper tests for draft rollers settings

This helps to mill to standardize the each processing machinery according to Lot Number and Machine Card Index Number . All these data is stored in data base so when same lot is re-entered this data can be reapplied to running machinery as a result complete control on yarn quality and technical data /machine settings are achieved..

2-With these procedures all the machines are checked and corrected

3-Applying pc-programs for further stages to determine New Tests for improving quality and productivity

There is a close correlation between fibre properties and yarn quality . For optimum quality and minimum manufacturing costs technical data/machine settings play a significant role for this Itru has suggests for spinning mill application of Spinning Mill Data Bank Pc-programs

You can see any defective running(gears, pulleys and belts,rollers, cylinders,top rollers,motors) items and also faulty settings on gearing diagram by just entering its wave length and comparing the chimneys on spectrograph on evenness Tester so it simplifies the quality manager and maintenance technician work.

4- When all the related machinery is completed mill can carry out complete coverage technical data /machine settings tests for further improvement of manufacturing costs and optimum yarn quality

Following pc-programs are delivered free of charge in relation to spinning mill data pc-programs

  • -Card Fibre Transfer Test with Carding Machinery Spinning Mill Data Bank
  • -Comber Data - with Combing Machinery Spinning Mill Data Bank
  • -Ring Spinning Performance and Spinning Geometry - with Ring Frame Spinning Mill Data Bank
  • -Spin Plan - For complete spinning mill data bank pc-programs

Spinning mills can also have options to select any processing stage for directly using the system according to their needs.

5- Card Fibre Transfer Test as an R&D project a Part of Spin Plan

We carry out Card Fibre Transfer Test Pc-program as a research and development project in spinning mills . Apply Card Fibre Data Research Projectin your mill» Order Card Fibre Transfer Now »


Card Fibre Transfer Test Pc-Program could be more effectively used with Itru UAK-1 + Fibre Length and Neps Size Distribution Measurement System especially reducing neps in combed yarn and Fibre Straightness.

Read More »

Process Improvement in Spinning with Card Fibre Transfer Test Read More »


E-Learning Course for Cotton Fiber Testing and Processing

This E-Learning Course is a team work training for Process Improvement and Cost Reductions for Spinning and Ginning Mills with Itru UAK-1 + Fibre/Fabric Information System and Yarn Process Engineering ver1.1 Software.Read More

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