Professional Documents
Culture Documents
A Thesis Submitted To
By
December, 2015
i
CANDIDAT’s DECLARATION
We certify that the thesis entitled” Investigative Study Of Periodic Yarn Faults And Its
Removal By Gearing Analysis” submitted for the degree of B.sc Textile Engineering is
the result of our own research, except where otherwise acknowledged, and that this thesis in
whole or in part has now been submitted for an award, including a higher degree, to any
other university or institution.
Muhammad Rizwan
Signed: ---------------------- Date: 14/12/2015
Muhammad Munawar
Signed: ---------------------- Date:14/12/2015
Muhammad Asad
Signed: ---------------------- Date:14/12/2015
Yasir Akhtar
Signed: ---------------------- Date:14/12/2015
ii
CERTIFICAT
It is to certify that this thesis entitled “Investigative Study of Periodic Yarn Faults
and Its Removal by Using Gearing Analysis” has been accepted as a partial
fulfillment of the requirement for the degree of B.sc Textile Engineering in
Bahauddin Zakariya University College of Textile Engineering Multan.
iii
DEDICATION
iv
ACKNOWLEGEMENT
First of all we want to thank AL-MIGHTY ALLAH who made us able to do this.
We are thankful to our parents who like to see us successful in all fields of life and
pray for us to have a happy and long live.
We want to thank administration and staff of Unit No.4, Fazal Cloth Mills, Fazal
Nagar Jhang Road, Muzaffargarh who were very kind and supportive to us.
Especially to Mr. Ahsanullah(General Manager of Unit No.4, Fazal Cloth Mills,
Fazal Nagar Jhang Road, Muzaffargarh) who helped us throughout the project and
gave free hand to perform our experiment.
We are thank full to our beloved senior Laal Khan, great teacher and again project
supervisor Mr. Furqan Khurshid, the guidance of whom has been always source of
light in darkness and he was always available to us. In difficult process of compiling
and writing of our project we are very thankful to him who told us the right way of
doing this.
v
ABSTRACT
It has been widely reported that periodic faults in cotton yarn are one of the main
reasons of yarn rejection from weaving mill. This thesis has been undertaken to
study periodic faults produced in cotton ring spinning mill, its rectification and
prevention from occurring. The purpose of periodic yarn fault detection system was
to identify defective part in the machine. This system is suitable for identifying the
source of periodic fault on the machine. It was developed because spectral analysis
of machines with complex driving systems requires time and work-consuming
calculations, which make it considerably more difficult to quickly find the cause of
the detected periodicity in the stream of fibers.
vi
TABLE OF CONTENTS
CHAPTER # 1 INTRODUCTION ........................................................................ 1
1.1 Yarn ............................................................................................................... 1
1.2 Types of Yarn ................................................................................................. 1
1.2.1 Filament Yarn .......................................................................................... 1
1.2.2 Staple or Spun Yarn ................................................................................. 1
1.3 Manufacturing Process of Staple or Spun Yarn ............................................... 2
1.4 Brief Introduction of Departments .................................................................. 3
1.4.1 Blow Room Process ................................................................................. 3
1.4.2 Carding Process ....................................................................................... 3
1.4.3 Combing process...................................................................................... 4
1.4.4 Drawing frame Process ............................................................................ 4
1.4.5 Roving frame ........................................................................................... 5
1.4.6 Ring Spinning Process ............................................................................. 5
1.4.7 Cone Winding Process: ............................................................................ 7
1.5 Yarn Faults ..................................................................................................... 8
1.6 Yarn Faults Classification ............................................................................... 8
1.6.1 Classimat Faults ....................................................................................... 9
1.6.2 Deviation in Yarn Quality Faults .............................................................. 9
1.6.3 Periodic Yarn Faults ............................................................................... 16
CHAPTER #2 Materials and Method ................................................................. 26
2.1 Material ........................................................................................................ 26
2.2 Method ......................................................................................................... 28
2.2.1 Identify the periodic fault length by mass spectrogram ........................... 28
2.2.2 Analysis the Gearing System .................................................................. 29
2.2.3 Identify Origination Point of Yarn Fault ................................................. 30
2.2.4 Rectification of Yarn Faults ................................................................... 30
CHAPTER #3 RESULTS AND DISCUSSION .................................................. 31
3.1 Investigation and rustication of periodic faults at breaker.............................. 31
3.1.1 Identify the periodic fault length by mass spectrogram ........................... 31
3.1.2 Analysis the gearing system ................................................................... 32
3.1.3 Identify Origination Point of Yarn Fault ................................................. 33
3.1.4 Rectification of Yarn Faults ................................................................... 34
vii
3.2 Investigation and rustication of periodic faults at Finisher............................. 35
3.2.1 Identify the periodic fault length by mass spectrogram ........................... 35
3.2.2 Analysis the Gearing System .................................................................. 36
3.2.3 Identify origination point of yarn fault .................................................... 37
3.3 Investigation and rustication of periodic faults at Simplex ............................ 39
3.3.1 Identify the periodic fault length by mass spectrogram ........................... 39
3.3.2 Analysis the Gearing System .................................................................. 40
3.3.3 Identify origination point of yarn fault .................................................... 42
3.3.4 Rectification of Yarn Faults ................................................................... 42
3.4 Investigation and rustication of periodic faults at Ring .................................. 43
3.4.1 Identify the periodic fault length by mass spectrogram ........................... 43
3.4.2 Analysis the Gearing System .................................................................. 44
3.4.3 Identify Origination Point of Yarn Fault ................................................. 45
3.4.4 Rectification of Yarn Faults ................................................................... 46
Conclusions .......................................................................................................... 47
References ............................................................................................................ 47
viii
LIST OF FIGURES
ix
LIST OF TABLES
x
Chapter: Introduction
-------------------------------------------------------------------------------------------------------------------------
1.1 Yarn
A yarn is defined as a product of substantial length and relatively small cross section
consisting of fiber and/or filament with or without twist.[1]
OR
The characteristics of spun yarn depend, in part, on the amount of twist given to the
fibers during spinning. A fairly high degree of twist produces strong yarn; a low
twist produces softer, more lustrous yarn; and a very tight twist produces crepe yarn.
Yarns are also classified by their number of parts. A single yarn is made from a
group of filament or staple fibers twisted together. Ply yarns are made by twisting
two or more single yarns. Cord yarns are made by twisting together two or more ply
yarns.
1
1.3 Manufacturing Process of Staple or Spun Yarn
Staple yarn manufacturing is a sequence of processes that convert raw cotton fibres
into yarn suitable for use in various end-products. A number of processes are
required to obtain the clean, strong, uniform yarns required in modern textile
markets. Beginning with a dense package of tangled fibres (cotton bale) containing
varying amounts of non-lint materials and unusable fibre (foreign matter, plant trash,
motes and so on), continuous operations of opening, blending, mixing, cleaning,
carding, drawing, roving and spinning are performed to transform the cotton fibres
into yarn.[3]
2
1.4 Brief Introduction of Departments
“The card is the heart of spinning mill” and “well carded is well spun” (Vijykumar,
2007) [5]
Card feeding is done by two ways. One is manually and other is through chute feed
system. In manual case the lap which is produced in blow room and it is feed to the
card. In chute feed the material is feed through air flow system to card
machine. It is important to say that lower the feed variation better is the carding
quality. Lower the feed variation then draft variation will also be less. Then yarn
quality will be consistent. If the card is having auto leveler then nominal draft
should be selected properly. In some circumstances card also act as a cleaner
and remove a certain amount of short fiber. Approximately 90% cleaning
efficiency is achieved with the help of carding machine.[6]
3
1.4.3 Combing process
For getting high quality of yarn, one extra process is introduced which is called
combing process.
Combing is an operation in which dirt and short fibers are removed from sliver lap
by following ways. In a specially designed jaws, a narrow lap of fiber is
firmly gripped across its width. Closely spaced needles are passed through the fiber
projecting from jaws. Short fiber which we remove is called comber noil. The
comber noil can be recycled in the production of carded yarn. Yarn which is
get from comber sliver is called comber yarn. Carded sliver are combine into
comber lap in a single continuous process stage. Flat sheet of fiber which is get from
comber lap is fed into the comber in an intermediate.
There are different ways by which value of combing is used in the manufacturing of
cotton. By spinning point of view combing process makes more uniformity in the
yarn. Strength of yarn is also high because in combing process short fiber are
removed and only fiber having good strength remains. So it play very
important role for increasing the yarn strength. Because of straightened
condition of fibers combing makes possible spinning smoother and more
lustrous yarn. In combing process length of fiber are strong so it need less
twist produced then carded yarn. [7]
4
Auto leveler is also used to adjust and to improve the linear density of the
sliver. Without auto leveler it is very difficult to improve the quality of the draw
frame sliver.
Its purpose is to prepare input package for next process. This package is to
prepare on a small compact package called bobbins. Roving machine is
complicated, liable to fault, causes defect adds to the production costs and
deliver the product. In this winding operation that makes us roving frame complex.
There are two main basic reasons for using roving frame. The roving sliver is thick
and untwisted. Because of it hairiness and fly is created. So draft is needed to
reduce the linear density of sliver. The ring drafting arrangement is not capable that
it may process the roving sliver to make the yarn.
Draw frame can represent the worst conceivable mode of transport and
presentation of feed material to the ring spinning frame.
The input of ring frame is roving which comes from roving section this is final stage
where yarn is make. Here in this section need more drafting to reduce the liner
density of roving and more twist to make a yarn. The output of ring frame is yarn
which is wound on a ring bobbin which is used for next winding process.
5
1.4.6.1 Function of Ring Process
There is a different function of Ring Spinning process in which roving is
converted into yarn through passing different zone like drafting, twisting and
winding zone. There are three important zone of Ring processes below here. [9]
Drafting Zone
Twisting Zone
Winding Zone
Drafting is the first zone of ring process and is very important part of machine and
mostly effects on the evenness and strength of yarn. In quality point of view, there
are many points which are related to the quality of drafting system.
It is the second zone and is also very important part of Ring machine in which
the strands of fiber are converted into a yarn by the twist inserted. The strength of
yarn is depend upon the amount of twist which are given in twisting zone and it is
most important than other zone due to required strength of yarn. There are some
very important points related to quality point of view in twisting zone are;
6
1.4.6.1.3 Winding Zone
This is the last section of ring machine in which yarn is wound on the plastic bobbin
by the up and down movement of ring rail which is linked to a small motor. It is also
very important because the setting of ring rail makes coils of yarn on bobbin in such
a way that the Z-twist is not open during winding process. Some points are very
important during winding process. That’s are;
7
Winding department plays an important role in the production and quality of
yarn and causes direct effect on them. The yarn which made in ring section is not
finish yarn and can’t sell to customer. After making the yarn in ring process,
auto cone section made it more even yarn by passing through the optical
sensor and capacitor sensor which is installed in different heads of machine.
The yarn which is obtained from winding section is able to sell the customers.
YARN FAULTS
SELDOM
COUNT CV PERIODIC
OCCURING
RANDOM
U% NON PERIODIC
OCCURING
HARINESS
CONTAMINATION
IPI
STRENGTH
8
1.6.1 Classimate Faults
The position of the frequent yarn faults (imperfections) in comparison to the position of
the seldom-occurring yarn faults in the classification matrix are shown in the figure. It
becomes clear, that both types of yarn faults differ from each other clearly by their size
and thus, cannot be compared with each other. In addition, the areas of the clearer
settings N, S, L, T, CCp and CCm are indicated in Fig. This shows where the settings are
effective. [16]
9
Figure 1.4: Effect Of Count Variation On The Fabric Surface
(Combed cotton 100%, Nec 30, Nm 50, 20 Tex)
Variation in average lap weight over long intervals (e.g. half shift) including
allowance to variation in humidity
High cm to cm variation in lap
10
Excessive variation in tuft size
Draft to waste difference between groups of cads or at combers.
Hank differences between D.F slivers
Stretch in the D.F slivers fed to roving
Use of one passage post comber D.F
Row to row differences in hank roving.
Draft differences between roving frame
Marked changes in hank roving over a roving frame bobbins caused by
irregular bobbins speed control
Draft differences between ring frame
Frequent changes of pinion in drawing and ring spinning
Creel draft variation and bobbin holders clogging with waste
Variation in top roller pressure
Variation in bare bobbins diameter
Spindle variation in ring finish
High variation in RH% age
At several stages in spinning process stretch take place and become a source of great
hidden menace as it not only undesirable variation (between bobbins and within
bobbins) but also results in high end breakages excessive wastes and lower the
quality of end product.
11
Yarn unevenness is much affected by roving and draft conditions. Long irregularity
is related to fore spinning process of middle roller of ring frame while short term
irregularity mainly process after middle roller of ring frame. Main factors involved
in the formation of short term irregularity are: limited irregularity due to random
fiber arrangement, imperfect fiber control which in roller drafting leads to drafting
waves varying in amplitude and length; and mechanical defects. The pattern of
irregularity in drawn and spun yarn is complex combination of wave length
introduced at each stage of drawing and in spinning. The most important wave is the
one with the shortest wavelength-introduced at the spinning frame. Long term count
variation may be influenced by the no. of doublings used during drawing and
spinning, short term irregularity is hardly influenced by this factor.[13]
Faulty roving
Faulty rotation of skewers
Wrong guiding of roving in creel
Chocking of trumpet
Faulty working of traverse bar
Wrong roller setting
Inadequate pressure on top roller
Eccentricity of rollers
Roller lapping & sticking
Defective & worn gears & bearings
Uneven dia. of rubber cots
Non alignment of apron
Worn & damaged aprons
Accumulation of lint under apron
Incorrect gap between aprons
Wider gauge in front drafting zone
Incorrect setting of lappet & spindle
Rough surface of separators
Defective spindles
12
Damaged & worn rings
Light travelers
Close setting of traveler cleaner
Erratic ring rail traverse
The standard deviation of the linear densities over which unevenness is measured
expressed as a percentage of the average linear density for the total length within
which unevenness is measured. C.V of irregularity can be measure using following
parameters;[14][15]
CVm: Coefficient of variation of mass with a cut length of approximately 1 cm. This
is the CV most often quoted in yarn specification and commercial transactions.
CVm (1m): Coefficient of variation of mass with a cut length of 1 m, simulating the
CV you would have got from cutting the yarn into 1 m sections and weighing those
sections. The same applies to CVm (10m) and CVm (100m). It should be noted that
as the cut length increases, the irregularity reduces.
13
During the weaving process, high hairiness can lead to entanglements of
warp threads.
Hairiness is high for low twist and vice versa.
Yarn winding will increase the yarn hairiness whereby the increase will
depend on the raw material, on the yarn twist and on the winding speed.
In uni-colored fabric, hairiness variations exceeding 1.5 between yarns lying
next to each other can be detected by the human eye.
The higher the hairiness, the softer a fabric.
The higher the short fiber content, the higher the number of imperfections. Frequent
imperfections can be very disturbing in a fabric. Fiber entanglement often results
from immature fibers which cannot absorb dyestuff and, therefore, remain white.
14
1.6.2.4.1 Thin place (-50%)
Number of places that have mass reductions of 50% or more with respect to the
mean value. Note that (-50%) is the standard sensitivity level used in the test. If a
different sensitivity level (-40%, -40%, -60%) is used, the result would have been
different. These thin places have a length of approx. 40 cm.
These are number of places that have mass increases of 50% or more with respect to
the mean value. Note that (+50%) is the standard sensitivity level used in the test. If
a different sensitivity level (+35%, +70%, +100%) is used, the result would have
been different. These thick places have a length of approx. 40 cm.
Number of places that have mass increases of +200% or more with respect to the
mean value and a reference length of 1mm. Note that +200% is the sensitivity level
normally used in the test. These short thick places in a yarn are often the results of
vegetable matter or entangled fibers.
1.6.2.5 Strength
Yarn strength is measure in tensile strength, which is defined as:-
The variation of maximum tensile strength is a measure for strength variations from
bobbin to bobbin. The causes of lack in fiber strength are
Fiber strength
Fiber growth
Fiber damaging in the spinning process( inadequate roller gauge)
Excessive rubber cots hardness
Excessive top roller pressure
Loose spindle tape
RH%
Singles (when using double roving)
15
Stretched roving due to improper regulation of bobbin speed on roving frame
and
poor handling of roving bobbins during transportation
Excessive twist
Defective piecing
Excessive short fibers content
Use of soft waste on mixing
Roving
16
periodic faults can be pressure marks on the top roller. If a spinning position or the
whole spinning frame is stopped and the pressure is not taken from the top roller, it
can lead to pressure marks on the top rollers after longer stops and thus to periodic
defects in the yarn.
The distance between the single events corresponds to the circumference of the
cylinders. With soft, even lapping can lead to moiré pattern. Furthermore can a
missing bottom belt rubber coating of the top roller also lead to periodic faults.
There are many possibilities for the origin of periodic defects when spinning
compact yarns. The reasons depend strongly on the spinning method. For regular
ring spun yarns, the reasons are mostly pure mechanical insufficiencies, which lead
to periodic faults in the yarn. For compact yarns, the reasons can be found in the
contamination with fibers and dirt. This dirt can build up for an uncertain time,
which makes it much more difficult to find the reasons. Therefore, the monitoring of
periodic defects in compact yarns is essential.
17
Figure 1.7: Moiré Effect
Mass variation in yarn can adversely affect many properties of textile materials such
as shade variations and strength. Mass variation can be attributed to the properties of
raw materials, inherent short comings in yarn making and preparatory machines,
mechanically defective machinery and/or external causes as a result of working
conditions and improper housekeeping.
Periodic mass variations in yarn can cause weft bars, diamond barring effects, moiré
effects, and weft stripes or rings in the resulting fabric. Hence, periodic irregularity
should not be permitted at all, since it greatly affects the appearance of fabric and
must be controlled. However, the presently available tools used to measure the
periodicity of mass per unit length variation have limitations. The spectrogram is
more reliable compared to other tools for determining periodicity; it works on the
principle of Fourier analysis, which sets out any function in a series of sine curves.
The actual mass variation will be resolved into different sinusoidal waves with
different amplitudes and wavelengths. Hence, spectrogram gives only the resolved
mass variation, which may not be present in the final yarn when different faults are
superimposed.
The spectrogram measures the periodic mass variations in a yarn by analyzing the
frequencies at which faults occur electronically. From the speed at which the yarn is
running the frequencies are converted to wavelengths and slotted into a finite
number of discrete wavelength steps. The result is a histogram as shown in Fig
18
where the amplitude is a measure of the number of times a fault of that repeat length
occurs owing to the fiber length having an effect on the distribution of repeats
around that Length the background level of the spectrogram is not flat but a
periodically repeating fault will show a level much greater than the background as is
shown in the figure. As a general rule the height of a peak in the spectrogram should
not be more than 50% of the basic spectrogram height at that wave length.[10]
19
Figure 1.9: Normal Mass Spectrogram
The spectrogram consists of shaded and non-shaded areas. If a periodic fault passes
through the measuring head for a minimum of 25 times, then it is considered as
significant and it is shown in the shaded area. Wavelength ranges which are not
statistically significant are not shaded. In this range the faults are displayed but not
hatched. This happens when a fault repeats for about 6 to 25 times within the tests
length of the material. As far as those faults in the un-shaded area is concerned, it is
recommended to first confirm the seriousness of the fault before proceeding with the
corrective action. This can be done by testing a longer length of yarn. Faults which
occur less than 6 times will not appear in the spectrogram. A spectrogram starts at
1.1 cm if the testing speed is 25 to 200 m/min. It starts at 2.0cm if the testing speed
is 400 m/min and it starts at 4 cm if the speed is 800m.min. For spun material the
maximum wavelength range is 1.28 km. Maximum number of channels is 80.
Depending upon the wavelength of the periodic fault, the mass variations are
classified as
20
Medium-Term Variation (wavelength ranges from 50cm to 5 m)
Periodic mass variations in the range of 50cm to 5m are not recognizable in every
case. Faults in this range are particularly effective if the single or double weave
width or the length of the stretched out yarn one circumference of the knitted fabric,
is an integral number of wave-lengths of the periodic fault, or is near to an integral
number of wave-lengths. In such cases, it is to be expected that weft stripes will
appear in the woven fabric or rings in the Knitted fabric.
Periodic mass variations with wave-lengths longer than 5m can result in quite
distinct cross-stripes in woven and knitted fabrics, because the wave-length of the
periodic fault will be longer than the width of the woven fabric or the circumference
of the knitted fabric. The longer the wavelength, the wider will be the width of the
cross-stripes. Such faults are quite easily recognizable in the finished product,
particularly when this is observed from distances further away than 1 m.
A periodic mass variation in a fiber assembly does not always result in a statistically
significant difference in the U/V value. Nevertheless, such a fault will result in a
woven or knitted fabric and deteriorate the quality of the fabric. Such patterning in
the finished product can become intensified after dyeing. This is particularly the
case with uni-colored products and products consisting of synthetic fiber filament
yarns. The degree to which a periodic fault can affect the finished product is not
only dependent on its intensity but also on the width and type of the woven or
knitted fabric, on the fiber material, on the yarn count, on the dye up-take of the
fiber, etc. A considerable number of trials have shown that the height of the peak
above the basic spectrum should not overstep 50% of the basic spectrum height at
the wavelength position where the peak is available.
21
1.6.3.1 Chimney Type Faults:
The eccentricity roller results in a sinusoidal mass variation whereby the periodicity
corresponds to full circumference of the roller. With one complete revolution of an
OVAL roller, a sinusoidal mass variation also results, but 2 periodic faults are
available. Chimney type of faults are mainly due to -mechanical faults -eccentric
rollers, gears etc -improper meshing of gears -missing gear teeth -missing teeth in
the timing belts -damaged bearings etc
Example of a chimney:
22
Combed Sliver: 4.0 x fiber length
Draw Frame Sliver: 4.0 x fiber length
A periodic fault which occurs at some stage or another in the spinning process is
lengthened by subsequent drafting. If the front roller of the second draw-frame is
eccentric, then by knowing the various drafts in the further processes, the position of
the peak in the spectrogram of the yarn measurement can be calculated. The
wavelength of a defective part is calculated by multiplying the circumference of the
part and the draft up-to that part. The wavelength of a defective part can be
calculated if the rotational speed of the defective part and the production speed are
known. Doubling is no suitable means of eliminating periodic faults. Elimination is
only possible in exceptional cases. In most cases, doubling can, under the best
conditions, only reduce the periodic faults. The influence of periodic mass variation
is proportional to the draft. Due to the quadratic addition of the partial irregularities,
the overall irregularity of staple-fiber yarns increases due to the periodic faults only
to an unimportant amount.
1.6.3.2.1 Drafting Faults
Drafting faults are created and influenced by non-optimal settings of one or several
of the following factors:
- Gauge distance between the drafting rollers (Nip)
- Roller Pressure
23
- State of the roller’s surfaces
- Humidity of material and surrounding climate
When searching to eliminate drafting faults, one would look for the main cause in
one of those factors first. In many cases though, a compromise has to be found, since
certain materials are more critical. Example: Combed cotton draw frame slivers,
where the fibers are highly parallel and thus slippery and difficult to draft optimally
at a reasonable speed. A drafting fault hill is to be found at a wavelength of about
2.8 × average fiber length. If the drafting fault hill does not lie around 2.8 × average
fiber length, one has to divide the wavelength λ of the hill crest by 2.8 × average
fiber length in order to get the approximate draft factor back to the origin of the
fault.
hill crest
Formula: Draft ratio
2. 8 average fiber length
Example:
24
Figure 1.13: Spectrogram and Yarn Board Image of a Bad OE Yarn.
The 10cm moiré was caused by a dirty Rotor groove.
The reason for the appearance of multiple chimneys lies in the behavior of wave signals.
Mathematically, it is complex (Fourier transformation), but graphically, it becomes quite
evident:
25
Chapter: Materials and Method
-------------------------------------------------------------------------------------------------------------------------
2.1 Material
Four outputs from Breaker, Finisher, Roving and Ring were chosen as raw material
for investigation of periodic yarn faults. These products were processed on the
standard spinning machinery with Pakistani Cotton. The properties of this cotton are
given in the table.
All samples from breaker sliver, finisher sliver, simplex roving and ring yarn were
prepared in “Fazal Cloth Mills, Unit # 4” by using Automatic Bale Opener Blow room
setup of Trutzschler Company, Trutzschler TC-03 card, Draw frame breaker Reiter
Rsb-2, Finisher Reiter RSB-D 40, speed frame Fl-100 and ring frame RX-240. The
sequence of machines is shown in the figure 2.1. Parameter, that were used for the
preparation of breaker sliver, finisher sliver, simplex roving and ring yarn on each
machine are in the Table 2.2.
The linear densities of the prepared breaker sliver, finished sliver, and roving were
68 grains/yard, 65 grains/yard, and 0.74 hanks respectively. Yarn samples of and
26
21/1 Nec were prepared from rovings at a spindle speed of 21500 rpm with a twist
multiplier of 3.75 respectively.
27
2.2 Method
Before testing, all the prepared yarn samples were conditioned in the laboratory
under standard atmospheric conditions of 21±1°C and a relative humidity of 65±2.
The periodic faults at breaker sliver, finisher sliver, simplex roving and ring yarn
were investigated and analyzed and rectified by following steps.
The spectrogram consists of shaded and non-shaded areas. If a periodic fault passes
through the measuring head for a minimum of 25 times, then it is considered as
significant and it is shown in the shaded area. Wavelength ranges which are not
statistically significant are not shaded. In this range the faults are displayed but not
hatched. This happens when a fault repeats for about 6 to 25 times within the tests
28
length of the material. As far as those faults in the un-shaded area is concerned, it is
recommended to first confirm the seriousness of the fault before proceeding with the
corrective action. This can be done by testing a longer length of yarn. Faults which
occur less than 6 times will not appear in the spectrogram.
Figure 2.3: Drafting Elements of a Ring Spinning Machine with Gearing Drive
If the gear Z3 is defective, then the effect in the fiber material is the same as that
produced with the gear Z2, because both gears are on the same shaft.
= 2.64 m
The front roller, therefore, turns 33 times until the defect at Z4is repeated. A defect
of the gear Z4 directly affects the back roller BR because this gear is on the same
shaft. The influence on the back roller, multiplied by the total draft, results in the
29
same wave-length as the influence of Z4on the front roller: Circumference of the
back roller
A defect of the gear Z4 affects the middle roller MR in the following manner
(Z4 and Z5 are on the same shaft):
= 2.63 m
So, using above principle, we analyze the gearing systems of Breaker, Finisher,
Simplex and Ring. The gearing diagrams along with wave length of each part are
given below.
30
Chapter: Results and Discussion
-------------------------------------------------------------------------------------------------------------------------
31
3.1.2 Analysis the Gearing System
32
Table 3.1: Periodic Fault lengths of Different Parts of Breaker
33
3.1.4 Rectification of Yarn Faults
When medium roller was checked, there was a cut in the top medium roller. So,
medium roller was changed and hence fault was removed. And UT4 report after
removal of fault is given below.
Hence it proves that our periodic fault detection system was working properly.
34
3.2 Investigation and Rectification of Periodic Faults at Finisher
35
3.2.2 Analysis the Gearing System
36
Table 3.2: Periodic Fault lengths of Different Parts of Finisher
When gearing system was checked, there was a problem in λNW1. So, λ NW1 was
changed and hence fault was removed. And UT4 report after removal of fault is
given below.
37
38
3.3 Investigation and Rectification of Periodic Faults at Simplex
39
3.3.2 Analysis the Gearing System
40
Table 3.3: Periodic Fault lengths of Different Parts of Simplex Fl-100
41
3.3.3 Identify Origination Point of Yarn Fault
From this fig it is seen clear that peak is higher than acceptable limits so by
matching the values of spectrogram with PERIODIC FAULT DETECTION
SYSTEM. We can compare the value of λ. By comparing it is noted that this peak is
equal to λ d(36 tooth gear of Simplex). Peak which shows that λd gear is faulty.
42
3.4 Investigation and Rectification of Periodic Faults at Ring
43
3.4.2 Analysis the Gearing System
44
Table 3.4: Periodic Fault lengths of Different Parts of Ring Frame RX-240
45
3.4.4 Rectification of Yarn Faults
When front roller was checked, there was a cut in the top front roller. So, front roller
was changed and hence fault was removed. And UT4 report after removal of fault is
given below.
46
Conclusions
In this work, periodic yarn fault detection system was developed. It is suitable for
identifying the source of periodic fault on the machine. It was developed because
spectral analysis of machines with complex driving systems requires time and work-
consuming calculations, which make it considerably more difficult to quickly find
the cause of the detected periodicity in the stream of fibers. The result shows that
this system is helpful to eliminate periodic yarn faults of breaker, finisher simplex
and ring machines.
47
References
[2] Werner Klein, Manual Of Textile Technology (Short Staple Spinning Series ).
The Textile Institute, p. Volume 4 (1–45).
[5] T. Vijykumar, “Report on experience with the Rieter C 60 CARD. Link, 51.,”
Rieter, vol. 19, pp. 3–6, Dec-2007.
[7] Peter R.Loard., The Economies, Science and Technology of Yarn Production.
Manchester, England: CRC Press; 1 edition, 1981, pp. chap.12, page149–171.
[9] Muhammad Adnan Abid, “How to minimize the defects rate of final product
in textile plant by the implementation of DMAIC tool of Six Sigma,”
University of Boras, 2010.
48
[11] T. P. A. T k Pattabhiram, Essential Facts Of Practical Cotton Spinning.
Mahajan, 1979.
[13] Muhammad Furqan Khurshid, “Study of yarn faults and their identification,
reasons, rectification and impact on subsequent process,” Bahauddin Zakariya
University College of Textile Engineering & Technology Multan, 2009.
[17] AUTEX Research Journal, Vol. 9, No4, December 2009 © AUTEX p: 103 -
105
49