ROVING FRAME – PACKAGE FORMATION

(BUILDING & DIFFERENTIAL MOTION)

 PACKAGE FORMATION
ROVING BUILD

Roving build package is convenient to transport and for storage. Characteristics of which are;

• First layer has maximum length

• Last layer has minimum length for tapering from one layer to other.

• Bare bobbin is of plastic

• Diameter of bobbin is 45mm for FL – 16.

• Length depends upon lift (usually 16” on FL – 16).

• Bobbin and bobbin rail both always move with variable speed.

• Flyer speed remains constant.

2
 PACKAGE FORMATION
HOW THE BELT IS SHIFTED:
• Building motion (BW and its pitch) is responsible for belt shifting. More pitch means less teeth, more belt
shifting, used for coarse count and vice versa.

BUILDER/ RATCHET WHEEL

• Builder wheel pitch control the displacement of belt of the cone drum. Pitch of the builder wheel must be
according to the increase in the diameter of bobbin. (More for coarse roving and vice versa)

• Wrong builder wheel (not according to the bobbin diameter) leads to slackness or tightness in winding.

• BW plays a cumulative role.

• Associate gears of BW (A or B) are present at simplex to be changed in place of BW. These are also known as
Builder Associates.

• New gear, alternate of associate gear known as patent gear, present at modern frames.

3
 PACKAGE FORMATION
DRIVE TO BOBBIN:
Jack shaft (Shaft on which differential mechanism is mounted)

 Twist wheel (driver of all machine parts but not spindle)

Top cone drum

 Bottom cone drum

 Winding gear

 Differential gear box (to give variable speed to bobbin and bobbin rail)

 LW (only controls the drive of bobbin rail but not bobbin)

 OR

 Bobbin driver gear (chain gear  sum of two drives constant and variable).

4
 PACKAGE FORMATION
PROFILE OF CONE DRUM:

• The desired variation in the speed of bobbin originates from the cone drums as a result of belt shifting
mechanism.

• The bobbin speed must be changed in a regular and linear manner. But the shifting of belt in a constant
amount on straight sided drums does not vary the bobbin speed in a linear manner.

• This problem can be resolved by using cone drums which have been made hyperbolic.
• Driver cone drum (top) is slightly convex

• Driven cone drum (bottom) is slightly concave.

• But hyperbolic cones are difficult to design. So the only solution remains is to shift the belt in variable steps
(initial step being relatively large and the later ones small) on straight side cone drums.

• Instead of hyperbolic profile on the cones, an eccentric is used in the belt shifting mechanism.
5
 PACKAGE FORMATION
CHANGE POINTS:
• There are four change points:
• DCP
• TCP
• LW
• BW

• The fine the count the less will be TCP, DCP, LW, but ratchet / builder gear of higher number of teeth will be
needed. The ratchet gear whenever is used has same diameter but differences in its number of teeth (i.e.
Pitch).
• The stroke of BW is transferred to horizontal rack and which transfer it to the belt of cone drum. So motion is
given to belt.

• Belt must be move to its initial position when a newer package has to build. If not a very small tension is
provided for first layer (due to slow speed of bobbin & rail) that has been added up to the last layer due to
the cumulative effect of BW and improper winding will happen.
• In old machine a handle shift the belt. In modern m/c small motors are used for this purpose.
6
 PACKAGE FORMATION
LAY:
CPI = CM count

• CPI = Coils per inch

• CPM = Coils per minute

• CM = Coils multiplier (6 ~ 13 on roving)

• Coils multiplier is a ratio between CPI and  count

• It is the measure of hardness of package. More CM more package compactness.

• More CM is preferred for finer count and vice versa.

7
 PACKAGE FORMATION
How to control CPI:
1. CPI = CPM / linear speed of bobbin rail
2. CPI = (b-f) / LBR ( b – f = bobbin speed – flyer speed)

3. CPM = L (front roller delivery)   DP (package diameter)

• We can’t change CPI by changing ( b-f ) as flyer speed is constant and bobbin speed is already being change
as package diameter increases. If we change bobbin speed tension varies. So we can only change the linear
speed of bobbin rail in order to change CPI in this case.
• CPM can only changed by 3rd relation.

• LW or LCCP (lifter constant change pinion) is changed to change CPI.

• If LW is driver then:
LC = CPI × LW (normally)
• While if LW is driven then:
LC = CPI/ LW (not common)
8
 PACKAGE FORMATION
TAPER ANGLE:

• Range of upper taper  = 80- 95 (vertical)

FACTORS:

1. Type of raw material

2. Spinning type

3. Count of roving

• Manmade roving needs more taper than cotton roving.

• Combed roving needs more taper than carded count.

• Finer roving needs more taper than coarse count

9
 PACKAGE FORMATION
TAPER GEAR
• Taper is provided to avoid the slipperiness of coils. More taper, more stability.
• However, More the taper less will be the capacity of package.

• Taper gear is present under the poker bar. It is a driver of poker bar.

• Greater the size of taper gear more will be the package taper.
• Taper gear is not the major change point in the machine. It is very difficult to change.

• It is not the frequent change place. It only changes when bigger change is needed to be done.

UN-EQUAL TAPER:
• There could be two reasons for unequal taper at top and bottom.
1. When the bobbin rail reaches at its center position, the poker bar must be horizontal. Otherwise an unequal taper
is obtained.
2. If the height of the adjusting bolt is unequal, then unequal taper fault occurs.

10
 CHANGE POINTS IN ROVING FRAME
1. DCP DCCP
2. TCP TCCP
3. LW LCCP
4. BW Builder associates/ Patent wheel
5. SSCW (Spindle Speed Change Wheel) Major change point
• SSCW (spindle speed change wheel) is only changeable when we have to change the production, so it is
also known as production control wheel. It is a prime mover for all other change points. It is located
near the machine on jack shaft thus affect directly on the differential mechanism.
6. TW (Taper Wheel) rarely change
7. WW (winding wheel/ gear)
• WW is used to control the tension in the first layer.
• BW role starts with the 2nd layer. Its effect is cumulative. If wrong builder wheel is present any error due
to WW in the first layer will be increases due to cumulative effect of BW and increased to last layer.
8. Initial position to cone drum belt.
• It is an alternate of winding gear for tension control in first layer.
11
 AUTOMATION
• Much of the work required on the roving frame is costly, time-consuming, physically demanding
and ergonomically unfavourable.

• Automation is therefore most desirable in order to improve working conditions, to reduce errors,
to prevent damage to the roving packages and to increase productivity.

• The layout of a roving frame (with its double row of bobbins arranged one behind the other, flyers
directly in the forefront, and the expansive creel), is far from ideal for automation.

• However, considerable advances have recently been made.

12
 AUTOMATION
• Can changing. Full automation would be too complex and would bring only minor benefits
because the change occurs too infrequently. However, can transport might be at least partly
automated.
• Piecing sliver breaks. This occurs even less frequently and is therefore hardly worth
consideration.
• Piecing roving breaks. This also occurs infrequently and could only be automated with
considerable effort that would make it highly uneconomic.
• Bobbin doffing. This is the most useful opportunity for automation and is long overdue since the
doff is a costly, frequent and ergonomically unsatisfactory operation that has a significant
influence on efficiency. Fortunately, bobbin doffing is state-of-the-art nowadays.
• Bobbin transport. This is also an obvious candidate for automation, since about 60% of wage
costs in a spinning mill using ring spinning machines can be attributed to the cost of transport.
Such systems are now available with varying degrees of automation.
13
 AUTOMATION
• Cleaning. Cleaning has already been automated to a great extent by means of cleaning aprons,
clearer rollers and suction systems at the drafting arrangement, and also by the traveling blowers
that keep the machine clean.

• Machine monitoring. Stop devices are now standard equipment on roving frames. In this area,
automation has already been satisfactorily achieved and the burden on personnel has effectively
been removed.

• Production monitoring. Utilization of personnel and of the installation are important. An

optimum is attained if the machines produce day and night with a minimum of interruptions. One
possibility for optimizing efficiency and keeping it under control is a production monitoring
system, in which interruptions in operation are recorded, evaluated and stored. (for instance,
SPIDERweb by Rieter).
14
 AUTOMATION
• Quality monitoring. In contradistinction to the drawing frame, where an almost complete quality

check can be carried out on the machine itself, total quality control on the roving frame would be

too expensive, since too many production positions would have to be checked. Checking roving

quality remains the province of the laboratory.

• Maintenance and servicing. Much, but not all, has already been achieved in this area by way of

central lubrication, low-maintenance design and so on.

15
 BUILDING MOTION
FUNCTIONS:

1. Reduction of the bobbin speed with the increase in package diameter to keep the tension constant through
the package diameter.

2. Reduction of bobbin rail speed to keep the CPI constant.

3. Tapering (shortening of total layer) of package equally on both sides, to minimize the effect of sloughing off
and to stable the package for transport.

4. Reversal of rail after the completion of one layer.

• Box – o – tricks, Shaping motion, Lifting motion are the name given to building motion.

16
 BUILDING MOTION
English building motion consist of the following parts:

1. Poker bar and taper wheel (same pitch)

2. Top cradle and adjusting bolts

3. Weight lifting lever

4. Bottom cradle with pigeons and weight

5. Reversing lever and reversing rod

6. Ratchet (builder) wheel with two pawls and hammer head

7. Horizontal rack and belt guide

8. A drum, support dead weight by means of a chain attached to both

17
 BUILDING MOTION
ROLE OF POKER BAR:

• Top cradle is carrying the poker bar in two sides. It is a two feet long bar having teeth cut in the underside.
The end of the poker bar is fasted to a stool, carried in a slid attached to the bobbin rail.

• Poker bar moves up and down as the rail moves up and down and gives a rocking motion to top cradle.

ROLE OF TAPER GEAR:

• Taper gear is fastened on the ratchet wheel shaft and meshes with the poker bar.

• It is used to change the taper angle on long run. It is not a common change point for taper angle of the
package

18
 BUILDING MOTION
ROLE OF TOP CRADLE AND ADJUSTING BOLTS:

• Top cradle is loose on the ratchet wheel shaft and so cause no motion of it. Adjusting bolts are attached to
the ends of top cradle. They release the pigeons (one at a time) from the bottom cradle as a result of rocking
motion of top cradle at the end of each bobbin rail traverse.

ROLE OF WEIGHT LIFTING LEVER:

• Weight lifting lever is connected to the poker bar slide and is carried up and down such as the bobbin rail
and poker bar. As the rail moves down poker bar and weight lever moves down from left. (Figure 1)

• While the weight hanging to the lower cradle on right side is lifted by the weight lever from right and vice
versa.

19
 BUILDING MOTION
ROLE OF BOTTOM CRADLE, PIGEONS AND WEIGHT:

• Bottom cradle is free to move on the builder wheel shaft. It does not move continuously like top cradle. But
just instantaneously at the end of each bobbin rail traverse.

• Pigeon controls the bottom bridge/cradle motion.

• Bottom cradle carries two weights, hanging on each end by rods.

• As the bobbin rail is moving down, left weight (fig. 1) hangs on the cradle and right weight is lifted by weight
lever, free on bottom cradle now.

• At the end of downward traverse of bobbin rail, the adjusting belt on the left side of top cradle releases the
left pigeon from the bottom cradle and bottom cradle immediately tips downward to the left.

• Same effect is repeated on the right side at the end of upward traverse of bobbin rail.

20
 BUILDING MOTION
REVERSAL OF BOBBIN RAIL:

• Lower end of the lower cradle is attached to the reversing gears (bevel gears) through reversing lever and
reversing shaft (rod). Change of meshing of the reversing bevel results in the reversal of the bobbin rail.

• When bottom cradle tips down to the left, rail is driven downward and when bottom cradle tips down to the
right, bobbin rail is driven upward.

DISENGAGING AND ENGAGING OF PAWLS:

• Disengaging of pawl from builder wheel is driven by bottom cradle. As the cradle tips from one position to
the other, one pawl is disengaging by the hammer head (also known as double bracket, attached to the
lower portion of the bottom cradle) and the other one is engaged by the spring. During this motion builder
wheel advanced to one half a tooth. In short, Hammer head disengage the Pawl, while spring engages it.

• The major reason of Tension variation in ascending and descending lays is the Unequal setting of Pawl on
both sides of ratchet wheel.
21
 BUILDING MOTION
RATCHET WHEEL AND RATCHET WHEEL SHAFT:
• Builder wheel is mounted at the ratchet wheel shaft which projects through the bottom cradle and the top
cradle.
• Taper wheel which meshes with the poker bar is also mounted on the same shaft.
• Top and bottom cradle are free to rotate on this shaft.

• When ratchet wheel moves one half a teeth at the end of each rail traverse, it also turns the taper wheel,
which causes the poker bar to move one tooth towards right, thus shortening its effective (working) length.
SHIFTING OF CONE DRUM BELT:

• A bevel gear is also mounted on the same shaft on which ratchet wheel is mounted, close to it. It drives
another bevel gear mounted on a vertical shaft.

• A gear is mounted on this shaft engages on a horizontal rack, end of which is attached to cone drum belt
guide. Each bobbin rail traverse causes the movement of gear on vertical shaft (one tooth) which moves the
rack, as a result of which belt shift occur on the cone drums.

22
 BUILDING MOTION
ROLE OF DEAD WEIGHT:

• Builder wheel and poker bar obtained the energy (to move belt guide) from a heavy weight, attached to a
chain, which runs over a guide pulley and around a drum on a vertical shaft.

• The pull due to the dead weight (force of gravity) tends to turn the builder wheel, which is stopped by the
pawls.

RAIL BALACING:

• Rail balancing is done by balancing the vertical rack

• Total mass of roving on one roving package = 2 ~ 2.5 kg

• Balancing weight is used to balance the bobbin rail weight.

23
 DIFFERENTIAL MOTION
• It is the mechanism, in which we are to feed two components,

1. One is variable (coming from the bottom cone drum and it is different from input variable

component). It decreases along the path and minimum at the end.

2. The other is constant (coming from the motor).

24
 DIFFERENTIAL MOTION
DIFFERENTIAL TYPES:
1. NEGATIVE TYPE
• It is used in case of flyer lead system but it was an old method and obsolete. Both input components
(constant and variable) run in the opposite direction.
2. POSITIVE TYPE
• It is used in case of bobbin lead system and is very common now – a – days. Both input components
(constant and variable) run in the same direction.

CONSTANT RATIO:-
Jack shaft : sprocket
8 9
VARIABLE RATIO:-
Spur gear : sprocket (bobbin driver)
9 1
25
 DIFFERENTIAL MOTION
FUNCTION OF DIFFERENTIAL MOTION:-

1. The basic function of differential mechanism is to deliver a variable speed to bobbin in roving speed.

2. As the diameter of bobbin increases, its surface speed increases, roving take up of bobbin increases, as

a result of which tension increases. Since the front roller delivery is constant. To keep the surface

speed same, the rotary speed of bobbin must be decreased gradually with increase in its diameter.

3. For this purpose differential mechanism is necessary. It delivers a resultant variable speed which is a

combination of constant and variable speeds.

26