Bale opening machines

Bale lay down

23m

32m
8.2

28m
m

4.3
5m

4.9
5m

IITD 2
1. Bale breaker/ opener Constructional features

• Two horizontal and one vertical lattice

Doffer roller • Rectangular bin/ chamber
Evener
• Reserve box in front
roller
• Two rollers with one ( evener roller) with
strikers and the other ( doffer roller) with flaps

Reserve box
Swing
door
• Opening zone: Spiked lattice and even roller.
Input • Spike density on ISL :
• Spike diameter = 6 - 7 mm
Output
Feed lattice
Inclined spiked • Opening intensity : gentle
Horizontal lattice lattice (ISL)
• The spikes are strong as they act on heavy
entangled tufts

Production : 1000 Kg/ h and depends upon

(i) speed of spiked lattice,
(ii) spacing between evener roller and spiked
lattice

IITD 3
 Working principle
Doffer roller
Evener
roller

Reserve box
Evener roller Swing
door

Input (bale pieces) Output

Inclined spiked
lattice (ISL)
Feed lattice Horizontal lattice
e
ttic
d la
e
Spik

Even dumping of cotton

Uneven dumping of cotton

IITD 4
 Doffer roller
Evener
roller
Swing
door

Reserve box
Input

Inclined spiked
lattice (ISL)
Feed lattice Horizontal lattice
Output

IITD 5
 Significance of inclination angle of ISL
Mixing possibility

IS L
Material
• Due to movement of feed lattice and
ISL, the tufts within the bin receive Feed lattice
turning moment and rotate . A. Obtuse angle B. Right angle C. Acute angle

Tuft loading Tuft

Tuft Tuft

ISL
θ θ
• More tufts will slip- off of the spiked W β
β co
lattice, if the inclination angle is acute W
sβ W W
as the component of weight acting α α α
along base of the spikes will be less
A. Obtuse angle () B. Right angle ( ) C. Acute angle ( )

IITD 6
 Intensity of opening action
Evener
roller
𝜔
• The gap ( ) between strikers of evener roller and spiked
lattice is adjustable. 𝑥
• The length of interacting zone = ∆y

• Let
𝑣

ce
• the surface speed of spiked lattice =

atti
• length of a typical tuft =

ed l
Spik
• speed of evener roller =
• number of rows of spikes on evener roller = p
• Time (t) taken by a tuft to cross this zone :
• Number of revolution (n) of evener roller in time t:
• [ reduction in opening intensity]
• Number of beatings (B) a tuft receives while crossing the • [ Increase in opening intensity]
zone: • Production rate depends upon
• speed of ISL
• spacing (∆y )
IITD 7
 Stripper roll
Bale opener (2) Reserve trunk

Cage
condenser
Constructional feature Evener Doffer roller
roller
• Similar to the earlier one Photocell
• Material reserve trunk with delivery

Reserve box
Delivery
roller is additional here roller

• It may be used to feed some other fibre Input

Inclined
spiked lattice
Feed lattice (ISL) Output
Horizontal lattice

Cross sectional view of Bale opener

IITD 8
 2. Hopper feeder

Constructional feature
• Similar to bale breaker / opener
Evener lattice Stripper
• No feed lattice roller

Reserve compartment
• Vertical reserve compartment / box at the
back to receive material Hopper (D)
• Reserve box in front

Reserve box
ce
atti
• Larger in size

ed l
S pi k
Bottom lattice
• Used to ensure steady and uniform supply
of material to the opening and cleaning line
• Reserve compartment hold material in the
main bin D at constant volume

• Working principle: similar to bale opener

IITD 9
 Difference between Bale breaker & Hopper feeder
Bale opener Hopper feeder Reason
1 Spike density on ISL 1.Tufts are more
Spike size opened so less stress
6mm diameter, smaller diameter & on spikes
long short 2. tuft size is smaller
2 Evener roller Evener roller Evener lattice Roller tend to form
laps when waste is
used
3 Spiked lattice Short Long to increase the
quantity of stock

Disadvantages
Spikes break and the slats need frequent repair
Shafts and blocks need cleaning periodically
Changing apron is time consuming

Alternative : Feed unit or feed trunk

IITD 10
Augmentation of basic unit of Bale opener / hopper feeder

• The basic unit can be augmented by various auxiliary units such

as deposition of material
• onto a conveyor
• into a suction duct
• into weighing unit
• into opening and cleaning unit of a cleaning machine

IITD 11
3. Automatic bale opening machine

General feature
• A travelling head extract tufts from laid down bales from top to bottom
• Machines extract material in batches ( i.e. process material from one/two/ three
bales simultaneously at a time).
• The bale layout may consists of ≥100 bales from 4 to 6 types of bales per fibre
blend

IITD 12
 Constructional /design feature
Turret
• A track ( around 50 m ) on which a movable head ( turret)
traverses forward and backward at around 20 m/min Extracting assembly

• Track length accommodate up to 200 bales

• The movable head holds extracting assembly which can pluck
tufts from bale’s top surface 1 2
Chassis
• An internal suction sucks the tufts from the surface of take off
Bales
rollers and transport it forward. Rail
• The head can turn by 180 degree and process bales on both
sides of the machine
• The take – off unit consists of double tooth disc which can Swiveling
change its direction of rotation flap
Pressing
• The take - off unit can adjust itself to various bale heights by roller
moving up & down
• Machines:
Bale
Trutzschler ( Blendo mat) , Reiter (Unifloc) and
Micro-floc (Hergeth Hollinsorth) , Bale plucker (LMW)
IITD 13
 Extracting Swiveling
assembly flap
Pressing Opening roller
roller Opening
roller
Pressing roller

Bale
Bale

• In the extracting assembly , the opening roller may be one or two with depth of penetration 2-4 mm
• One opening roller
• The roller has double sided tooth disc so that it can pick up tufts both in clockwise or anticlockwise
direction of rotation.
• Rotational direction changes in back & forth direction of movement of the head .
• With two opening rollers,
• The direction of tooth disc are different on each roller.
• What ever is the traverse direction , one roller will have working tooth discs in the direction of traverse
and the other in the opposite
• Two layers of tufts are plucked in one pass . The disc opposing the direction of traverse pluck the first layer
and the other disc penetrates the bale further down and pluck second layer of tufts
IITD 14
 Working principle
• Bales are lined up on both sides of the machine Swiveling
x
flap
in length or cross wise dircetions Pressing
Bale
roller
• Bales heights are automatically detected and the machine
Depth of penetration
calculates penetration depth and traverse speed automatically.
(x= 2- 4mm)
• As the tower travels , the rotating take off roller plucks tufts Bale
from bale’s top surface
• The removed tufts are transported pneumatically to the next
machine L
2 3
• Reaching the end of the traverse, it turns by 180 degree and
1
start processing bales on the other side of the machine n gt h w i se
Le
• Spaces to be left between individual bale groups so that
extraction roller can adapt to varying bale height if any wise
Cross
• The machines in this zone open the material gently , generate
smallest flocks of equal size ( 30 – 80 mg)
• Production = upto 2000 Kg/h Mixe
d

IITD 15
 Bales lay down
Type Bales lay down variants ( Top view) Rows Description

1 1 one row of bales with broad sides in

the direction of detaching
2 One and half rows of bales with long
1.5 and broad sides in the direction of
detaching
3 2 Two rows of bales with long side in
the direction of detaching
4 Three rows of bales with long side in
3 the direction of detaching

5 Four rows of bales with long side in

4 the direction of detaching

IITD 16
Calculation of Number of bales per lay down
Example:
A spinning mill has 4 different bale groups and wishes to combine these according to the proportions 20%, 10%, 50%
and 20%. 40m duct length makes bale lay-down length 34 m.
(i) How many bales can be accommodated in the lay down?
(ii) Calculate number of bales in different group

Bale Bale length Bale width Bale weight % Cross(Q) / length (L)
group ( L m) (B m) ( G kg)
1 1.3 0.6 190 20 Q
2 1.6 0.7 230 10 Q
3 1.7 0.65 180 50 L
4 1.4 0.80 200 20 Q

IITD 17
 First, the average length of a bale has to be determined.
out
B Lay tion
c
- For crosswise arrangement , the bale length = bale width = B dire
2
1
– For lengthwise arrangement

with 2 bales, the average bale length is: [ bale length = L]

out
with 3 bales, the average bale length is: Lay ction
L dire
Bale Bale length (L) Bale width( B) Bale weight (G) % Cross(Q) / length (L) 2
group ( m) ( m) ( kg) 1
1 1.3 0.6 190 20 Q
2 1.6 0.7 230 10 Q
3 1.7 0.65 180 50 L
4 1.4 0.80 200 20 Q L ay ou t n
L ctio
i re
2 d
Average Bale width for different type of arrangement 1
3
Bale group 1: crosswise, Bale width(B) = 0.6 m
Bale group 2: crosswise ,Bale width(B) = 0.7 m
Bale group 3 :lengthwise, Bale width (L/2) = 1.7÷2 = 0.85 m
Bale group 4 : crosswise Bale width(B) = 0.8 m
IITD 18
Average Bale width for different type of arrangement

Over all average width : (0.6+0.7+ 0.85+0.8) /4 = 2.95÷4 = 0.74 m

Total number of bales that can be accommodated

Number of bales per bale group

Bale group 1 : 46 ÷ 100% x 20% = 9.2 bales ≈ 9

Bale group 2 : 46 ÷ 100% x 10% = 4.6 bales ≈ 5

Bale group 3 : 46 ÷ 100% x 50% = 23 bales ≈ 23

Bale group 4 : 46 ÷ 100% x 20% = 9.2 bales ≈ 9

Total Bale = 46

IITD 19
0.6m 0.7m 0.8m 1.7m

0.65
m
1.4
1.3

1.6

m
m

0.65
m
Bale arrangement

IITD 20
Thanks

IITD 21
Bale arrangement,
A 1700 -mm take-off unit
A : max. 1.6 m
B : Dependent on bale width
C : min. 1.5 m
D : max. 1.6 m
E : max. 1.4 m

IITD 22
 Swiveling
flap

Bale

x
Bale

Depth of penetration
(x= 2-4mm)

IITD 23
 Stripper roll

Reserve trunk
Cage
condenser
Doffer roller
Evener
Photocell roller

Reserve box
Delivery
roller
Input Inclined Output
spiked lattice
(ISL)
Feed lattice
Horizontal lattice

Cross sectional view of Bale opener

IITD 24
 Draw frame:
Introduction & drafting
principle
R Chattopadhyay

25
 Sliver drawing
• At leat two pair of rollers are required
Front roller
• Top and bottom rollers must be Back roller
pressed against each other m0, v 0 m1, v1
Delivery
• Surface speed of front pair must be Ratch
direction
faster than the back pair (i.e. V1 >V0)
Back roller nip Front roller nip

• Distance between nips > fibre length Sliver drawing in the drafting zone
[ to avoid fibre stretching instead of sliver
stretching leading to breakage of fibres]

26
 Friction force field
Back roller Front roller
• The pressure transmitted to the fibres spreads horizontally
along the sliver and acts as normal pressure resulting
Sliver inter fibre friction.

Friction
• Fibre bulk under back roller > those under front roller.
field
Pressure
• Friction field spreads over larger area near the back zone
Drafting zone
than that in front zone.

Pressure distribution on fibres in drafting zone

27
Consequence of friction field
Friction force field
Back roller Front roller • Non overlapping
• over lapping
• Ideal
Sliver
• The friction field helps in guiding the shorter
fibres to move at back roller speed.
Friction
field
Pressure • If the friction fields overlap drafting
disturbance may occur.
• If they are too far apart , poor guidance of
short fibres will result in uneven sliver.
Pressure distribution on fibres in drafting zone
• The ideal condition : Rear field extends far
into the drafting zone and the front field is
narrow and well defined.

28
Draft
Input mass fed per unit time = output mass delivered per unit time

mo and m1 = Linear density ( direct system) of slivers in the input and output
n = number of slivers fed.
To keep the mass flow uniform

29
 

[ Direct system ]

Hin & Hout are input and output sliver linear densities.

[ Indirect ( English) system]

30
Ideal Drafting • Fibres in sliver are of same length () & fineness.
• All the fibres are perfectly straight and parallel to the
𝑥 sliver axis.
𝑙
A B
• The fibres are arranged in an echelon fashion
throughout the product i.e. as one fibre end
terminates another appears to take its position
• All parallel lines inside the parallelogram ABCD are
C D
representing fibres.
• The line BC represents the number of fibres (m) in the
cross section of sliver.
• The distance between the fibres leading ends =

31
 .
Geometrical Analysis of fibre movement

V0 V1 - nip to nip distance = fibre length ‘l’

- the fibres are accelerated only when their leading
ends reach the front nip
𝑙 𝑥 - BC represents the number of fibres (m1) held by
A B
Fibre-m back roller nip

- DE represents number of fibres (m2) held by front

Fibre 2 D 𝑦
C roller nip
Fibre-1 - = distance between leading ends before drafting
E F - = distance between leading ends after drafting

32
 Consider Fibre-2
V0 V1 Time taken by fibre-2 to reach the front roller nip:

During time t, fibre CD moves a distance : v1t

A
𝑙
𝑥
B
Fibre-m
The distance between their leading ends now becomes
𝑥
Fibre 2 C
Fibre-1
D 𝑦
( 𝑦 =𝑣 1 𝑡=𝑣 1
𝑥
𝑣0
𝑣1
=𝑥 =𝑥 𝑍
𝑣0 )
E F

33
 V0 V1
Let,
BC represents the number of fibres (m1) held by
back roller nip 𝑙 𝑥
A B
DE represents number of fibres (m2) held by front Fibre-m

roller nip.
Fibre 2 C D 𝑦
𝑙
𝑚1 =
𝑥 Fibre-1
E F

[ Since, ]

Number of fibres in the sliver cross section after drafting will be 1/Z times of what it
was before drafting.

34
 Average separation between fibres
V1
Relative movement between any two consecutive V0

fibres after drafting =

Time taken by the last fibre AB to reach the front 𝑙 𝑥

A B
roller nip: Fibre-m

Fibre 2
C D 𝑦
During this time the first fibre CD will move a distance
Fibre-1
𝑙
𝑣 1 × =𝑙 × 𝑍 E F
= 𝑣0

35
 V0 V1

The minimum separation = 0

𝑙
Maximum separation i.e. separation between A B 𝑥
the first and last fibres: Fibre-m

= Fibre 2 D 𝑦
C

Therefore, average separation   E

36
Fast & slow moving fibres within drafting zone
Back nip
BD represents change in number of fibres moving at
Front nip
C' E' back roller speed(V0 )
V0 M’ V1
P OF represents change in number of fibres moving at
B B'
front roller speed (V1)
Q
R BF characterizes change in number of fibres in drafting
m1 region
F
MM’ a line drawn vertically at an arbitrary point in
m2 drafting zone 
L
O KR = number of fibres in the given section moving at V0
K D
M PR = m1- KR = difference between the number of fibres
E
C held by back rollers and numbers moving at speed V1.

LK = QR = number of fibres in the given section moving

37
at V1
Back nip
C' Front nip
M V1
E
V0
B P’ '
B
Q '
R
m1 F

m
L
O D2
K
M E
C

38
 Considering similar triangles BB'D and BPR

C' E' i.e.

V0 M V1
P
B ’ B' Considering similar triangles OFD and OLK
Q
R [as BB’= OD and BP =OK]
m1
F
OR
L m2
Combing
O
K D
M E
C

39
 C' E'
V0
P M’ V1 LK = QR = number of fibres in the given section
B B' moving at a speed of V1
Q
R
m1
F

L m2
O
K D
M E
C

• The change in the number of fibres moving at front roller speed ( LK) depends upon
draft (Z)
• However, the change in number of fibres moving at feed roller speed , does not depend
upon draft.
40
Mass profile of fibre in the drafting zone

If the fibres are of same length and change

their speed uniformly in a region close to the
Mass/unit length

front roller , the mass profile will change

linearly
T

T/Z The profile will be similar to the profile of

Back roller Region of fibre number changing within drafting zone.
nip velocity change Front
roller nip
Sliver mass profile

41
Objectives of drawing

• To remove entanglements between

fibres present in card sliver
• To straighten out and align fibres along
sliver axis
• To reduce mass irregularity
• To blend / mix fibres
• To remove micro-dust

42
Disentanglement & straightening

Before After

Straightening &
Drafting
orientation

Drafting
Disentanglement

• Friction between fibres due to sliding past each other

43
 Reduction in mass irregularity

Doubling
Slivers combined = n
Standard deviation of mass variation of slivers: σ1, σ2, σ3, ....
σn.

Since variance has additive property,

Hence , mass variance of combined slivers ( σc ) .
Drafting zone

Let all the sliver come from the same source, then,
Slivers

44
 Let, m = weight / unit length of each feed sliver.

The CV% of individual feed sliver : CV%

CV % of combined n slivers:

𝑛
CV % VS

• Rate of change of CV % of combined feed slivers decreases with increase in number of doubling.
Hence doubling beyond 6 or 8 does not help much in improving irregularity.
• In doubling thick and thin places in sliver coincide and compensate each other.
• Too many slivers increase drafting force and increase the chances of fibres getting plucked from
the back roller nip in bunch form without real drafting

45
 Draw backs & limitations of doubling
• If doubling is increased keeping draft same, attenuation becomes less. Linear
density of the product increases. More number of passages will be required.

• Repeated passages may lead to increase in mass irregularity generated by the

drafting process itself i.e. equalizing effect due to doubling may be less than
generated due to drafting.

• If the linear density of feed slivers deviate from normal linear density due to
some reason, doubling can not compensate it.

46
Blending / mixing Sliver A Sliver B

• It is achieved due to doubling of slivers.

• Assume 8 slivers containing black and white fibres
are placed side by side. Drafted ribbon
• After drafting, each sliver will be thinner eight
times ( draft =8) and will emerge as thin ribbon Drafted sliver
from the nip of front roller slivers
• Once consolidated , it will contain 4 white and 4
white ribbons 1st step of drawing
• If eight of these mixed slivers are doubled and
drafted again keeping draft 8 in the next step, a
mixture of sixty four drafted black & white ribbons
will be seen in the final sliver.
2nd step of drawing

47
 Removal of micro dust
Drafting
zone
• Lot of micro dust is liberated due to sliding
Sliver
action between fibres as a result of friction in s
the drafting zone

• The opportunity is exploited by sucking out

dust laden air under controlled condition
from the drafting zone

48
End

49
Carding
R Chattopadhyay
 1.
Objectives of carding Individualization
of fibre tufts

5. Production
of an assembly 2. Cleaning of
of random fibre stock
array of fibres

3. Extraction
4. Mixing of of fibre
fibres clustures/nep
s
 Why?
Individualization Essential to produce a
Production of
of fibre tufts clean fault free
an uniform yarn.
yarn Production of
an assembly
Cleaning of
of random
fibre stock
Such an assembly is array of fibres
ideally suited for easy
manipulation into a yarn
Required to improve
appearance of
Mixing of Extraction of yarn
fibre
 For averaging out fibres clustures/neps
variation in fibre
characteristics
 
 Fundamental
actions in card

Carding Stripping
 • Two saw tooth covered surfaces faces each other ( A & B).
CONDITIONS FOR  

CARDING ACTION • Distance between the interacting surfaces ≈ 0.3 mm

• Teeth (Wire points) of both the interacting surfaces should be

V2 inclined with inclination direction opposite to each other.

A
•  The surfaces should move either in same OR opposite
0.3mm directions. If they move in the same direction, the
surface charged with material should move at a faster speed in
B the direction of inclination of the teeth.
V1

V 1>>V2 •  The inclination angle (α) of the front edge of the tooth should
be such that : cot α1 > µ
[ µ = fibre to tooth coefficient of friction ].
CARDING ACTION
Let, R = tension acting on the fibre
Top surface A
P1  RSin 1 P2  RCos 1
α2
P1
For carding action to be effective : P2  P1
R
where µ = coefficient of friction between wire point and fibre.
P2
Fibre under tension
α1 RCos 1  RSin 1
Cot 1   ...............(1)
Bottom surface B
Similar situation for top surface
Cot 2  ...............(2)
 Values of α
––––––––––––––––––––––––––––––––––––––––––––––
Fibre Values of µ between Value of α1
steel & fibre

––––––––––––––––––––––––––––––––––––––––––––––
Cotton 0.27 < 75o

Wool 0.23 < 77o

 
Polyester 0.40 < 68o
––––––––––––––––––––––––––––––––––––––––––––––––
 
CONDITION FOR
Stripping Action • There should be saw tooth point (pins/ teeth ) covered
surfaces facing one another ( A & B)

V2 •The distance between the interacting surfaces at their

closest approach should be ≈ 0.3 mm
A
• Tooth points of both the interacting surfaces should be
inclined in the same directions

• The surfaces may move either in the same direction.

• the speed of the surface receiving the material
should be greater than the other.
B
V1
 A  

α • The difference between the inclination angle of the front

S1
ß edge and wedge (α - θ ) of the tooth being stripped

R
should be such that
ß
S2
cot ß > µ or cot (α –  ) > µ as α = ß +
B

Where, α and  are the inclination angle of the front flank

and convergence angle of the tooth being stripped.
Proof Let, R = tension acting on the fibre

S1  RSin
S 2  RCoc
A
α For stripping to be effective
ß S1
ß
 S 2  S1
R
ß Or
S2 RCos  RSin .............(3)
 Cot   ....................( 4)
B
 CARDING MACHINE CONFIGURATION

Feed Carding Sliver Packaging

section section formation
 Feed Section
Packaging
Carding Silver
formation

Tuft Feed Flat Web

doffing

Cylinder
Can
Doffer
Taker in

Cylinder under-casing

Card
End
Design features & operating
principle of draw-frame
R Chattopadhyay

63
Draw frame

64
Design features & working mechanism

• Drawframe consists of
four sections : Suction

• creel
Drafting Web Packaging
• drafting unit Sliver creel rollers condensation unit
• web condensation
Pneumatic
• packaging unit loading

Drafting unit
Different sections of draw-frame

65
 Operating principle
Draft zone
Sliver Guide roller
• Sliver fed : 6- 8
Trumpet
• Draft: 5-8 Feed
sliver Calendar
• Drawn sliver can capacity: 15- 22 kg roller

• No. of heads : single / double

• Delivery rate: 350 – 800 m/min Can
Delivered
sliver
Card sliver Can
Schematic of drawframe

66
Machine components

67
 Feed Creel
Purpose:
It has to accommodate a maximum of sixteen cans for
feeding card slivers to two drawing heads

• Creel length : 2- 8m
• Creel has a long smooth table with lifting and guiding rollers
• Some modern drawframe may not have guide table to
avoid frictional drag of slivers over table surface
• There are stop motions to detect missing sliver

68
Placement of can in creel
Creel length
Cans are arranged in 2 ,3 or 4
rows
Creel width

For big size can and for single

2 x 8 arrangement
delivery machine 2- row
Creel
arrangement
length

Two rows T- form

Creel arrangement save space.
width

4x 4 arrangement Two rows , T- form

arrangement
69
Drafting unit
V2 > V1 > V0
• Three pair of rollers
Back
• Bottom rollers are made of steel with flutes roller
Middle Front
Low
roller roller
on its surface. pressure
• The top rollers are covered by synthetic
Dust
rubber V0 V1 V2
Delivery
• Bottom rollers are positively driven i.e. they direction
are connected to the motor through gears.
• Top rollers are driven due to frictional
contact with bottom rollers. Drafting unit ( cross-sectional view)

• Drafting unit is placed in a low pressure Break draft zone Front / Main draft zone

chamber

70
Drafting roller diameter

• The choice of roller diameters is guided by following factors

• fibre length
• production rate
• avoiding incidence of roller lapping
• frictional grip on fibres

• The roller diameters must cater to the cotton whose staple length
varies between 22 - 54 mm without resorting to frequent changes.

71
 Close

Influence of fibre length

to fibre
length

Nip to
• The simplest drafting roller Nip
distanc
arrangement with two pair of rollers e
< >
(dia: DR) Fibre Fibre
length length

Nip Nip
• At the closet approach the ( nip to nip ε
DR
DR /2
distance between them will be DR
DD

Roller arrangement B
A

72
For roller diameter () The fibre length ( Ῑ ) the drafting unit can DR ε
process without undue stretch to the fibre is:
DR DR /2

To avoid contact between the rollers a minimum gap () between

the rollers has to be maintained . Therefore the fibre length the
drafting unit can process now keeping allowance () is : A B
Roller arrangement

 Hence , for a given fibre of length Ῑ and allowance , Influence of fibre length on roller diameter
S No. Fibre Allowance ( ) to Roller
Roller diameter :
length (l) avoid accidental diameter (DR)
(mm) contact (mm) (mm)
• Roller diameter therefore needs to be different
1 22 3 19
for different fibre length .
2 28 3 25
• It appears a range of rollers are needed to 3 32 3 29
4 38 3 35
process available cotton fibres
5 51 3 48
73
• Thus lower bound of roller diameter for different fibre length can be determined

• Changing roller diameter frequently for accommodating fibres of different

lengths can not be a suitable option in industrial practice.

• Hence, there is a need to decide diameter/ diameter combination that suits a

wide length range of the cotton by manipulating the allowance () i.e. setting .

• For an example with 26mm diameter rollers and allowance varying between 3 to
6 mm, one can process 29 to 32mm fibres without the risk of breaking them.

74
Rotational speed & roller diameter
• For a given delivery rate(V) the Drafting roller speed ( rpm)
rotational speed ( N) will be     Roller diameter(D) mm
S Delivery rate (V) 28 36 50
No. (m/min)
1 300 3,410 2,652 1,910
2 400 4,547 3,536 2,546
3 600 6,820 5,302 3,818
4 800 9,094 7,072 5,092
• The bigger roller will turn at a lesser 5 1000 11,368 8,841 6,366
speed

75
 Bigger diameter : Advantages & disadvantage
Advantages Disadvantages
• The bigger roller will run at a lesser speed at • Bigger roller will increase nip to
a given delivery rate and will exert less thrust nip distance and make many
on bearings. fibres shorter than the ratch to
• Bigger diameter front rollers due its lower behave as floating fibres, which
curvature , reduces the lapping tendency of may increase drafting irregularity
the drafted fleece ( to be discussed later)
• Larger rollers causes large surface area of
contact between fibres and rollers thus
enhance grip on fibres facilitating transfer of
motion from rollers to fibres.

76
• Roller diameter therefore should neither be too small nor too big.
• Both upper bound and lower bound of diameter therefore exist.
• Rollers of different diameter combinations can also be used to derive
benefits of both small & big diameters
• The reference fibre length could be the fibre used for producing the
yarn count 30s to 40s range whose consumption is maximum in the
world.

77
 Drafted web/ fleece condensation

• The drafted fleece is too weak and thus needs to be collected and
Fleece
condensed immediately
• In slow speed machine, the fleece collected on a tray is passed
through a trumpet for consolidation.
• At high speed , due to air turbulence around the front roller and air
drag, a fleece funnel / web guide is placed close to the front roller
nip to gather the web and pass it through the fleece channel to
the sliver trumpet. Fleece funnel

• The geometry of the web condensation zone should facilitate

• collection,
• guidance and
• consolidation of the fleece.

78
• The angle between the delivery direction of the
drafted fleece and the can axis should be minimum.
• Old drawframe: The angle is almost 900. As a result
the drafted fleece has to turn by almost 900 for
getting into the trumpet. At slow speed such a
configuration may not matter much.

• However, at high speed delivery, the trajectory of

delivered fleece will extend. Therefore gathering
the web and immediately redirecting it into the
trumpet at high speed will be difficult
• Hence, in high speed drawframe, the front top roller
is so placed that the delivery direction of the web, is
better aligned with the the trumpet.
Slow speed High speed

79
 Trumpet
Trumpet
• The trumpet is a funnel with smooth inner surface. cross section

• The sliver get compressed by the reaction force as

the bulky material passes through the constricted
space of the trumpet bore. Fibres

• To ensure easy passage of sliver, the inner surface Entry

of the trumpet is polished and should be free from
dust / spin finish accumulation.
• The sliver compaction depends upon the trumpet Trumpet

bore dimeter in relation to sliver mass and its bulk.

Sliver strength increases with compaction. Exit
• The trumpet gets heated due to friction between 𝑑 𝑡𝑟𝑢𝑚𝑝𝑒𝑡 =𝑘 √ 𝑆
fibres and its inner wall and the heat may damage
S = sliver linear density(K tex )
to thermoplastic fibres.
K = 1.6 - 1.9( for finer to coarser sliver)
80
Package formation Trumpet
Calendar roller

Sliver laying within can

Coiler
• The consolidated sliver is pulled out by a pair of plate
calendar rollers from the trumpet and pushed into
the coiler tube fixed on rotating coiler plate . Sliver
stack

• As the plate rotates, the sliver is delivered into the

can in the form of coils . Within the can there is a
spring loaded plate on which the sliver is laid. Spring

• Each can accommodate 5000 m of sliver (15 - 25Kg).

• The coil diameter is slightly less than can diameter to

avoid any hindrance to withdrawal of sliver due to
friction between inner wall of the can and the sliver
Over centre
while it is withdrawn. Under centre
coiling
coiling
81
 Sliver can   Can capacity ( Kg)
• Cans are hollow cylindrical vessel closed at the Can diameter Can height ( mm)
base. ( mm)
  900 1000 1100 1200 1300
• At the base there exists a plate supported by 500 14-18 15 – 20 17-22 19-24 –
three spiral springs. 600 19- 24 21 - 26 23 - 29 25 - 32 –
800 – 32 - 37 35 - 41 38 - 46 41 - 51
• When the can is empty , the spring 900 – – 45 - 55 49 - 60 53 - 64
deflection is nil and the plate stands close to 1000 – – 53 - 65 58 - 73 63 - 80
the rim of the can .
• Draw frame cans hold around 22-25 Kg of
sliver.
• The cans have castors at the bottom, so that
they can be moved easily by rolling on the Void
floor. space

• The diameter of the spring plate is 15-20 mm

less than the inner diameter of the can Circular can Rectangular
can
Cross sectional view of four cans put together

82
 Sliver withdrawal
Lifting roll

Sliver
Sliver
h Sliver
Sliver

Spring compression
Spring

column height
Spring
deflection

Sliver withdrawal from Can

0 0
• As the sliver is withdrawn, the pressure on the spring Sliver withdrawal (kg) Sliver withdrawal (Kg)
progressively reduces.
• The spring expands and the can plate moves up with the Change in sliver column height and spring
column of sliver on it compression with removal of sliver weight
• The top layer of sliver column also moves up by a similar
amount and thus it always stay closer to the lifting rollers.
• This is required to avoid sliver breakage due to its own
weight.
83
End

84
Card Feed region

85
 Objectives of card feed region

• To ensure uniform feeding of lap / fibrous mat to the

carding zone

• To transform large tufts into small tuftlets

• To extract impurities/neps still left in lap /cotton tufts

86
 Lap feed
Card feed
system Continuous
feed /Chute
feed

87
 Lap feed system
Licker-in cover Lap weight/m: 500 - 800 g

Lap roller diameter: 15cm

Lap Feed roller
Feed roller:6 cm
Licker-in
Licker in diameter: 23cm

Feed plate Licker in speed: 800- 1200rpm

Lap roller Grid bars
Mote knife
Impurities

88
 Advantages of Lap feed system
 
• Greater control can be exercised on the regularity of feed, as
production of uniform lap sheet in Scutcher is relatively easy
 
• The system is flexible i.e. different material can be processed on
different cards , as the cards are not linked together to a common
supply of fibres

89
 Analysis of lap feed P
Let
P= Normal force on feed roller Lap sheet Feed roller
F1
F2
F1 = frictional force acting on the top surface of lap and the feed
roller.
Feed plate

F2 = frictional force acting in between bottom surface of lap sheet

Forces on the feed roller
and the feed plate

µR = coefficient of friction between feed roller and lap

µF = co‑efficient of friction between feed plate and lap.

F1 = µR P and F2 = µ F P

The condition for uniform feeding is : F 1 > F2

  i. e. µR P > µF P or µ R > µF
90
 For uniform feed
• Feed plate should be smooth

• Feed roller should be grooved and pressed against the feed

plate with adequate force

• Feed roller to feed plate gap should be uniform across full

width of the machine so that lap sheet is not plucked

91
 Feed plate geometry
Wedge shape
space

Feed
roller
Licker -in

Feed plate

Mote knife
Grid bars

* Curved plate : for increased surface area of grip of feed roller on lap sheet or fibrous mat

* Wedge shape space : for gradual penetration of licker-in teeth to avoid excessive stress on
fibres

92
Length of nose of feed plate
Long nose
Short nose

Feed Plate Feed Plate

Licker in

Licker in

Tapered lap fringe ( long fibres) Tapered lap fringe ( short fibres)

93
 New design ( lap feed over feed roller)

• In old design, the lap is presented against the direction

Feed plate
of rotation of licker‑in teeth. The fibres bend and are
subjected to high stress.
Lap
Licker -in • To avoid stress on fibres during feeding sharp bend of
fibres is to be avoided especially at high speed

Feed roller • In new design the direction of rotation of licker-in teeth

and lap sheet is similar

Reiter feed system

94
 Continuous feed
Chute feed system
• In Chute feed system several cards are fed simultaneously by a single
source of material .

• There is a central distribution system that feeds tufts to several vertical

chutes connected to a set of cards.

• Depending upon production rate of blowroom , 6-10 cards are

connected to the distribution system.

95
Schematic view of tuft distribution in card
From blow room
Flow of tufts

Card 1

Card 2

Card

Card
…..

10
Duct Duct Duct Duct

From blow room

Duct Duct Duct

Chute1 Chute 2 Chute…. Chute 10

Card 1 Card 2 Card 10

Card …..

96
 Types of chute

Single piece chute Double piece

without any chute with
opening system opening system

97
 Single Piece Chute

• Chute is a vertical chamber connected to

the card
• A column of material (tufts) with variable
height is maintained.
• The material is pushed towards delivery
roller that feeds the tufts to the feed roller
of card

98
 Double piece chute
Fibre from over
head duct

Feed roller

Beater

Chute
Tufts

Feed roller
Licker-
in
Feed plate

Mote knife Grid Bars

99
 Continuous feed Vs lap feed
Disadvantages with Continuous feed
Disadvantages with lap feed system system
1. The very purpose of breaking tufts in blow
room is defeated by transforming well opened 1. Lack of flexibility since a 8 to 10 cards
tufts into a compressed sheet i.e. lap. are fed simultaneously by the same
  material supplied by the blow room.
2. Whenever a lap runs out in card , a new lap
needs to be introduced. The last portion of
the running lap and the beginning of the new 2. Generation of re-workable waste due
lap are joined together manually which to `running out' the system when
becomes a source of fault in sliver and changing from one stock to another
generation of waste.
 
3. Difficulty in ensuring even feed leading
3. The laps need to be transported manually
to medium to long term sliver mass
from blowroom to card room.
irregularity
 
4. Additional space for storage of laps is
required
100
Licker in/ taker-in region

101
 Function of Licker –in / Taker -in Licker in
Feed roller
- to tear apart the lap into minute tufts without damaging the
fibres. Cylinder

- to lead the tufts on dirt eliminating parts for elimination of

trash particles, short fibres, etc.
Mote knife
- to transfer fibres to the cylinder Trash Box
surface. A. Single licker in
• One licker –in may not be sufficient for processing trashy cotton at high
throughput rate and hence multiple units

• Surface speed of licker –in must be increased in the material flow direction
from first to last licker-in by either increasing speed or diameter

• Licker-in diameter = ( 25 cm), Rotational speed = 800- 1600 rpm

• Surface speed: 16 m/s = 57.6 Km/h Suction pipe
• 600,000 wire points pass through the lap fringe per sec B. Multiple licker in
102
Opening intensity

103
WASTE ELIMINATION

104
 Waste elimination Classical technique
Cleaning assembly consists of
Licker-in cover
• Two mote knives and
Lap
• a grid
Feed roller

Licker-in Half of grid was made of slotted sheet and rest of

perforated sheet.

Feed plate 1. Elimination of trash takes place exclusively by

scraping off on the mote knives and
Lap roller Grid bars 2. Elimination by centrifugal force through grid
Mote knife bar openings
Impurities

The grid also serves as guide to the tufts and

holding-back fibers from falling.

Licker–in under-casing
105
 Vortex generation due to mote knife
Plate
Placement of mote knives perpendicular
to flow of boundary air circulating along
with licker –in, leads to vortex
Flow Boundary Vortex generation behind licker-in which causes
Layers
reentry of trash into the fibre flow.

Plate Placement of mote knives are therefore

Voretex generation more and more tangential to the
boundary air flow direction.

106
Modern design
• Mote knifves are placed at an angle

• The tufts are guided over a mote knife

Licker in
Feed roller
followed by  carding plate
Cylinder
• The combination repeats again to
complete trash elimination

• The carding plates are fitted with special

Mote knife
Trash Box
clothing so that it does not hold the fibre/
fibre tufts
Carding plate

107
 Opening intensity
 
Degree of combing (C) = Number of wire points acting / fibre

Number of wire points passing through the lap /min

= ––––––––––––––––––––––––––––––––––––––––––
Number of fibres fed /min.

108
 Let,
Nx = linear density of lap or mat of fibres (K. Tex i.e. g/m)

Nf = linear density of fibre (d.tex)

v = surface speed of feed roller (m/min)
l = fibre length (mm)
N = rotational speed of licker‑in (r.p.m)
z = Total number of teeth or wire points on licker‑in
The number of wire points passing through the lap per min will be = z n
Quantity of material (in g) /min. = v Nx

Weight of one single fibre (in g ) = Nf l 10‑7

vN x
So, Number of fibres fed/min =  107
N fl

NzN f l
So, Degree of Combing =
vN x  107
109
The opening intensity may also be expressed in terms of number of fibres per wire point
(F) instead of number of wire points per fibre (C).

In that case the relationship between F & C will be

1 vN x
F  107
C n z N f l

110
 Intensity of opening
• Feed material parameters

- Lap linear density i.e. thickness

- Degree of openness of tufts in lap
- Degree of orientation of fibres in lap.
 
• Licker‑in parameters
  - Wire point density and angle of inclination
- multiple licker-in
 
• Processing parameters
 

- the distance between the licker‑in and feed plate at the closest approach.
- Rotational speed
- Material throughput rate.

111
End

112
An aluminium carding profile (1) consists of 2 carding bars (2). One of the advantages of bars is
that they can be provided in different finenesses, e.g. they can become finer in the through-flow
direction. Different manufacturers use differing numbers of elements (between one and four) per
position. Special clothing is required that must not be allowed to choke. Most modern high-
performance cards are already fitted with these carding aids as integral equipment; all other
machines can be retrofitted by, for example, Graf of Switzerland or Wolters of Germany.
In use are also other carding devices of different design and with different components, e.g. mote
knives (4) with guiding element (5) and suction tubes (3), etc.

113
Effect of carding elements on carding force

Carding
force
Carding

No. of flat starting from the entry point

force

No. of flat starting from the entry point

114
 Feed Section
Packaging
Carding Silver formation

Tuft
Feed Web doffing
Flat

Cylinder
Doffer
Can

Taker in

Cylinder under -casing 115

Carding section
Card

Flats

Cylinder

Mat

Doffer
Licker-inr
Rieter card
 Geometry of Carding zone Flat

Cylinder is surrounded by
Carding zone Post carding zone
1. Chain of flats 2. Carding bars Pre carding zone (4)
(2)
3. Front & back plates 3 Carding bars
Carding bars 2 4
4. Doffer , 5. Under casing
6. Suction system Licker -in
1 5 Doffer

Total peripheral length available
= π× Dia of cylinder = 405 cm

Carding zone = 158 cm Suction

Distribution of this peripheral space varies from
manufacturer to manufacturer Under casing

• Cylinders diameter: 1280‑1300 mm (50 3/4inch) 1 + 2 + 3 + 4 + 5 +  = 360 , 0

• Length : 1000mm
• Speed: 200‑600 rpm
 Flats
• Flats are cast iron bar having inverted `T' shaped cross-
Flat
section.
• The lower surface is smooth & contains wire points.
• Flat width = 32-35mm , Wire points/ Pins

• Wire points spread over on 22 mm.

• The flats are linked together in the form of a chain ( 80-
110 flats)
• The flats rest on a metallic strip known as flexible
Flat
bend whose curvature of the follows the curvature of
the cylinder.

Flexible bend
Function of flats

• Participate in conjunction with cylinder wire points in separating

fibres from tuft to an individual state, known as “carding action”.
• Open out neps

•  Extracte short fibres, trash particles, neps and dust i.e. cleaning Flat waste
action.

• Generally both the actions take place simultaneously.

• However, carding action is completed within first few flats ( 16-18 )

and cleaning action continues over the entire flat region.
 
 Why flats are moved?
• The flats get progressively loaded with fibres and impurities as a
result of carding action and loose their carding ( opening) capabilities.

• With a stationary carding surface, continuous operation of the

machine will be hindered since the flats have to be taken out time to
time for cleaning.

• The wire points of the flats need to be sharpened time to time.

• Chain of flats can be driven slowly, which would permit necessary

cleaning as soon as they move out of carding zone . Subsequently
they can be fed back for carding again. This would facilitate
continuous operation.
Flat end support
At both ends, the flat rest on adjustable flexible bends and slide over Flat
Single point
it. support

The length of flat is slightly longer than the working width of the
Flexible bend
machine.

Heel & toe arrangement

To facilitates gradual increase in the intensity opening of fibre tufts .

Two point support

Flat

Cylinder

Heel & toe arrangement

• Flats may be considered as a beam supported at two points at their ends.

• The gap between the flat and cylinder wire points must remain constant across the full width of the
machine.

• The bending rigidity of the flat therefore should be as high as possible.

• A `T' shaped cross‑section enhances bending rigidity and hence reduces sagging of the flats at the
middle.
Flat Wire points

Flexible Flexible
bend bend

Cylinder
Theories of carding
 Classical theory
• A fibre can be carded provided the inclination of wire points
is such that the sliding component of tension acting on the
fibre is strong enough to move the fibres down the wire
towards its base. This condition is fulfilled only when
Cot  > 
𝛼
 Where,  = inclination of wire point &  = coefficient of friction between
the fibre & wire
A B
The classical theory does not take into account
the centrifugal force and
presence of air current due to rotating elements
Strang’s Theory
A tuft is introduced into this boundary layer is subjected
V=0 Tuft to a terrific force ( F) caused by the shearing action of
Flat
the air moving with different velocities in the narrow
S space between cylinder and flats.
r
r y laye V= Vc  
nda nt
Bou ir curre Vc
of a
Where,
R = coefficient of viscosity of air at given temperature (Poise)
Cylinder
V = velocity of air current (m/s)
A = projected area of fibre tuft in the direction perpendicular
to the air stream (m2)
s = depth of air boundary layer (m)
Vc = velocity of cylinder( m/s)

Velocity profile of boundary layer

 Kaufmann’s Theory
• Tufts on cylinder surface approach the cylinder flat zone at a very
high speed and enter the narrow space between the flats and
cylinder wire points.
• Compressive force develops which forces the fibres into the wire
clothing of both flats and cylinder
• Since the flats are practically stationary as compared to fast moving
cylinder surface, the loading factor of compression force against
the flats is much more than that against cylinder as cylinder
presents a larger surface area for the same compression force.
• The penetration of teeth into the tuft is immediately followed by a
shearing action on the tuft due to great relative speed between
them
• The process repeats itself when part of the tuft held by the cylinder
approach the subsequent flat and so diminishing the size of the tuft
progressively.
Thanks
Flats
Analysis of opening &
cleaning action by flat
 Opening
Carding force process

Cleaning

Carding force
• It is the force required to open out the process

fibre tufts
• How long the opening continues?
• Indirect evidence of Opening is carding
1 5 10 15 40 45
force trace curve Delivery side
Feed side Flat location

• Carding force declines as tufts move Carding force trace curve

forward
• Force becomes constant after 16-18th flat
location
• Opening takes place progressively
 Cleaning process
Opening
process
• Working flats : 45 to 48

Carding force
• Flats beyond 16th position keeps Cleaning
process
absorbing trash & other impurities
thrown away by cylinder by centrifugal
force during their journey
• Certain long fibres are pushed into flats
5 10 15 40 45
at the initial stage. Hence each flat 1
Flat location
contains both long & short fibres along
with impurities Carding force trace curve

• More cylinder speed more cleaning is expected

• Too high cylinder speed may lead to short fibre generation due to fibre breakage
 Direction of
flat movement

Forward Backward
Forward Movement of flat
• Advantages
• The cylinder assists in moving the flats by providing part of drive through carding
force and
•  The removal of flat strip becomes easier due to downward inclination of flat wire
points at the front of the card.
 
Disadvantage
Larger size trash particles liberated through carding action and absorbed into the
first few flats are crushed into smaller pieces as these flats remain in the carding
zone for a long period of time. These crushed particles re-enter the carded stock
and thus affect cleaning.
 Backward movement of flat
• The cleaner flats introduced from the doffer side.
• Though flats fibre absorbing capacity reduce by
the time they reach the entry to the carding zone,

Flat Loading (g)

sufficient still remains to eliminate dirt.
• The dirt take up by flats shows that first few flats
take up more dirt particle than the rest.
• Advantage
1 45
The larger size impurities, are not transported Feed side Delivery side
through the whole carding zone but removed Flat Location
immediately. Dirt take-up by backward moving flats
Analysis of forces acting on fibre
on cylinder
Forces on fibre T q
(Emanuel and Katser ) H

h 
T = Centrifugal force acting radially upwards
P = Air drag acting parallel to the clothing base P
 F N
 = Inclination of the wire point
Q

Wire point
Resolving force T 
q = T Sin  (along the wire point and away from base) Cylinder surface
h = T Cos  (perpendicular to the wire point)
 
Similarly P can be resolved into
Q = P Cos  (along the wire point and towards base)
H = P Sin  (perpendicular to the wire point)
• The perpendicular forces give rise to frictional resistance (F) to fibre
movement, which is equivalent to T q
H
F =  (H + h)
where,  = coefficient of friction between fibre and wire point. h 
• Forces F and Q jointly resist the displacement of fibre towards the
P
wire tip.  F N
• The equilibrium equations are : Q
Wire point


and Cylinder surface

 
The fibre can move towards the tip of the wire point. If,

 
or
 > ………. (3)

Therefore, fibre movement along the wire point tip resulting shedding depends upon angle  and .
If  is kept constant at 0.23, the conditions of shedding for various values of  are
 
T/ P > 0.93 for  = 60o
T/ P > 0.75 for  = 66o
T/ P > 0.66 for  = 70o
 
Similarly for a fixed value of  = 66o, the conditions for different values of  are
 
 T/ P > 0.71 for  = 0.2
T/ P > 0.75 for  = 0.23
T/ P > 0.8 for  = 0.26

Therefore the conditions of fibre shedding becomes favourable at larger values of 

and smaller value of  .
The Centrifugal force T is:

  ….(4)
Where, G = weight of fibre, g = 981 cm / sec2 acceleration due to gravity, Vc = surface speed of
cylinder (cm/s) and R = radius of cylinder over wire point tips (cm)

 where , d = fibre diameter (cm), l = fibre length (cm) and  = fibre density (g/cm3)

Substituting the value of G in T, one gets

 ….(5)
The air drag force acting on the fibre can be determined from the following
relationship:

.. (6)
where
C = drag coefficient  = density of air (g.sec2/cm4)
A = largest projected cross‑sectional area of fibre in the direction of the air flow (cm2)

Vrel = relative velocity of air flow (cm/sec)

……… (7) 

where, Vabs = absolute velocity of air at the plane of the fibre.

 
Vrel is therefore equals to zero, when the fibre is close to the cylinder surface.
However, it quickly becomes equal to Vc as the fibre moves away from the wire point
base.
 Substituting the values of T and P, the ratio T/P therefore becomes

𝑇 𝜋 𝑑2 𝑙 𝛾 𝑉 2𝑐
= … … .. ( 8 )
𝑃 2 𝑔𝑅𝐶𝐴 𝜌 𝑉 𝑟𝑒𝑙
2

The chances of a fibre being thrown off the wire point increases as T/ P increases with
 
(a) increase in cylinder speed, fibre diameter and fibre density and
 
(b) decrease in cylinder radius and
(c ) decrease in relative air velocity.
 
  As a result a short fibre situated close to the cylinder surface is more likely to shed since Vrel
is small in this zone.

A long fibre situated in a zone remote from the cylinder surface is less likely to be thrown off
since Vrel is high here.
 
 Cylinder – doffer region ( modern card)
• The middle plate is replaced by a suction hood and post
carding segments to suck out the dust laden air within the
card generated by the vigorous carding action Mote knife with suction

Back cover

• The post carding segments is meant for further opening Post carding
segments
action on those fibre clusters which might escape carding
action due to high production rate
Doffer

• The rest of the place covered by plate ensures prevention

of loss of fibres from cylinder
 Under-casing
• In high production card, this slotted sheet
was replaced by closed sheet with suction
hood to avoid the creation of small air
vortices and Cylinder

• Eliminates the possibility of fibre loss due

to high centrifugal force.

Under casing with suction hood

Thanks
SLIVER FORMATION
 Doffer

• A cast iron cylinder

• Diameter: 27 inch
• Surface : filled with wire points
(pins)
• Speed: 10 - 60 rpm Doffer

147
Separated fibres are to be transferred to Doffer from
cylinder
Mechanism of
fibre transfer

Carding Stripping

148
 Carding OR Stripping?

The deposited fibres on doffer should be thick enough to form a

coherent web which can be stripped of and handled easily for
further processing.

149
Difficulty with stripping mode of transfer
• In case of stripping action, the lap thinned down to the extent of
2000 times on cylinder surface would have been too thin to be
handled properly for lack of coherence.

• Besides high doffer speed would have resulted in throwing off fibres
due to high centrifugal force.

• Further, it would have been extremely difficult to transform this web

into a coherent sliver at such a high speed (greater than cylinder
surface speed).
150
 Disadvantages with Transfer by carding mode

• During transfer from cylinder to doffer sudden deceleration occurs as

the speed reduces from 26 m/s to 1.3 m/s on doffer. As a result the
orientation of fibres achieved on cylinder surface gets destroyed and
the fibres get disoriented on doffer surface.

• The transfer being not 100% , lot of fibres are retained by the
cylinder and carded again along with newly fed fresh fibres from
licker‑in side. This results in building up a thick residual fibre layer on
cylinder. This residual layer in steady state may become too thick to
deteriorate quality of carding.
151
Advantages of carding mode of
transfer
• Fractional transfer of fibres from cylinder to
doffer provides an opportunity of mixing of
fibres belonging to different return fibre
layers on cylinder. Cylinder

• The fibres receive repeated carding action

between the f cylinder and flat.

152
 30
26m/s

1.225Ktex
0.245 ktex (from licker-in)
20 13m/s , + 0.980 ktex ( return fibre layer on
0.49 Ktex cylinder)
Velocity (m/s)

=1.225 k tex

10

490 Ktex 1.3 m/s

0. 013 m/s 4.9 Ktex

0
Feed roller Licker-in Cylinder Doffer

Draft 2.0 0.05

1000

Velocity and linear density profile of material on Card

153
Mass balance :
[= linear density of web on doffer]

• The delivery from doffer = 1.3 x 4.9 g/m = 6.37 g/s [ 4.9K tex = 4.9 g/m ]
• Let the transfer efficiency from cylinder to doffer = 20% OR 0.2.
Therefore, the material to be presented to doffer per sec for transfer = 6.37/0.2 = 31.85g/s
• This material is brought to doffer @ 26m/s
• Hence, the web linear density on cylinder has to be
• The cylinder continuously receives fibre layer from licker-in of linear density
Therefore, the return layer linear density on cylinder =
OR
Fibres returned to cylinder after transfer to doffer =
Linear density of returned fibre layer=

154
 Doffing arc Fibre layer

It is the arc AC of doffer over which fibres get transferred

Cylinder
x = (R + r + e) – r cos  ‑‑‑ (1) a
R
AC2 = ( R+ a )2 – { ( R + r + e ) – r cos  } 2 ‑‑‑ (2)
C
r
Doffer
AC2 = r2 – (r cos  )2 ‑‑‑ (3)  
O A
x O’
e
Combing Equation 2 & 3 R + r +e

( R+ a ) 2 = r2 + ( R+ r +e ) 2 – 2( R+ r+ e ) r cos  ‑‑‑ (4)

( R+ r+ e ) 2 + r2 – ( R+ a )2
or cos  = –––––––––––––––––––––– ‑‑‑ (5)
2( R + r + e) r
155
 a ( 2R + a )
cos  = 1 – ––––––––– ‑‑‑ (6)
2r ( R + r )

Arc AC = r

a ( 2R+ a )
= r cos‑1 1 – ––––––––––– ‑‑ ( 7)
2r(R+r)

Therefore the doffing arc will increase with increase in

R ( cylinder radius),
r ( doffer radius) and
a ( thickness of fibre layer on cylinder).

156
• Fibre transfer from cylinder to doffer is stochastic in nature.

The probability of transfer will be be proportional to the

(i) Fraction of fibre protruding ends at a certain distance from cylinder

surface
(ii) Length of doffing arc ( i.e. number of doffer wire points with which
fibres come in contact)
• Therefore, the chance of fibre transfer, occurring at different distance
from cylinder surface, can be stated as

Chance of transfer = fraction of fibres at a particular distance from

cylinder surface x potential arc of contact  

157
 STRIPPING OF DOFFER SURFACE

Q = force which counteracts stripping of web from doffer wire

 
F = force of friction between doffer wire points and fibre.
  doffer N= P sin 
Q F
Let surface
 = stripping angle i.e. angle at which P is directed. Doffer

 P
 = inclination of doffer wire point.
Fibre
P1 cos 
Q + F = P cos  and .. F = P cos  – Q ‑‑‑ (1)

N = P sin  ‑‑‑ (2)

158
So F =  N =  P sin  ‑‑‑ (3) (  = coefficient of friction)

 P cos  – Q =  P sin 

 So, Q = P cos  –  P sin  = P (cos  –  sin )

Q
or P = ––––––––––––––– …………. (4)
(cos  –  sin )

The stripping force P depends upon Q, stripping angle  and coefficient friction 

The strength of the web < stripping force in order to avoid breakage.

159
 Web stripping
• Doffer speed being in the range of 25‑ 60 rpm, the oscillating doffing
comb can not be used for stripping
• Hence draw‑off rollers have been designed for the purpose of
continuous stripping of doffer surface.

The methods used for web removal are

  (i) stripping by a flexible straight or rigid wire covered roller
(ii) pulling by a combination of flutted draw‑off roller and a blade.
(iii) lifting action by wire covered roller.

160
Cylinder Cylinder

Flexible straight draw off roller

Rigid wire covered draw off roller

Cylinder Cylinder
web

Fluted draw off roller Wire covered roller

161
Consolidation of web into sliver
• A web which is a thin two dimensional sheet has to be converted into a round, rope like
assembly known as sliver.

• This sliver form is necessary since it possess the necessary coherence for it’s storage and
subsequent handling.

• More important is it’s characteristics which is close to yarn in terms of arrangement of fibres.

The method of transforming a web into sliver are

(i) Trumpet & Calendar roller combination
(ii) Traverse belt

162
 Trumpet & Calendar Roller Condensation
• Doffer surface to trumpet distance : 30 – 50 cm
Doffer surface

• The calendar rollers moves slightly faster than the doffer.

• As the web passes through the trumpet, sufficient lateral pressure Web
gets generated that transform the two dimensional sheet into a
round shape sliver.
Trumpet

• The trumpet bore size and the pressure on the calendar rollers Calendar roller
decide the level of compression the fibres receive i.e. degree of
consolidation.
• Normally the trumpet and the calendar roller are placed at the Symmetric condensation of web
centre with respect to doffer.

163
• Trumpet – calendar roller assembly is placed off the centre
of doffer. Such a placement leads to asymmetric
condensation Doffer surface

• It causes any unevenness present in the web, to be

distributed over a larger length of sliver.
Web
• As an example a thick region, instead of occurring locally at
one place get distributed over a longer length, hence Trumpet
reduces in intensity.
Calendar roller

• Calendar roller moves slightly faster than the doffer and

the ratio of surface speed between them is 1.01‑1.05

Asymmetric condensation of web

164
 Traverse belt condensation
• Because of high delivery speed , the web is likely to
disintegrate due to air resistance if it has to travel a long Web detaching rollers
distance.

Doffer
Solution
• The web is to be condensed immediately and close to the belt
e rse
detaching or stripping device. Crush rollers rav
T
• A traverse belt is placed close to the crush rollers. As the belt
moves transversely, the web moves laterally and get
Traverse belt condensation
condensed while passing through the nip of the belts.
• Two counter rotating bands or a single circulating band
carries the web to the middle or side of the machine and
condense it.
• The difficulty of such devices is that the web can not be
visually seen for judging it’s quality.
165
 Web Crush roller
Crush roller
• Two precision ground, hardened steel rollers
positioned one above the other .
15 N/Cm
• The rollers, are loaded with a pressure : 15 N/cm

• The purpose is to crush out foreign particles in web and also the bond between the
particles and the fibres.
• The particles fall out either immediately or during subsequent operations.
• Hence the sliver may not necessarily look always clean but the yarn will look clean.
• It is most effective on low grade cottons.

166
Precaution

• Clean fibres do not need crushing. On the contrary the fibres might
get damaged because of the roller pressure in the absence of trash
particles

• Cotton with too much SEED COATS should not be crushed in order to
avoid roller lapping since oil may get extracted from crushed seed
particles.  

167
End

168
Carding process
R Chattopadhyay

169
 Transfer efficiency
Let,
K = Transfer efficiency
q = Amount of fibre transferred to doffer per revolution of cylinder.
Q = Load on cylinder i.e. quantity of fibre on cylinder at steady state

 
….. (1)

170
 Let, P = the production rate ( g/min)
[Ne = sliver count] 

Rd = doffer radius diameter (inch)

nd = speed of doffer (r.p.m.)
nc = speed of cylinder (r.p.m.)
The weight (q) of sliver delivered per revolution of cylinder is
 

 
 

The transfer efficiency can be easily calculated from either equation (4), after experimentally determining
the magnitude of cylinder load Q.
  171
 Determination of cylinder (Q)
• Start a card engaging a lap under feed roller. Let it run for few minutes till it attains
steady state operating condition i.e. sliver of nominal linear density.
• Now stop the movement of flats. This should immediately be followed by
simultaneous stopping of feed roller and doffer by disengaging appropriate gears.
• Allow cylinder to run continuously. Restart the doffer keeping drive to feed and flat
C inoperative. One can now notice that the doffer is delivering a sliver consisting of
fibres (in the form of a sliver) which was already existing on its lower half at the
time of stoppage followed by fibres stored on cylinder in the form of fibre load. It
now becomes important to differentiate between these two groups of fibres from
the same sliver.

172
 A clear cut dividing line exists between the fibres which were already on the
lower half of doffer when it was stopped (AB) and the fibres transferred from
cylinder later (BC), in the form of a thick deposition of fibres.

C Fibes transferred later from cylinder B Fibres already A

existing on doffer

Schematic view of delivered sliver

173
Carding process
• When a card is started keeping feed engaged, one can notice a gradual increase
in the sliver linear density before it reaches the steady state nominal value.

• Similarly if feed to a running card is suddenly stopped, the linear density ( or

thickness ) of the sliver gradually reduces till it becomes zero.

• The behaviour of the card during these two transient stages is very important
and gives an interesting insight about the carding process.

174
Continuous feed
• Let us examine the situation at successive revolutions of cylinder for
an uninterrupted continuous feed.

𝑓 𝐶𝑛

Cylinder revolution (n) Cylinder revolution (n)

175
 1st revolution of cylinder
Let,
The amount of fibres fed (f ) from licker‑in per cylinder revolution = (constant)
Hence, the amount of fibres presented to doffer :
The amount of fibres transferred to doffer : [ = fraction transferred to doffer]

The amount of fibre retained by cylinder :

 

𝑝
𝐶1

1 Cylinder revolution (n)

Cylinder revolution (n)
176
 2nd revolution of Cylinder

At the second revolution in addition to , fed from licker‑in side, fibre R1

retained by cylinder will also be presented to doffer for transfer. So

  Amount of fibres presented to doffer / in the 2nd revolution of cylinder:

The amount of fibres transferred to doffer

 
The amount of fibre retained by cylinder :

177
th revolution of cylinder
 
The corresponding quantities are:
 
 

…….(1)
 

178
Input – output relation
(Steady state operation)

, ,

𝐶 𝑛 =𝑝 [ 1 − ( 1 −𝛾 )𝑛 ]

𝑝 𝑝
𝐶𝑛

Cylinder revolution (n) Cylinder revolution (n)

179
Cessation of Feed

• After attaining steady state operation the feed to the machine is

stopped.

180
1st revolution of cylinder
(feeding stopped)

The quantity of material left on cylinder at steady state :

So, the amount presented to doffer:

Amount transferred to doffer:

Amount retained by cylinder :

181
Second revolution of cylinder
(feeding stopped)

The corresponding quantities will be

The amount presented to doffer :

:
 
 
Amount retained by cylinder :

182
 Nth revolution of cylinder (feeding stopped)

 
,
 
  As

 Hence the steady state values will be : B = B = 0, C = C = 0 and R = B = 0

 

𝑛−1
𝐶 𝑛 =𝑝 ( 1 −𝛾 )
f
C

Cylinder revolution (n) Cylinder revolution (n) 183

RESPONSE OF A CARD TO STEP CHANGE IN FEED

• Amount fed per cylinder revolution= p. A

𝑝

Output(C)
• Output (C) builds up slowly over a period of time T0
(T0) represented by the curve OA and reaches
the steady state value i.e. C1 = p. O
t
1

• c(t) = represents output as a function of time t

𝑝

Input(I)
• The hatched area OPA represents the fibres retained
by the cylinder in the form of fibre load on it.
0 t1
Time

184
 G D

At t1:
Input ( Feed) increased by p & continued
𝑝 A

Output(C)
B C2
C1 T1
Extra Mass fed:
Mass delivered :
O
t  t2
> WT1 1

p p
– WT1 i.e. hatched area (BGD) represents the
amount of material retained by the cylinder as 𝑝

Input(i)
cylinder load .

 t2
t1 Time t3

185
 G D E
At time t3 Input ( Feed) is suddenly reduced by
p and continued at this level

Output will recede progressively over a time T2 A F

i.e. t4 – t3 as shown in the curve EF and stabilizes
𝑝 B 𝐶2 H

Output(C)
at the level C1. C1 T1
T2 C1
 
During the transient period T2, the quantity of O
material fed and delivered by the machine are t
1
 t2 t3 t4

p
𝐸𝑥𝑐𝑒𝑠𝑠𝑚𝑎𝑠𝑠 𝑓𝑒𝑑 : 𝐼 𝑇 2=0 p
𝑝
∆𝑙
Mass delivered:

Input(I)
t2 t4
t1 t3
Time

186
 G D E

𝑝 A
B H
Output(C) 𝑐 ′2
C1 T1
C1

O
t
1  t2 t3

p

𝑝
∆ 𝑙1
Input(I)

t1 t2 t3
Time
187
 Practical consequences
- a sudden increase in feed results in gradual increase in sliver linear
density due to gradual response of the process and as a result part of the
fibre fed during this transition period, accumulate on cylinder as cylinder
load.

- similarly, a sudden decrease in feed results in gradual decrease in sliver

density rather than being abrupt. In this case, the additional material stored
as excess cylinder load, is gradually delivered over several cylinder
revolutions. Therefore the sliver thickness also reduces gradually to the
earlier steady state value .

- Feed disturbance there fore smoothened out by card

188
 Mixing Action on Card

• Doffer takes only part of the fibres presented to it by the cylinder.

The rest goes back as return fibre layer and joins the freshly fed
fibres from licker‑in side.
• The process repeats with each revolution of the cylinder and thus the
fibres fed over several cylinder revolutions get mixed up in the form
of layers after layer in a sandwich fashion on the cylinder.

• In steady state operation, the material that remains on cylinder,

consists of fibres fed at different points of time ( cylinder revolution)

189
At n th revolution of cylinder
2 𝑛
𝑅𝑛 =𝑝 ( 1−𝛾 ) +𝑝 ( 1 −𝛾 ) + … … … … … …+𝑝 ( 1− 𝛾 )

Amount retained from nth Amount retained from 1st

revolution of feed Amount retained from the feed revolution of feed
1 revolution earlier i.e. of (n-1)th
revolution

Rn = fibres retained on cylinder at nth cylinder revolution beginning from any arbitrary time
p = the amount fed per cylinder revolution
 = proportion transferred to doffer or transfer co-efficient

• The maximum portion of the fibre belongs to the present revolution (i.e.nth) and
• the amount progressively reduces for the earlier revolutions.

190
 Layer belonging
to present cycle of Fibre layer
feed
Since the doffer removes material without any
bias, any section of the sliver will consist of
fibres fed to the machine at different points of
time i.e. different revolution of cylinder. Cylinder

The degree of mixing depends upon the Layer belonging

to previous
doffer’s collecting fraction or transfer cycles of feed
coefficient

Mixing of fibres 

191
 Share of material on cylinder fed at different cylinder revolution
2 𝑛
𝑅𝑛 =𝑝 ( 1−𝛾 ) +𝑝 ( 1 −𝛾 ) + … … … … … …+𝑝 ( 1− 𝛾 )
for  = 0.10
 

for  = 0.2
 

• The lesser the transfer coefficient, the more will be the material returned as return fibre layer and
hence more time it will spend on cylinder before its complete removal. This gives it an opportunity
to the layers to get mixed with more number of fibre layers fed in successive revolutions.
 
• However, a too low transfer coefficient is detrimental to good carding since it increases cylinder
load. A balance therefore needs to be achieved during practical carding operation.
 
 

192
End

193
 Average time spent by a tuft
Tuft of weight = w on cylinder.

1st revolution of cylinder :

Mass on cylinder = w
Mass transferred to doffer = w
Mass remaining on cylinder = (1- ) w

2 nd revolution of cylinder:
Mass transferred to doffer = (1- ) w
Mass remaining on cylinder = ( 1-  )2 w

Therefore each part of the splitted tuft arrives at different times ( in terms of cylinder revolution ) for
transfer to doffer i.e. the transfer of the entire tuft takes place over a period of time.

Doffer Wγ W (1 –  ) W(1 –  ) 2 

Cylinder w (1 –  ) W( 1- γ) ( 1- γ) W(1 –  ) 2 (1-)

=W(1 –  ) 2 = W(1 –  ) 3
194
Average time spent by a tuft
Let
The average delay of the tuft is given by the sum of the tuft fractions multiplied by their individual
delays i.e.

( x 0 ) +  (1 –  ) + 2  (1 –  ) 2 + …………
 

=  Σ n(1–)n = 1/
n =1
 
 

195
 G D E

A F

Output(C)
P B C2 H

T0 C1 T1
T2 C1

O
t0 t
1
 t2 t3 t4

p
p
p
Input(I)

t2 t4
t1 t3
Time

196
 Settings, draft , cleaning
efficiency and production

R Chattopadhyay
Draft

198
The draft is a measure of degree of attenuation i.e. degree of
reduction in weight per unit length of the material being
processed.

Draft

Mechanical Actual

199
 Mechanical Draft

Mechanical draft is calculated based on speed of machine elements.

 
 

OR
 
 

𝑙𝑒𝑛𝑔𝑡ℎ𝑜𝑓 𝑠𝑙𝑖𝑣𝑒𝑟 𝑑𝑒𝑙𝑖𝑣𝑒𝑟𝑒𝑑 𝑝𝑒𝑟 𝑢𝑛𝑖𝑡 𝑟𝑜𝑎𝑡𝑖𝑜𝑛 𝑜𝑓 𝑓𝑒𝑒𝑑 𝑟𝑜𝑙𝑙𝑒𝑟 (𝑚)

¿ 𝑀𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝑑𝑟𝑎𝑓𝑡=
𝑙𝑒𝑛𝑔𝑡ℎ𝑜𝑓 𝑙𝑎𝑝 𝑓𝑒𝑑 𝑝𝑒𝑟 𝑢𝑛𝑖𝑡 𝑟𝑜𝑎𝑡𝑖𝑜𝑛 𝑜𝑓 𝑓𝑒𝑒𝑑 𝑟𝑜𝑙𝑙𝑒𝑟 (𝑚)

200
Determination of draft
• For mechanical draft determination
• One has to calculate the speeds from gearing diagram OR
• Measure the speeds using tachometer

• For actual draft

• One has to measure the linear density of lap and sliver

• Draft in carding machine varies between 80 - 110

201
Actual Draft
It is based on linear densities of material fed and delivered.

Feed material : lap or mat of fibres

Delivered material : sliver

202
 Relation Between Actual & Mechanical Draft

 In steady state operation

Amount fed / unit time = Amount delivered / unit time

 
 
Weight/unit length fed Surface speed of delivery roller
Or ––––––––––––––––––––––– = ––––––––––––––––––––––––––
Weight/unit length delivered Surface speed of feed roller

i.e. Actual draft = Mechanical draft

203
However, due to waste extraction by licker-in , cylinder and flats

=100(1-)

204
 Card drive

5
4
n
Fa

2
L
i
c

r
ffe
Do
Lap

er
d
n
li
Cy
Coiler k
feed

Licker-in
calendar
e
roller
r-
i

1
n
3

Modern cards today are driven by a number of individual motors. Each motor takes care
of one section of the card so that the speed of these sections can be controlled
independently and quickly from a central computer controlled controller.
205
 Typical draft distribution in conventional card
 
Draft zone Draft
 
1. Lap roller to feed roller 1.06 Tension draft
2. Feed roller to licker- in 1000
3. Licker in to cylinder 2.0
4. Cylinder to doffer 0.04
5. Doffer to calendar roller 1.10
6. Calendar to coiler calendar roller 1.05

All drafts are >1 except draft between cylinder & doffer
In the present case, total draft = 1.06×1000×2.0×0.04×1.1×1.05=97.94
206
 Production calculation
𝜋 × 𝑛𝑐𝑐 × 𝑑𝑐𝑐 × 60 453.6 ncc = speed of coiler calendar roller (rpm),
𝜀
𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 ( 𝑘 𝑔 / ℎ )= × × d =diameter of coiler calendar roller (inch)
36 × 840 ×ℎ 1000 100 cc
h = sliver hank (Ne) & = efficiency (%)
OR  
𝜋 × 𝑛𝑐𝑐 × 𝑑 𝑐𝑐 × 60 𝜀
𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 ( 𝑘𝑔 / ℎ )= × ℎ× [dcc =mm & h = Ktex]
1000 × 1000 100

Since, there is very little draft between doffer and coiler calendar roller, the production
for all practical purposes can be calculated from doffer speed also.

𝜋 × 𝑑𝑜𝑓𝑓𝑒𝑟 𝑠𝑝𝑒𝑒𝑑(𝑟𝑝𝑚)× 𝑑𝑜𝑓𝑓𝑒𝑟 𝑑𝑖𝑎𝑚𝑡𝑒𝑟 (𝑖𝑛𝑐ℎ)×60 453.6 𝜀

𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 ( 𝑘 𝑔 / ℎ )= × × … … ( 2)
36 × 840 ×ℎ 1000 100
OR
𝜋 × 𝑑𝑜𝑓𝑓𝑒𝑟 𝑠𝑝𝑒𝑒𝑑(𝑟𝑝𝑚)× 𝑑𝑜𝑓𝑓𝑒𝑟 𝑑𝑖𝑎𝑚𝑡𝑒𝑟 (𝑚𝑚) ×60 𝜀
¿ × 𝑆𝑙𝑖𝑣𝑒𝑟 ℎ𝑎𝑛𝑘( 𝐾𝑡𝑒𝑥) ×
1000 ×1000 100
207
 Production constant
𝜋 × 𝑑𝑜𝑓𝑓𝑒𝑟 𝑠𝑝𝑒𝑒𝑑 (𝑟𝑝𝑚)× 𝑑𝑜𝑓𝑓𝑒𝑟 𝑑𝑖𝑎𝑚𝑡𝑒𝑟 (𝑖𝑛𝑐ℎ) ×60 𝜀
𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 ( 𝑘 𝑔 / ℎ )= ×
36 × 840 ×ℎ 100

In the calculation of production for a machine producing a sliver of given linear

density ignoring efficiency, all the parameters mentioned in the above equation
remain constant except doffer speed which is a variable.

 
 

   

208
End

209
Production & draft calculation
R Chattopadhyay

210
Mechanical draft
• the ratio of surface speeds of front & back rollers
• the ratio of linear movement of back roller and front rollers in a
single revolution of back roller.

211
 Draft distribution

Z3 Z2 Z1

𝑛1 𝑑 1 𝑛2 𝑑 2 𝑛3 𝑑 3 𝑛1 𝑑 1
n2, d2
𝑇𝑜𝑡𝑎𝑙 𝑑𝑟𝑎𝑓𝑡 : 𝑍= 𝑍 1 × 𝑍 2 × 𝑍 3= × × =
n4, d4 n3, d3 n1,d1 𝑛2 𝑑 2 𝑛3 𝑑 3 𝑛 4 𝑑 4 𝑛 4 𝑑 4
Back Middle Front
zone zone zone
Draft equations
 
Rotational speed ( rpm) Diameter (m) Surface speed ( m/min) Draft
 
Front roller n1 d1  V1= πn1 d1

2nd roller n2 d2 V2= πn2 d2  

    
3rd roller n3 d3 V3= πn3 d3
Back roller n4 d4 V4= πn4 d4
   
 

212
 1440 rpm
Φ=110 to 310
Motor

Total draft
Φ= 165 Draft Change

101
Linear displacement of back roller surface per

98-
35
pinion (N)

33
Back roller revolution of back roller = πdBR

(30 - 110
N ( 66)
Top roller P= 80 Kg
Bottom roller Φ=28 Number of revolution ( N) of front roller for 1

V
V= 20,24,30,34
revolution of back roller
Φ=28
2
8

109
1
G 8
P=80Kg
4
1

Φ= 20

4
2
2
0

Middle roller
131
14
3
Φ=25
2
5

P= 60kg
2
7

3
3

Φ=35 Break draft Change

3
5

Front roller pinion

84 (G),148,144,138,134
Calendar roller
Φ=50
4
7

213
 1440 rpm
Φ=110 to 310

Break draft
It is the ratio of displacement of the back and middle Φ= 165 Draft Change

101
98-
35
pinion (N)

33
roller surfaces respectively per revolution of back roller. Back roller

(30 - 110
N ( 66)
P= 80 Kg
Number of revolution ( N) of middle roller for 1 Φ=28

V
revolution of back roller V= 20,24,30,34

Φ=28
=1.07

2
8

109
1
G 8
P=80Kg

4
1
Φ= 20

4
2
2
0
Middle roller

131
DMR = diameter of middle roller and DBR = diameter of back

14
3
Φ=25

2
5
roller
P= 60kg

2
7

3
3
Φ=35 Break draft Change

3
5
Front roller pinion
84 (G),148,144,138,134
Calendar roller
Φ=50

4
7
214
Actual draft
• It can be estimated from the length of delivered sliver for a given
length of feed sliver or linear density of input and output slivers.

Method I: Based on length of input and out put sliver

From a can remove six sliver pieces of 1m length. Feed this 1m sliver pieces
together at the back and run the machine. Collect the delivered sliver and measure
its length. Find out the length ratio (delivered : feed). The length ratio will be the
draft i.e.
 

215
Method II: Based on input and out put sliver linear density

In an industry situations measurement of speed and diameter of the

rollers or teeth of the gears may not be feasible some times. In such
situations, one can find out the linear density of input and output sliver
and calculate the draft.
 

OR

216
 Draft constant
• Drafting rollers are driven by a chain of gears. No. of teeth of any gear
in the chain can be altered to change the speed ratio between them.
• The machine designer has given the flexibility to change the teeth of two
gears ( one for total draft and the other for break draft) for altering total
and break drafts.
• In the calculation of draft therefore, if the teeth of changeable gear is
considered as a variable, then the numerical value of the ratio of no. of
teeth of the gear chain we get in estimating draft is draft constant.
• Draft constant is a mechanical constant.
• It can also stated as the estimated draft when teeth in draft change
pinion ( DCP) is considered 1 only.
217
 Draft constant 1440 rpm
Φ=110 to 310

Based on the gearing diagram Φ= 165 Draft Change

101
98-
35
pinion (N)

33
Back roller

(30 - 110
N ( 66)
P= 80 Kg
Φ=28

V
V= 20,24,30,34

Where, tDCP = number of teeth in draft change pinion, DFR Φ=28

2
8

109
1
G 8
P=80Kg
= diameter of front roller(35mm) and DBR = diameter of

4
1
Φ= 20

4
2
back roller ( 28mm)

2
0
Middle roller

131
14
3
Φ=25

2
5
P= 60kg
𝑡 𝐷𝐶𝑃

2
7
1 35
𝐷𝑟𝑎𝑓𝑡 = ×131 × × =0.118 × 𝑡 𝐷𝐶𝑃

3
3
Φ=35 Break draft Change

3
5
42 33 28 Front roller pinion
84 (G),148,144,138,134
Calendar roller
This ratio “0.118” is known as draft constant. Φ=50

4
7
218
Draft ( Z) = Draft constant ( K)× no. of teeth in draft change pinion ( N)
12.98

From the draft constant one can easily determine draft by multiplying draft Draft

constant by number of teeth chosen in DCP .

Example 3.84
30 Teeth in DCP 110
If one chooses a DCP of 57, the draft would be = 0.118 x 57 = 6.72
One would be interested to know the number of teeth in DCP to be chosen for Draft VS teeth in DCP
fixing a certain draft.
One would be interested to know the number of teeth (N) in DCP to be chosen
for fixing a certain draft (Z).

 
For a draft of 6.2, the DCP should have

219
Production calculation

𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 / ℎ𝑒𝑎𝑑=¿ ¿

220
Production (Kg) per head /8 h at 100% efficiency

 
=
 
If the sliver count is expressed in English system ( Ne),

221
 Example 1440 rpm Φ=110 to 310

Φ= 165 Draft Change

101
98-
35
pinion (N)

33
Back roller
m/min

(30 - 110
N ( 66)
P= 80 Kg
Φ=28

V
= 258.9 m/min V= 20,24,30,34

Φ=28

2
8

109
1
G 8
P=80Kg

4
1
Φ= 20

4
2
2
0
Middle roller

131
14
3
Φ=25

2
5
P= 60kg

2
7

3
3
Φ=35 Break draft Change

3
5
Front roller pinion
84 (G),148,144,138,134
Calendar roller
Φ=50

4
7
222
 Production rate/h = delivery speed (m/min) × 60 × Sliver linear density ( K tex) / 1000 Kg

Example
For 5 K tex sliver,
The production / h/ head = (258.9 × 5× 60)/ 1000 = 77.67 Kg
For two head machine, production / machine /h = 77.67 × 2 =155.34 Kg
Production / shift / machine ( assuming 7.5 h in a shift ) with 100% efficiency = 155.34 × 7.5
= 1165 Kg

223
Machine idle time
• During a shift, the machine may remain idle for short/ long time
due to many reasons such as :
(i) can changing time , (ii) minor cleaning,

( iii) sliver breaks on creel , ( iv) roller lapping

(v) trumpet choking , (Vi) shortage of feed can

(vi) power failure etc.

• Hence, the Actual production < theoretically calculated production.

224
The ratio of actual production to theoretically estimated value is known as efficiency.
 
 
  The efficiency of a draw frame lies between 75 to 85% depending upon the mixing of
fibres.
 
Actual production:

225
Can filling time

For Capacity of can = 22 Kg, Machine producing = 80 Kg/h

Filling time = (22/80) × 60 min = 16.5 min
 

226
Length of sliver in can
Let,
the empty can weight = w Kg
Full can weight = x kg

Sliver linear density = S Ktex

For W= 22 Kg and sliver linear density = 5.5 K tex,

 
 

227
End

228