Analyzing the Effect of Speed Variation of Opening Roller on Rotor Yarn Quality

Analyzing the Effect of Speed Variation of Opening Roller on Rotor Yarn Quality

Md. Leon Hossain and Abu Hanif Mohammad Mostafa
Department of Textile Engineering
Northern University Bangladesh
Email: leonhossain324@gmail.com

 

Abstract
A study on Analyzing The Effect of Speed Variation of Opening Roller on Rotor Yarn Quality is done in this work. Use of Count -10 OE Rotor. Lot-29, and use Uster Tester-06 machine, Yarn strength testing machine, and REITER-R35 Rotor spinning machine also studied in this project work. In this analysis the major task was to identify and differ the yarn properties on speed variation of opening Roller. In this project we observe three test reports of Rotor yarn on standard opening Roller speed, Higher opening Roller speed and Lower opening Roller speed. After the comparison we can clarify few significant changes in yarn properties like, CSP, Hairiness, U%, CVm%, IPI etc. Result of U% is more on standard Opening Roller Speed than higher and lower opening roller speed. Result of CSP is more on higher opening Roller Speed than standard and lower Opening Roller speed. Result of IPI is more on standard opening Roller speed than higher and lower opening Roller speed. Result of CVm% is more on standard opening Roller speed than higher and lower opening Roller speed. It is quite clear that the impact of yarn conditioning is prominent ensuring better quality so that it provides the best performance in subsequent processes.

CHAPTER 1
INTRODUCTION

1.1 Introduction
Rotor Spinning is a more recent method of yarn formation compared to Ring Spinning. The first functioning of rotor spinning, machine was presented at the ITMA in 1967. Yarn spinning according to the rotor spinning principle predominates for all non conventional spinning methods. It omits the step of forming a roving. After drafting, the sliver is fed into a rotary beater. This device ensures that the fibers are beaten into a thin supply which enters a duct and gets deposited on the sides of the disc (rotor). The transportation of the fibers is achieved through air currents. This is a form of open-end spinning where twist is introduced into the yarn without the need for package rotation allowing for higher twisting speeds with a relatively low power cost. In rotor spinning a continuous supply of fibers is delivered from delivery rollers off a drafting system or from an opening unit.

1.2 Aim of the research

  • To Know about Rotor Spinning.
  • To Know Yarn Properties on opening Roller speed variations.

1.3 Objectives

  • To Know Yarn Properties on speed variation of opening Roller.
  • To Reduce Lost Time of Rotor spinning Machine.
  • To Increase Machine Efficiency.
  • For Improve Yarn Quality.

1.4 Research questions

  • What do you mean by Rotor spinning machine?
  • How Rotor spinning machine works?
  • What are the important parameters of Rotor spinning?
  • How Rotor spinning can play a big role on yarn properties?

CHAPTER 2
LITERATURE REVIEW

2.1 Rieter-R35 Rotor Spinning M/C:
The strength of Rieter’s rotor spinning lies not only in its high productivity, but also in its flexibility in terms of raw material and yarn construction. The fully automated rotor spinning machine offers state-of-the-art technology for manufacturing Com4®rotor premium yarns with the highest productivity and lowest energy consumption. The semi-automated machine has been specially designed for economic production with manual support and combines high yarn quality with efficient machine operability. Independent machine sides offer maximum flexibility for both machines.

Rotor Spinning Machine
Figure-2.1: Rotor Spinning Machine

2.2 Important Parts of Rotor Spinning Machine:

Feed Roller: The feed roller and feed plate push the sliver into contact with the opening roller, which runs faster than the feed roller, thereby giving a high draft.

Feed Roller
Figure-2.2: Feed Roller

Q 10: Cleaning Trash and Dust.

Q-10
Figure-2.3: Q-10

Cot Roller: To create pressure on Fibers.

Cot Roller
Figure-2.4: Cot Roller

Overhead: To remove flying dust.

Overhead
Figure-2.5: Overhead

Temperature meter: To measure Temperature and RH%.

Temp Meter
Figure-2.6: Temp Meter

Sliver Can:

Sliver Can
Figure-2.7: Sliver Can

Conveyor Belt: Help To unload Coun.

conveyor belt
Figure-2.8: Conveyor belt

Uster tester – 06: Uster tester – 05 m/c are use count IPI and U%

Uster Tester-06
Figure-2.9: Uster Tester-06

Strength Tester m/c: Strength tester m/c normally is use ley strength, CSP, Rkm, find out the yarn count.

Strength Tester
Figure 2.11: Wrapreel

Wrapreel: Measure skeins of yarn of a pre-determined length and number of turns for count and strength testing.

Wrapreel
Figure 2.11: Wrapreel

2.3 Maintenance:
Maintenance is a procedure by means of which we can maintain active functioning in operation according to the behavior and utility of particular elements/substance.

2.4 Importance of Maintenance:

  • It elongates machine life and helps the machine to run trouble free.
  • It increases productivity (machine efficiency) and quality products.
  • It minimizes production and operating cost.
  • It sustains or improves the machine quality and life.

2.5 Types of Maintenance:

a) Schedule Maintenance: Here mainly all the machines are checked on the basis of a fixed schedule of time. Different machine parts are opened, cleaned, lubricated, gauged and replaced if necessary.

b) Predictive Maintenance: This type includes maintenance of machine parts on the basis of suspicion that they consists problem and will cause greater problem in future. It also includes the gear changes that are done to adjust count, tax etc. of machinery and overhauling.

c) Breakdown Maintenance: When a machine stops due to failure of machine parts, then it is called machine breakdown. The maintenance that is done to repair and make it ready to run is called breakdown maintenance

2.6 Lubricants:
Lubricant is a substance which is placed in between two mating parts which are in relative motion with each other, so that they can move without any friction.

2.7 Function of Lubricants:

  • To reduce the friction and wear between the contact surface.
  • To carry away the heat/to cool the moving elements.
  • To keep the surface clean
  • To prevent adhesion
  • To carry heavy loads.
  • To prevent corrosion
  • To absorb shock and transmit hydraulic power.

2.8 Types of Lubricants:
According to the phase of lubricants that commonly occur:

  • Liquid – any kind of lubricating oil.
  • Semi-solid-grease
  • Solid-graphite,
  • Gaseous-air, steam etc.

CHAPTER 3
MATERIAL AND METHODOLOGY

3. Materials:

3.1 Materials:

Raw cotton 22%
Ring Dropping 1 52%
Ring Dropping 2 8%
Neumofil 9%
Rotor D1 3%
Rotor D2 4%
A/C+U/C 2%
Total 100%

Length: 400.0m

Count: 10 OE

Lot: 29

Conditioning Machine:
RIETER-R35
Origin: Switzerland.

Uster Tester-06:
Evenness tester machine
Origin: Switzerland.

3.2 Preparatory Process

Method: The method we applied here is based on time, temperature and procedure system. I observe the procedure of yarn properties change. First time we checked fiber properties then made 10 OE Rotor yarn by Opening Roller speed 8000.Then same package are keep separated and insert Rieter Rotor machine. That time Opening Roller speed was 8500 and after that Opening Roller speed was 7500. We have got both three various types of Rotor conditioned yarn was tested in uster and strength tester. Then, we compared the three reports to know the changes of yarn properties.

3.3 Speed Variation Results of Opening Roller:

Standard opening roller speed test result (Opening Roller Speed 8000):

Parameter Test Results
Count 10 NE
Lot No 29
Yarn Type Normal
U% 10.15
CVm% 12.80
Thin -50% 0
Thick +50% 12
Neps+200% 125
IPI 137
CSP 3599
Hairiness (H) 8.61

Higher opening roller speed test result (Opening Roller Speed 8500):

Parameter Test Results
Count 10 NE
Lot No 29
Yarn Type Normal
U% 9.73
CVm% 12.28
Thin -50% 1
Thick +50% 12
Neps+200% 104
IPI 117
CSP 3610
Hairiness (H) 9.19

Lower opening roller speed test result (Opening Roller Speed 7500):

Parameter Test Results
Count 10 NE
Lot No 29
Yarn Type Normal
U% 9.60
CVm% 12.09
Thin -50% 0
Thick +50% 7
Neps+200% 105
IPI 112
CSP 3592
Hairiness(H) 8.59

CHAPTER 4
RESULT AND DISCUSSION

Chart 4.1: Result of U%

Result of U%

U% normally does not change for yarn conditioning. U% usually changes due to fiber and M/C condition. Here U% has increased a bit at standard Opening Roller speed.

Chart 4.2: Result of CVm%

Result of CVm%

CVm% normally related to U%. We know CVm%= 1.25xU%. Since the U% has increased after yarn conditioning so CVm% has also increased proportionally.

Chart 4.3: Result of IPI

Result of IPI

Here, we see that on standard Opening Roller speed IPI was High.

Chart 4.4: Result of CSP

Result of CSP

Here, CSP has increased on Higher Opening Roller speed. Strength is highly emphasized in the ultimate yarn which can be obtained after this conditioning process.

Chart 4.5: Result of Hairiness

Result of Hairiness

We see that, on Higher Opening Roller Speed Hairiness was increased. But on standard opening Roller speed, Hairiness was lower than Higher Opening Roller Speed.

CHAPTER 5
CONCLUSION

5.1 Conclusion
In this project we tried to find out yarn properties on standard, higher and lower opening roller speed at RIETER Rotor Spinning machine. After, processing the yarn packages are kept in normal temperature for 3-4 hours with a view to cooling the yarn. Then, it is taken for the testing operation where Uster Tester 6 and Elestretch T strength tester are used. The results are obtained after conditioning. Comparing the Three result of same Rotor yarn on Standard, Higher and Lower Opening Roller Speed at RIETER Rotor Spinning M/C. We see that Result of U% is more on standard Opening Roller Speed than higher and lower opening Roller speed. Result of CSP is more on higher opening Roller Speed than standard and lower Opening Roller speed. Result of IPI is more on standard opening Roller speed than higher and lower opening Roller speed. Result of CVm% is more on standard opening Roller speed than higher and lower opening Roller speed. Result of Hairiness is more on higher Opening Roller Speed than Standard and lower opening roller speed. We observe that, for 10 OE  Rotor yarn, test results of standard opening Roller speed (8000) is better than higher (8500) and lower (7500) opening Roller speed. As a result, it provides an overall better yarn quality on standard opening Roller speed for 10 OE Rotor Yarn.

5.2 References:

  1. RIETER-R35 Rotor Spinning Machine. https://www.rieter.com/products/systems/rotor-spinning
  2. USTER TESTER 6 evenness tester machine. https://www.uster.com/fileadmin/user_upload/customer/VARIOUS/Download_dhaka 2016/USTER Summits_USTER_TESTER_6_presentation_final.pdf
  3. MAG- ELESTRETCH T strength tester. https://www.indiamart.com/proddetail/elestretch-strength-tester-9897043191.html

ANNEX

Standard Opening Roller speed (8000) Result
Figure 2.12: Standard Opening Roller speed (8000) Result
Higher Opening Roller speed (8500) Result
Figure 2.13: Higher Opening Roller speed (8500) Result
Lower Opening Roller speed (7500) Result
Figure 2.14: Lower Opening Roller speed (7500) Result

You may also like:

  1. Working Principle of Rotor Spinning | Fiber Processing in Rotor Spinning
  2. Factors and Productivity in Rotor Yarn Spinning Process
  3. An Overview of Open-End Rotor Spinning
  4. Open End Rotor Spinning Performance Under Some Important Technical Variables with Special Reference to Winding Angle and Package Density
  5. Yarn Production Flow Chart with Input and Output Materials
  6. Basic Concept of Yarn Manufacturing Process (Machine Flowchart)
  7. Machines of Cotton Yarn Manufacturing: Working Principle & Technical Data
  8. Cotton Yarn Spinning Process Step by Step

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