CALCULATIONS
SPINNING CALCULATIONS
Conversion of Weight units
1kg = 2.2046 lbs
1kg = 1000 grams
1gm = 15.432 grains
1lbs = 453.6 grams
1lbs = 16 oz
1lbs = 7000 grains
1grain = 0.0029 oz
1oz = 437.50 grains
1penny = 24 grains
1ton = 2204.6 lbs
1bundle = 10 lbs
1bag = 100 lbs
1mund = 40 kg
1mund = 88.18 lbs
1m = 1.0936 yards
1m = 39.37 inches
1m = 100 cm
1m = 1000 mm
1cm = 10 mm
1yard = 36 inches
1yard = 0.9144 meter
1yard = 91.44 cm
1ft = 12 cm
1ft = 30.48 mm
1hank = 840 yards
M.R = w/D*100
M.C = w/w+D*100
=
M = R/(1+R/100)
C.C.W = D * (100+R/100)
D = C.C.W *(100/100+R%)
C.C.W = D+R%
C.C.W = D+(D*R/100)
Dm =(D1+D2+D3
Conversion of length units
Moisture Relation for Textile Materials
w/W*100
Volume of air = area
(feet sq) * liner speed (ft/min)
Pm = CA + CB/WA + WB = PAWA + PAWB/WA + WB
Blow Room & Carding Section
Cleaning Efficiency = trash removed/total trash fed *100
Efficiency = tr/tf * 100
=
tf-tr/tf * 100
Waste = trash + lint
Waste Extracted = weight fed * waste%
Waste Extracted = weight fed weight delivered
Weight Delivered = weight fed - waste extracted
Weight Delivered = weight fed * (100 w/100)
Weight Fed = weight delivered * (100/100 w)
Lap length (directly proportional) lap change wheel
Lap length = lap length constant * lap length constant wheel
Beats/min = rpm of beater * number of strikers
Beats/inch = beats per minute/feeding rate (inches/min)
Beats Constant = beats/inch * rpm of paddle roller
Beats Constant = beat per minute/feeding rate
Efficiency = actual production/calculated production * 100
Actual production = calculated production * efficiency
Actual production = weight of lap(lbs) * number of lap/hr
M.D = s.s of shell roller/s.s of paddle roller
Production of B/R (lbs/hr) = production constant * N(shell roller rpm) * W(oz/yd)
Production of card (lbs/hr) = DN * 36 * 60 * 1 *
36
* 840 * count
Production of card (lbs/hr) = DN * 36 * 60 * (weight in ozs) * /36 *
16
No of scutchers required = feeding rate of cards/production of one scutchers
No of card required = production of blow room/feeding rate of card deptt
Production of card (lbs/hr) = delivery rate(m/min) * grain/yds * 1.0936 * 60 *
7000
Time to complete full card can = sliver length(yds)/delivery rate(yds/min)
No. of scutchers required = production of blow room/production of one scutchers
No. of card required = production of card section/production of one card
Tension Draft = s.speed of C.C.R/s.speed of Doffer
Total Lap weight = lap length * weight/yd
D(Trumpet guide) = 0.015625 * count * W
Waste% age = input output * 100
Input
Draw frame Section
Actual Draft =
weight/yd fed
* No. of doublings
weight/yd delivered
Production(lbs/hr) = delivery rate(m/min) * 1.0936 * 60 * No. of deliveries/7000
Production(lbs/hr)(only for two deliveries)= delivery rate(m/min) * 0.45 *grains/yd *
Production(lbs/hr) =
DN
* 60 * tension draft *
36 * 840 * hank sliver
No. of Deliveries Required= feeding rate of simplex/production of finisher draw frame
Unilap Section
Production(lbs/hr) = delivery rate(yd/min) * lap weight(grains/yd) *60 *1.0936 *
7000
Note = 1 penny = 24 grains/yd
Comber Section
Production(lbs/hr) =
L *
7000 *
F * N * H * (100 W) * 60 *
36
*
100
Note
L = lap weight in grain/yd
F = feed rate in inches/min
N = nips/min
W = noil %age extracted
H = no of comber heads
Simplex Section
Feeding Rate = * D(dia of back roller) * Rpm(back roller)
Delivery Rate = * D(dia of front roller) * Rpm(front roller)
TPI = TMcount delivered
TPI =
spindle speed________________
Delivery rate or F.R delivery in inches/min
Production(lbs/hr) = front roll delivery * 60 *
1
*
36
*
840 * count
Production(lbs/hr) = flyer rpm
*
60 * No. of spindles *
TPI * Hank roving * 36 * 840
Production(lbs/hr) = 5.7 * flyer rpm
*
TPI * Hank roving
TPI =
flyer speed______________
Delivery rate or F.R delivery in inches/min
CPM = front roll delivery(inches/min)
Bobbin circumference
CPI =
CPM_______________
(for 120 spindles m/c)
Liner speed of bobbin rail(m/min)
CPI =
CPMcount delivered
TCP(NEW) = TCP(old) *
/count(new)
count(old)
L.W = L.W(old) *
count(old)
/count(new)
B.W = B.W(old) *
count(old)
/count(new)
Roving Tension =
winding rate/delivery rate
(b f)D/l
Roving Tension = (b f)D/front roll delivery(inches per min)
Lifter Constant = CPI * lifter wheel
Turns per meter(TPM) = flyer rpm/delivery speed( meter per min)
Draft = count deliver/count fed
New DCP = old DCP * old draft/new draft
New DCP = old DCP * old count/new count
No. of Simplex required = production of finisher draw frame/feeding rate of one simplex
No. of Simplex required = total feeding rate of ring section/production of one simplex m/c
Production(OPS) = spindle speed
* 1 *
1
* 60 * 8 * 16 *
TPI
36 * 840 * count
Production(OPS) =
DN
*
60 *8 *16 *
36 * 840 * count
OPS from bags/day = total bags/total frame * No. of spindle per frame
No. of ring frame required = total production of simplex section/feeding rate of one ring frame
Traveler speed = spindle speed winding speed
Winding speed = front roll delivery(inches per min)/bobbin circumference
Traveler angle = bare bobbin dia/full bobbin dia
Linear speed of traveler(m/sec) = DN/1000 * 60 (where D is ring dia & N is spindle speed)
Ring Frame Sestion
Auto Cone Section
Cone Length(meters) = count * cone weight(lbs) * 840/1.0936
Production(lbs/hr) = delivery rate(m per min) * No. of spindles * 60 * 1.0936 * /840
Production per spindle(lbs/hr) = * Dia of Drum * Drum RPM * 60 *
36 * 840 * count
Open End
Production/Rotor(gm/hr) = 0.0006 * N * tex * /T.F
Production/Rotor(lbs/hr) = 0.0019 * N * /T.M * (count)
T.F = T.M * 9.61
(where N is Rotor Speed)
Some Other Relations
A.D = M.D * 100/(100 W%)
A.D = count delivered/ count fed
A.D = weight fed/weight delivered
Waste% = (A.D M.D) * 100/A.D
M.D = A.D * (100 W%)/100
M.D = s.s of delivery roll * Driver gear
s.s of feed roll
* Driven gear
M.D = s.s of delivery roll
s.s of feed roll
Condensation Factor = s.s of cylinder
s.s of doffer
Density = mass/volume
590.5 = tex * count
Yarn Diameter = k/count
(Where k is Constant)
Different Formulas of Weaving Calculation:
Reed Count
It is calculated in stock port system.No. of dents in 2 inches is called Reed Count.
EPI
Reed count = ..
1 + Weft crimp percentage
Reed Width
100 + Weft crimp percentage
Reed Width = Cloth width X .....................
100
Cloth Cover Factor
EPI
1. Warp cover factor = .
Warp Count
PPI
2. Weft cover factor = ..
Weft Count
Wp.C.F. X Wt.C.F.
3. Cloth cover factor = Wp.C. - F Wt.C.F +
28
Crimp % :
Crimp Percentage is defined as the mean difference between the straightened thread
length and the distance between the ends of the thread while in cloth, expressed as a
percentage.
Warp length - Cloth length
Warp crimp% = .. X 100
Cloth length
Weft length - Cloth length
Weft crimp% = .. X 100
Cloth length
Loom:
Motor pully diameter
Loom Speed = Motor RPM X .....
Loom pully diameter
Actual Production
Loom Efficiency (%) = .. X 100
Calculated Production
Fabric Specification:
EPI X PPI
Fabric specification = . X Fabric width
Warp count X weft count
Or
Warp count X weft count
Fabric specification = . X Fabric width
EPI X PPI
Weight of yarn in a cloth:
The weight of cloth manufactured on looms depends upon the weight of yarns in
the warp and weft: ends/inch, picks/inch and the weight of size on the warp.
Therefore, Cloth weight = Weight of warp + Weight of weft + Weight of size (All in lbs.)
Total No. of Ends X Tape Length in Yds.
Where as Weight of warp in lbs. = ..
840 X Warp Yarn Count
Length of Cloth (Yds) X Picks / inch in Cloth X Reed Width
(inch)
Also Weight of weft in
lbs.= .
840 X Weft Yarn Count
Weving Calculations:
Calculating linear yards of fabric produced on a weaving machine per hour of operation
can be done using the following formula:
Linear Yards/Hour = (picks per min. / picks per in.) x (60 min. per hr. / 36 in. per yd) x
loom efficiency (%)
Linear Meters/Hour = (picks per min / picks per centimeter) x (60 min. per hr. / 100 cm
per meter) x loom efficiency (%)
Square Yards/Hour = Linear Yards Per Hour x Fabric Width (Yds.)
Square Meters/Hour = Linear Meters Per Hour x Fabric Width (Meters)
Rate of Filling Insertion (Yards/Min) = Loom Speed (Picks/Min) x Loom Width (Yds.) x
Loom Efficiency (%)
Rate of Filling Insertion (Meters/Min) = Loom Speed (Picks/Min) x Loom Width
(Meters) x Loom Efficiency (%)
Exmple of Weving Calculations:
Example-1:
What are the linear yards of fabric produced on a machine running 650 picks per
minute, inserting 58 picks per inch, and operating at a 92% efficiency?
Linear Yards/Hour = (picks per min. / picks per in.) x (60 min. per hr. / 36 in. per yd) x
loom efficiency (%)
Linear Yards/Hour = (650picks per min. / 58picks per in.) x (60 min. per hr. / 36 in. per
yd) x .92 loom efficiency
Answer: 17.2
Example-2:
What is the rate of filling insertion in a loom running 720 picks per minute with a width of
2.5 meters at 93% efficiency?
Rate of Filling Insertion (Meters/Min) = Loom Speed (Picks/Min) x Loom Width
(Meters) x Loom Efficiency (%)
Rate of Filling Insertion (Meters/Min) = 720(Picks/Min) x 2.5 (Meters) x .93 Loom
Efficiency
Answer: 1674 meters of filling inserted per minute
Warp count x weft count
Fabric specification = .......................................................
Ends per unit x picks per unit
1. PPI calculation:
For one revolution of one teeth of Rachel wheel (A)
= 1 pick take up
GxExC
Then, No. of revolution of A = 1 x
FxDxB
90
89
X
= 1 x x x ......
15
24
36
90
89
X
No. of picks for 1 rev. of H = 1 x .. x x x 4
15
24
36
90
89
X
24
Picks per inch = 1 x x x x
15
24
36 15.05
90
89
60
24
= 1 x x x x [C=60]
15
24
36 15.05
= 59.13
2. Pick spacing:
Pick spacing is the reciprocal of the pick density
1
i.e. pick spacing = ..
PPI
B
D
F
H
Pick spacing = 1 x x x x
C
E
G
A
36 x 24 x 15 x 15.05"
=
60 x 89 x 15 x 24
= 0.0169 inch
Or pick spacing = X = 0.0169 inch
3. Loom Constant:
To find out loom constant, the no of teeth in a change wheel is always = 1 i.e X = 1
GxExCxA
PPI = 1 x ..
F x D x B x 15.05
90 x 89 x X x 24
= 1 x .
15 x 24 x 36 x 15.05
90 x 89 x 1 x 24
Loom constant = 1 x .
15 x 24 x 36 x 15.05
= 0.9836
Hence, PPI = Loom constant x change wheel
= 0.9856 x 60 = 59.136
In the loom the fabric remains under tension. When it is out of loom, it becomes relaxed. So in
relaxed state lengthwise contraction of fabric increases the PPI of fabric and normally
contraction is of 1.5%
G
E
C
A
100 + 1.5
Hence, PPI = 1 x .. x x x . X ..
F
D
B
15.05
100
90
89
60
24
= 1 x . x .. x .. x . x 1.015
15
24
36 15.05
= 60.02 - See more at: http://textilecalculation.blogspot.in/2015/09/calculation-of-7-wheeltake-up-mechanism.html#sthash.Vdig06ji.dpuf
